It may resemble any other 3D printer, but this one is colossal, akin to a crane, and is methodically constructing a hotel in the Texas desert, layer by layer. El Cosmico, an established hotel and campground on the fringes of Marfa, is undergoing expansion. The plan involves erecting 43 new hotel units and 18 residential homes across 40 acres, all crafted by a 3D printer. According to El Cosmico owner Liz Lambert and her partners—Austin-based 3D printing firm ICON and architectural firm Bjarke Ingels Group—this marks the world's inaugural 3D-printed hotel. Lambert extols the technology for its unparalleled creative potential. 'Most hotels are confined within four walls, often repeating the same unit design,' she notes. 'This technology allows for such fluidity and freedom in design—the curves, domes, and parabolas. It's an unconventional way to build.'

The new units can incorporate architectural elements that would typically be cost-prohibitive with traditional construction methods. The initial two units, a three-bedroom residence and a single-room hotel unit, feature single-story, 12-foot-high walls. These curvaceous, beige walls are being extruded by ICON's Vulcan, a 46.5-feet-wide 3D printer standing 15.5 feet tall and weighing 4.75 tonnes. A print technician oversees Vulcan as its robotic arm and nozzle traverse the site on a gantry. The 'ink' for this 3D printer is a cement-based material named Lavacrete, a proprietary blend engineered for strength, affordability, and printability. ICON CEO Jason Ballard explains that workers adjust the material's composition based on weather conditions. 'The secret lies in the admixtures that enable continuous printing,' he says, highlighting how humidity, temperature, and irradiance influence the material's behavior and even its final hue.

ICON is also pioneering a 3D-printed neighborhood of homes near Austin. Long-term, 3D-printed construction could potentially replace some skilled labor jobs, according to Milad Bazli, a science and technology lecturer at Charles Darwin University. 'From a social and economic perspective, especially concerning local jobs in remote areas, this shift to 3D printing is a challenge we must address,' Bazli observes. The expansion of El Cosmico is slated for completion by 2026, with hotel units priced between $200 and $450 per night.