Mexico: Mexico-based design studio MANUFACTURA has developed a bio-based construction material, Corncretl, which it says can reduce emissions by up to 70% compared with conventional Portland cement. The material replaces clinker-based cement with lime-based binders that harden at room temperature and require lower calcination temperatures during production. As a result, the process reduces energy use and greenhouse gas emissions. Corncretl combines limestone aggregates, dried corn residues and recycled nejayote, a calcium-rich byproduct of corn processing. The use of agricultural waste forms part of a circular material strategy aimed at lowering embodied carbon and reducing landfill volumes. The studio said the material maintains mechanical performance suitable for additive manufacturing and reported that it offers humidity regulation and self-healing properties typical of lime-based systems.
MANUFACTURA tested the material using a WASP Concrete HD Continuous Feeding System with a KUKA robotic arm to assess printability and controlled deposition. For its first 3D-printed prototype, MANUFACTURA sourced the waste through collaborations in Europe, collecting residual material in Berlin and then transporting it to Italy for processing. A full-scale 3D-printed prototype was later installed at the Shamballa open-air laboratory in northern Italy to evaluate structural feasibility and assess material behaviour under real-world conditions.
