Wall
System
The Wall System is a high-performance 3D-printed concrete wall assembly engineered to deliver superior strength, energy efficiency, and design freedom. The system extrudes precise, layered wall geometries that serve as the building’s primary load-bearing structure.
A Look Inside
Core Highlights
Engineering Service Report 4652
The WALL SYSTEM
The ICON wall system combines advanced 3D-printed concrete construction with high-performance spray foam insulation to deliver superior thermal efficiency. The dual-bead printed shell creates an insulated cavity that minimizes thermal bridging while maintaining structural integrity.
Features:
3D-printed FormCrete Shell: Durable, precision-manufactured concrete envelope
Cavity Insulation: Injection open-cell spray foam for complete thermal barrier
Configurable Core Spacing: 4ft on-center structural cores
Bond Beam Integration: Solid Concrete sections for floor and roof connections
Cross-tie Reinforcement: Steel ties connecting inner and outer shells
Printed Reinforced Concrete: Reinforcement is embedded in-line from the nozzle of the printer
3D Printing vs Traditional Wall Costs
Conventional Wall System
ICON Wall System
Advanced materials
FormCrete is our proprietary, next-gen building material.
Mixed on site and pumped directly to the printer, FormCrete combines locally sourced ingredients to create a new category of high-performance cementitious construction.
FormCrete reduces embodied carbon both within the material itself and through locally sourced inputs that lower procurement emissions. The mix achieves a 24% carbon reduction, equivalent to 85 kgCO₂e per cubic yard, while delivering compressive strengths of 2,500–3,500 psi. By building with FormCrete, we can meaningfully lower construction-related environmental impact while delivering durable, energy-efficient structures designed for long-term sustainability.
Combined with ICON’s robotic wall system, FormCrete delivers a scalable, low-carbon alternative to stick-framed construction, validated by a 2024 MIT study showing reduced embodied and operational impacts.
ICON’s wall system combines 3D-printed concrete and spray foam insulation to create an insulated dual-bead structure that reduces thermal bridging while preserving strength and performance.
ICON’s 3D-printed double-shell wall system extrudes rapidly curing CarbonX to form a monolithic, load-bearing assembly with alternating reinforced cores, a continuous insulated cavity for MEP routing, and uninterrupted load paths that eliminate traditional formwork and jointed construction.
Basket Weave
Chevron Pattern
Non-Planar Surfaces