A joint research effort in Brisbane is reshaping thinking around how artificial intelligence and 3D concrete printing could influence the delivery of complex civil infrastructure in Australia. Running between 2023 and 2025, the collaboration brought together Queensland University of Technology and Everhard Industries to investigate how digital technologies might enhance conventional precast manufacturing, particularly for underground assets that require bespoke designs.

The team focused on creating concrete mixes that can be reliably 3D printed for civil uses. Traditional precast methods depend heavily on custom moulds, which can drive up costs and extend production timelines. By contrast, 3D printing allows components to be formed directly from digital models, offering a faster and more flexible way to produce customised drainage, utility and infrastructure elements that do not fit standard designs.

Reducing the environmental impact of concrete was a central aim of the research. QUT researchers tested mixes that partially replace cement with supplementary materials such as sugarcane bagasse ash and fly ash. Early testing indicates these alternatives can lower emissions while still delivering the strength and durability required for infrastructure projects, aligning with growing regulatory and commercial pressure to cut carbon output.

Photo by Ricardo Gomez Angel

Artificial intelligence has been used to streamline both material development and manufacturing processes. Machine learning models helped predict how different mixes would behave during printing, reducing the need for repeated physical testing. This approach shortens development cycles, limits waste and supports more precise experimentation, particularly when working with unfamiliar binders and printing conditions.

AI tools are also being explored for quality control during the printing process. Imaging systems can monitor layer formation and consistency in real time, allowing issues to be identified early. For precast manufacturers, this could improve reliability when producing complex geometries where precision is critical.

Dr Mohammad Kangavar, a senior civil engineer at Everhard Industries involved in the project, said the use of AI enables a much earlier understanding of how mixes will perform. He said it reduces material waste, supports better decision making and increases confidence when working with new and more sustainable materials.

Initial results have been encouraging, with the team producing printed prototypes and assessing their structural behaviour, including strength development and shrinkage. While large-scale commercial use is still some way off, these trials are helping establish a technical foundation for future applications.

Photo by Ricardo Gomez Angel

Ongoing testing remains essential before wider adoption can occur. Civil infrastructure must meet strict durability standards, and printed elements will need to prove long-term performance in varied conditions. Australia also lacks specific standards for 3D printed civil structures, highlighting the need for clearer design and compliance frameworks.

Despite these hurdles, interest in the approach is growing. The ability to avoid mould fabrication, speed up prototyping and produce cost-effective customised components makes 3D printing attractive for civil construction. Combined with AI-driven optimisation and monitoring, the technology could help reduce waste, improve efficiency and support the shift towards lower-carbon infrastructure.

For Australia’s construction and precast industries, the Brisbane research suggests digital tools are moving closer to practical use. With further development and clearer guidance, AI-supported 3D printed concrete could become a meaningful part of delivering more flexible, efficient and sustainable civil infrastructure.