New Horizons

On a quiet stretch of land along Tom Miller Street, something extraordinary has been taking shape layer by layer. At first glance, the homes look modern yet warm, with gently curved walls and textured surfaces that beg a second look. But it’s how these homes are built that sets them apart. Instead of traditional framing crews and stacks of lumber, Icon is using robotics and 3D-printing technology to construct the walls of these houses, marking a new chapter in homebuilding.

New Technology  

Icon, an Austin-based construction technologies company, is reimagining how homes are built by combining robotics, software, and integrated design. The company’s proprietary Vulcan construction system, which includes a 3D printer, an on-site delivery system, and CarbonX, a cement-based building material, allows Icon to print a home’s wall system faster and with less waste than traditional construction methods. 

When construction begins, the printer is set up directly on the concrete slab on precisely leveled rails. CarbonX is mixed on site and pumped into the printer, which pushes out the material layer by layer based on a digital design file. The design directs the printer where to start and stop, allowing windows, doors, plumbing, and electrical systems to be seamlessly integrated into the walls as they’re printed. 

Speed is one of the most obvious differences between 3D-printed construction and conventional homebuilding. Icon can print the full wall system of a 2,000-square-foot, single-story home in about seven days. With typical daytime working hours, a more traditional process generally takes 14 to 20 days. In Mueller, the homes feature 3D-printed first floors, with second stories constructed using traditional methods. Once the wall system is complete, roofs, windows, doors, and interior finishes are added, blending this advanced technology with familiar building practices. 

Beyond efficiency, 3D printing creates new architectural possibilities. Curved walls, rounded corners, and textured surfaces which can often be cost-prohibitive or impractical with conventional construction are easily achieved through robotic printing. In the Mueller homes, that freedom is on full display in details like the basketweave-inspired design near the front of each house, that has quickly become a favorite among homeowners. 

Focus on Sustainability 

Sustainability is central to Icon’s approach. CarbonX was developed to reduce the environmental impact of residential construction while delivering exceptional durability and resilience. By replacing multiple traditional building components such as framing, insulation, drywall, vapor barriers, and exterior finishes with a streamlined wall system, Icon reduces material use, labor, and construction waste. The concrete walls also provide increased thermal mass, helping regulate indoor temperatures and reduce heating and cooling costs over time. 

“By automating construction and reducing material waste, we’re able to build homes that are not only faster to deliver, but more energy efficient and resilient over their lifetime,” says Brooke Bauguess, SVP of marketing and communications at Icon. 

That focus on efficiency and longevity made Mueller a natural fit for the project. The homes occupy some of the final undeveloped lots in our community. Icon also partnered with the Mueller Affordable Homes Program, with select homes priced starting around $195,000. “Mueller’s blend of walkability, green space, and sustainability aligns closely with our values,” Bauguess says. 

Community response has been overwhelmingly positive. Icon hosted a neighborhood gathering during construction, inviting residents to watch the printing process and ask questions. Passersby routinely stopped observing the printer in action, and several buyers of the new homes already lived here in Mueller, so they were able to watch the progress as it happened.

For many visitors, the biggest surprise came when they stepped inside the homes. Despite any preconceived notions about concrete construction, the interiors feel warm and inviting. The visible layers of the printed walls and the gentle curves create a softness that brings character and comfort to the space. 

Looking ahead, Icon envisions a future where thousands of robotic printers are building tens of thousands of homes each year. With plans to release a new multi-story printer and expand access to its technology globally, the company sees 3D printing as a powerful tool in addressing housing shortages worldwide. 

For now, the focus remains local. “We’re grateful to be bringing these beautiful, resilient homes to Mueller, one of Austin’s most beloved communities,” Bauguess says. “Handing over the keys and welcoming new homeowners into the neighborhood is what makes this project especially meaningful.”