Aussie building firm turns to 3D printing to cut production costs

Ahmed Mahil, Co-founder and Chief Executive Officer, Luyten 3D

Boss Products, one of Australia’s oldest family-owned building products manufacturers has transitioned from its traditional manufacturing processes to the launch of the country’s first 3D printing factory in the building and construction industry. The Boss Products 3D printing factory is located in Melbourne and produces products for the industry across the commercial and domestic sectors. It is one of the biggest suppliers of planter boxes and retaining walls.

Why did Boss Products transition to 3D printing?

Michael Boss, Boss Products CEO, said the decision to transition to 3D printing operations was made two years ago. “We could see the challenges ahead were going to be tough.”

“As one of the leading manufacturers and suppliers of street furniture for parks and public outdoor spaces, planter boxes for commercial settings and retaining walls for domestic and commercial use, we were constantly having to find ways of making the manufacturing process more efficient but key elements including labour, power, and other operating costs were continuing to rise. We had to find another way,” Michael Boss further commented.

“We looked into 3D printing and realised that this was the answer. We searched the world for the most advanced and reliable 3D printing technology for building and construction and ended up finding the tech right here in Melbourne; Luyten 3D is the world’s best in its field.”

“Companies are buying Luyten’s 3D printing tech and transforming their businesses, their customers and their industries. We couldn’t believe how lucky we were to find the world’s best 3D printers for manufacturing and building and construction in the suburb next door.”

“We purchased their Platypus X2 3D printer which they customised for us. It is a large machine with extraordinary capacity that is extremely easy to use and incredibly versatile.”

Why is the traditional process no longer appealing?

According to Boss, the traditional process of manufacturing a planter box involves an order time of 4-6 weeks to allow for materials. During this time, the company builds the supporting structure for the mould, makes the mould, pours the concrete mix into the mould, and waits for the mould to dry. The actual manufacturing process takes up to 10 days in total.

“The traditional process involves significant resources, labour and other costs. It also takes a long time. Using our new Platypus X2 3D printer, we are able to print a planter box in 20-30 mins.We have cut time, resources and costs up to 95%. We are now literally able to manufacture at a rate that is hundreds of times higher at a fraction of the cost,” Boss said.

“We are able to provide our clients with an unlimited number of designs and the flexibility to change the shape, size of the boxes at the touch of a button. Using Luyten’s proprietary concrete mix, our planter boxes are six to eight times stronger than regular concrete.”

Boss believes that his business is now equipped to grow the business at an exponential rate and insulate the business against other issues impacting Australia’s manufacturing sector.

“We are looking at setting up a new factory close by to give us the increased production space to quadruple our printing capacity of planter boxes. We did our research and our homework has paid off. Our investment in 3D printing is already delivering significant returns.”

How has Luyten steered the industry towards the tech?

Founded in Melbourne, Victoria, Luyten 3D is a technically advanced 3D printer manufacturer for the construction industry. Luyten is the first 3D printing building and construction company to build a 3D printed house in the southern hemisphere. It has partnered with the University of New South Wales to progress printing of structures and base camps on the moon.  

“We are absolutely thrilled to see our technology being used right here in Australia. In fact, many businesses are starting to realise the unrivalled benefits of 3D printing. Our focus is to bridge the technological gap in large-scale and manufacturing industries through the introduction of robust construction automation technologies such as cutting-edge 3D printing and additive technologies,” Luyten Chief Executive Officer, Ahmed Mahil commented.

“We design custom large-scale three-dimensional construction printers for construction. In the case of houses, these can be printed in two days and assembled on day three. Printed elements are ready to handle and be moved within only five hours of being printed,” he said.

“This is the great thing about our special concrete mix, it cures quickly and delivers results that supersede what is currently available in the market at four times less cost. In addition, the build cost 70% less in comparison to traditional methods,” Ahmed Mahil further said.

Since launching, Luyten’s mission has been to make construction easier and more sustainable across a broad range of industries by reducing the time and cost to build, the amount of construction waste generated, and the impact of build activities on the surrounding environment. Luyten’s cutting-edge 3D printing and additive technologies have become a worldwide success story as companies across the globe scramble to purchase its printers.

“Luyten transforms construction projects that traditionally take months or years to complete, and finishes them within a number of days. The 3D concrete printing revolutionary technology reduces 60% of construction waste, 70% of production time, and 80% of labour costs when comparing hands-on construction projects,” Mahil further commented.

“The tech increases construction site efficiency with 60% guaranteed costs savings, 300-500 times shorter execution times, and an 80% total reduction in monetary expenses without formwork in concrete construction. The world has never seen capabilities like this before.”

“When forming Luyten, we were cognisant of the construction industry’s carbon footprint, and determined to create construction solutions for generations to come that reduce emissions. Our unmatched technology employs up to 40% less carbon dioxide emissions through proprietary mixes that reduce the use of cement, and the robotic systems reduce construction site and logistics carbon dioxide footprints by 50 to 70%,” Mahil concluded.