Case Study: Carnegie Mellon School of Architecture achieves sustainable, low‑waste architecture and upcycled concrete design with ExOne binder jet 3D printing

Design Research Team Reinvents Eco-Friendly Architecture and Upcycled Materials

Carnegie Mellon School of Architecture faced the challenge of reshaping pulverized construction materials (like concrete and sand) into efficient, low-waste architectural components that support local environmental revitalization. To explore recycled-material workflows and climate-responsive urban furniture, the school partnered with ExOne and used the ExOne M-Flex® binder jet 3D printing system.

Using ExOne’s binder jetting at CMU’s Mill 19, the team 3D printed cradle rocking planters from sand and reclaimed concrete powders, then infiltrated them with bio-based resins to achieve cement-like strength. ExOne enabled customized, locally produced geometries and lattice designs that reduced material volume, improved water capture and plant growth performance, diverted demolition materials into reusable feedstock, and supported community engagement and Hazelwood revitalization (including ExOne industry partnership matching funds).

Carnegie Mellon School of Architecture

Dana Cupkova

Associate Professor