ICON’s Vulcan Revolutionizes 3D-Printed Hospitality in Texas
In a groundbreaking development for the construction industry, Texas will soon host the world’s first 3D-printed hotel, significantly enhancing modern architecture and design. Located on the outskirts of Marfa, the expansion of El Cosmico will introduce 43 new hotel units and 18 residential homes, utilizing ICON’s innovative Vulcan construction system.
A New Era of Construction
El Cosmico, known for its unique accommodations, is expanding its facilities to a new location of over 60 acres. Under the leadership of owner Liz Lambert, this initiative will redefine hospitality in the West Texas desert. Lambert is partnering with ICON, the Austin-based company recognized for its work on the largest 3D-printed community in Georgetown’s Wolf Ranch neighborhood. The architectural vision is spearheaded by the renowned Bjarke Ingels Group.
Set for completion by 2026, the new hospitality units at El Cosmico will range from $200 to $450 per night, showcasing how 3D printing can create unique and adaptable living spaces.
“ICON is a leader in the most bipartisan issue being discussed in America today—housing. They seek to make beautiful and attainable housing for all, whether it is housing for high-end clientele in Marfa, homeless veterans in Austin, indigent workers in Mexico, or Artemis astronauts on the moon. We are excited to partner with this industry-changing company led by innovative Aggies.” — Patrick Suermann, Ph.D., interim dean of the College of Architecture
The Vulcan Printer: A Game Changer
At the heart of this expansion is ICON’s Vulcan printer, an impressive machine measuring 46.5 feet wide and 15.5 feet high, weighing nearly 5 tons. The Vulcan has already begun printing two prototype units, featuring single-story structures with inviting curved beige walls. One will serve as a three-bedroom residence, while the other will function as a hotel unit.
“The traditional hotel structure often limits design to four walls, repeating the same unit,” Lambert said. “With 3D printing, I can build with fewer constraints, allowing for fluid shapes like curves and domes. It’s an exciting new way to create.”
Innovative Materials and Methods
ICON employs a specialized concrete-based material known as Lavacrete, engineered for durability and printability. This material is tailored to local environmental conditions, including humidity and temperature, ensuring optimal performance and aesthetic appeal.
“The magic happens in the admixtures that allow us to continue printing,” said Jason Ballard, CEO and co-founder of ICON. “Factors like humidity and temperature influence the material’s properties, ensuring each structure is uniquely suited to its environment.”
Equipped with a robotic arm and nozzle, the Vulcan operates over the site using a gantry system that supports its movements. While this printer is making waves in the hotel industry, ICON is also set to unveil the Phoenix, a new model capable of constructing entire buildings, including roofs and foundations, thereby expanding design possibilities.
The Future of Construction
3D printing in construction offers notable advantages over traditional methods, including reduced construction time, lower costs, and minimal waste. Some estimates suggest that 3D-printed walls of a home can be completed in as little as three weeks depending on the size.
As the construction industry evolves, innovations like those from ICON are paving the way for a more sustainable and efficient future. By integrating technology into the building process, the potential to address housing demand while minimizing environmental impact becomes increasingly viable.
Understanding the 3D Printing Process
The process of 3D printing, or additive manufacturing, begins with creating a digital model using computer-aided design (CAD) software. This model is then sliced into horizontal layers to prepare it for printing. Each layer is meticulously crafted, with considerations for temperature, speed, and material properties.
As the world watches, ICON stands at the forefront of these revolutionary changes, embracing the future of construction and design. With initiatives like the El Cosmico expansion, the possibilities are endless, transforming how we think about buildings and community spaces.
