An Austin startup is changing the future of military construction and making history in the process.
At Fort Bliss, the Army just opened the first of ten 3D-printed barracks, part of the Pentagon’s largest deployment of robotic construction technology to date.
The barracks were built by Austin-based ICON Prime with the Army Corps of Engineers. The project is designed to show how fast robotic construction can scale while providing modern accommodations for troops.
Bunks and gear lockers line a barracks hallway inside a newly built 3D-printed structure. (Photo: ICON)
“We’ve done something that’s unheard of. We printed 10 military barracks in six months,” said Will Hurd, ICON Prime President. “The military — the Department of War — has said in Senate hearings that this project would have normally taken 24 months, and we did it in six.”
Hurd says the speed doesn’t come at the expense of quality or cost.
“Not only are our soldiers, sailors, airmen and Marines going to be able to live in a place where they can recharge and be ready to defend our nation against our threats, we’re doing it cheaper, we’re doing it faster, and we’re doing it better — by using an innovation,” Hurd said. “And these are the tools that ICON Prime has perfected here in North Austin.”
Aerial view of newly completed 3D-printed barracks buildings with metal roofing. (Photo: ICON)
From Georgetown Homes to Military Barracks
ICON’s 3D-printing technology was proven right here in Central Texas before it ever reached Fort Bliss. The company teamed up with homebuilder Lennar to construct 100 homes in Georgetown’s Wolf Ranch community, built with high energy efficiency. From there, ICON branched out into resort homes, and it also built housing in Austin’s Community First Village for people experiencing homelessness.
“We are creating a completely different industry,” Hurd said. “The AI-enabled software you need in order to manage the big robots and the entire process — all of this is a new industry. We’re training people how to build using robots.”
A close-up view of ICON’s robotic printing arm as it lays down layered material to form a wall. (Photo: ICON)
Tackling a Military Readiness Problem
Army leaders say better housing means a better quality of life — and stronger readiness for troops. ICON Prime says that mission is central to why it’s working with the military.
“We’re here to help repair military readiness,” Hurd said. “What does that mean? Our barracks, our installations, are failing our soldiers. The Secretary of War has made it very clear that military readiness is eroded because of the disrepair these facilities are in. And a number of officials from multiple different administrations have said that our installations — like barracks — are as important as our weapon systems, just like our ships, tanks and planes.”
Next Stop: The Moon
ICON Prime's boldest goal may be even further from Earth. Working with NASA, the company has already demonstrated how moon dust — known as regolith — could be melted into solid construction material for roads, launch pads and astronaut habitats.
“Anything you do with concrete on Earth, you’re going to be able to do with this regolith piece, and we’re going to be demonstrating that as early as 2028,” Hurd said. “We’ve done all the testing with NASA.”
A robotic arm rigged with sensors and wiring is tested as part of ICON’s development of technology for lunar construction. (Photo: ICON)
