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Houston startup constructs eco-friendly 3D printed homes

seeing green

HIVE 3D is bringing science fiction to reality with this Texas project. Photo courtesy of HIVE 3D

A Houston company has teamed up with a Utah-based sustainable cement alternatives producer to construct eco-friendly homes made from 3D-printed pieces.

HIVE 3D was already revolutionizing the home-builder industry with its lightweight gantry system and mobile robotic arm system to 3D print its homes, but it took a giant leap further with its partnership with Eco Material Technologies.

Together, they are building the world’s first near-zero-carbon, 3D-printed homes. Using Eco Material’s cement mixture called PozzoCEM Vite, which has 92 percent lower emissions than traditional concrete that can set in just a few minutes, they are focusing on providing a sustainable, cost-efficient and affordable housing solution.

“We want our homes to last 1,000 years,” Timothy Lankau, CEO, Hive 3D CEO, tells InnovationMap. “We want archaeologists to dig them up and wonder what they were. I mean, you go to the Parthenon in Rome, and it looks similar today to how it did 2,000 years ago because the materials are so stable.

“Concrete's just a very stable material. It doesn't change over time, and that's also why building with stone and masonry is important for the future. We think it's more sustainable because it's ultimately going to be better in terms of longevity.”

Key collaboration

Eco Material Technologies and HIVE 3D’s collaborative mission began through a mutual desire to develop sustainable and eco-friendly solutions for the construction industry.

“Both companies recognized the pressing need to reduce the environmental impact of traditional construction materials and processes and the need for affordable, high-quality housing,” says Grant Quasha, CEO of Eco Material Technologies. “The partnership between the two companies began when Eco Material Technologies reached out to HIVE 3D to explore the potential of incorporating their eco-friendly materials into 3D printed construction.

“HIVE 3D recognized the opportunity to combine their expertise with sustainable material solutions. The finished product of this collaboration is an eco-friendly construction material that can be 3D printed into various structural elements like walls, floors and columns.”

Proof of concept

Photo courtesy of HIVE 3D

HIVE 3D’s first full project, a 3,150-square-foot home located in Burton, Texas, was printed with a rotating team of just four people using PozzoSlag, which replaces 50 percent of the portland cement in concrete and has been used in roads and bridges in Texas for over a decade.

The home used several innovations that hadn’t been used in a 3D printed house before, including parametric wall designs, foamcrete wall insulation, and pigmented concrete layers.

“Our product is more sustainable because it utilizes proprietary technology that allows for the use of alternative materials to replace the clinker and processes from traditional cement that contribute to its high emissions,” says Quasha. “It is estimated that the portland cement industry contributes to 8 percent of global emissions annually, but by utilizing Eco Material Technologies' cement replacement solutions ... builders can significantly decrease their carbon emissions without compromising on the product's setting time or long-term strength."

Each ton of portland cement replaced by a ton of Eco Material's products, PozzoSlag or Pozzocem, reduces emissions by close to one ton, Quasha explains.

The Calais project, located in Round Top, Texas, behind the Halles, an antique shopping and design destination, broke ground in March 2023 and will feature a collection of tiny homes known as casitas, including studio, single-bedroom and two-bedroom models, ranging from 400 to 900 square feet.

“These small homes will serve as a model for affordable and eco-friendly housing throughout the country,” says Lankau. “We plan to build them at a speed and cost point that is unprecedented in the affordable housing space.

“Ultimately, we want to build houses at a disruptive price point. We want to be vertically integrated and put our homes on the market at a significant discount to market wherever they are. And by significant, we're talking 20 or 30 percent. That's our goal.”

The right resources

Photo courtesy of HIVE 3D

HIVE 3D worked with CyBe Construction to create a mobile construction 3D printer and mixing system that allows the printing mortar to be mixed onsite, which eliminates a significant amount of labor and time, which means those savings can be passed on to the consumer.

“We worked with a company called CyBe in the Netherlands to build a robotic arm, and that arm has about an 11-foot reach, and it can go all the way in a circle around itself,” says Lankau. “So, it drives around the foundation of the house, printing sections of the house at a time. So, it'll print a section, drive to the next section, and print the next section.

“So instead of having this many different materials and these many different traits, people that do all these different things, we have a machine that just uses one material and prints the wall.”

HIVE 3D has an internal engineer that works through all of the structural issues that may come up on projects and helps them build homes with monolithic, foot-thick concrete walls with rebar and steel supported in them.

According to Lankau, their 3D printed homes are tornado-proof, hurricane-proof, pest-proof, bullet-proof and can virtually withstand anything because of the sustainable materials used to build them.

“They're everything-proof,” says Lankau. “Just because of the natural strength of the concrete and the steel we use to create them, they can support millions of pounds. So, it's actually a stronger material than a typical house. By a factor of 100. Like I said, it's bulletproof and tornado-proof. You could drive a car into it, and it would total the car. I mean, it's a very, very sturdy structure.”

A bright future

Photo courtesy of HIVE 3D

Moving forward, HIVE 3D would like to continue to innovate and advance its 3D printing technology by leaps and bounds.

“The science fiction goal here, which is maybe a five-year goal, is to be able to drive onto a site, press a button, and watch the robots work,” says Lankau. “We want to be a significant home builder. So, in five years, we want to be building a lot of houses quickly and affordably and we want to continue to automate more and more of the process.”

Right now, there is no formal process for commissioning a HIVE 3D printed home. Perspective customers are directed to the website, then put in a request to build a home, go through a screening process and if the project is a good fit, they'll put that project into their pipeline.

“We can build them quickly. It's just a matter of getting to them,” says Lankau. “We're also going to be doing some developments in Texas probably to start. We also have some international things that we'll be looking into next year. But right now, it's mostly in Texas. We'll be building some developments and putting those homes on the market. We hope to have some out this year and then a bigger chunk next year as we get more machines working. Those will be announced on our website.”

As HIVE 3D continues to find ways to scale its business model, there is a laser focus on the diminishing idea of the “American Dream,” where young families are able to purchase their first home. With the rising costs of supplies and labor, those families have been priced out of the market.

“That’s almost all we think about,” says Lankau. “Homeownership and that part of the American Dream is really struggling right now because the affordability gap between what the average person makes and what the average house on the market costs is just getting wider and wider.

According to Lankau, there are a lot of options to address the supply gap, but there aren’t an equal number of options to solve the affordability issue. Their goal is to find the best ways to deliver real cost savings over both traditional construction and other automated technologies.

“About three weeks ago, we kind of hit the inflection point in our current project where we printed a little house in three days. The cost of the house was what we wanted the cost to be, which is a disruptive amount less than what you could do traditionally or with any other construction technique. And we said, okay, now we're far enough along. We have this system. It's a scalable system. So, we're right now putting some capital together to go out and buy, build more of these machines and get out and start doing these truly affordable housing projects. Because that's where our heart is. Our heart's on the affordable side.”

HIVE 3D’s project in Burton, Texas isn’t available for sell yet, but it will be listed on Airbnb for interested customers to go and experience when it’s completed.

Additionally, the Casitas units in Round Top will be short-term rentals for festival patrons.

“We’ll go directly to market with our next projects,” says Lankau. “And then we'll sell that big house property in Burton at the end of this year.”

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This article originally ran on InnovationMap.

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Houston's KBR to provide tech for Singapore SAF plant

SAF agreement

Houston engineering and technology contractor KBR has been picked as the technology provider for what’s expected to be Asia's first commercial-scale ethanol-to-jet sustainable aviation fuel (SAF) plant.

The proposed plant on Jurong Island in Singapore is being developed by Keppel Ltd.’s Infrastructure Division and Aster Chemicals and Energy. KBR will provide technology licensing and Front-End Engineering Design (FEED) services based on its PureSAF technology.

The plant has a planned production capacity of up to 100,000 tons of SAF per year. The plant is subject to final investment decisions and regulatory approvals.

“We are looking forward to working with Keppel and Aster on this key project and to support Singapore’s ambition of becoming Asia’s leading SAF hub and advancing the ongoing efforts to decarbonize the country’s aviation ecosystem,” Stuart Bradie, KBR president and CEO, said in a news release.

According to KBR, its PureSAF Technology can process multiple feedstocks like bioethanol, syngas, carbon dioxide and hydrogen and convert them to SAF, diesel and gasoline.

The technology was developed by Swedish Biofuels AB and commercialized by KBR.

“KBR’s PureSAF is a feedstock-flexible, bankable technology that is designed to deliver a 100% drop in jet fuel, ready to power aircraft without blending,” Bradie added in the news release. “We are constantly innovating our SAF solution to make it compatible with feedstock availability in different regions and to enable the aviation industry to transition to low-carbon jet fuel with a cost-optimized approach.

KBR has also entered into a memorandum of intent with Keppel’s Infrastructure Division, which states that the companies will collaborate again on decarbonization efforts across biofuels, plastic recycling, digitalization via AI, and SAF.

KBR announced in October that it would spin off its Mission Technology Solutions business, nicknamed SpinCo. The scaled-down KBR, nicknamed RemainCo, would concentrate solely on sustainability technology and services designed to reduce carbon emissions and support energy transition efforts. SpinCo named its new CEO and CFO earlier this month.

Houston energy expert discusses why hydrogen still has a future

Guets Column

Not long ago, hydrogen was hailed as the next big thing in clean energy. Investors poured in, and countries from Japan to Germany built ambitious hydrogen strategies. It wasn’t a new discovery; hydrogen has been used for over a century in refineries and fertilizers, but it suddenly found itself reborn as the world began working toward decarbonization.

When hydrogen burns, the only byproduct is water. Green hydrogen, produced with renewable power, could replace fossil fuels in everything from trucks to ships to steel mills. But the momentum has cooled. Costs remain stubbornly high, several projects have been delayed or canceled, and policy support has wavered. In the U.S., a change in administration has created uncertainty. In Europe, some governments are slowing funding or revising hydrogen mandates. Even the International Maritime Organization (IMO) recently postponed a key vote on fuel-carbon standards.

Yet as Mike Graff , former Chairman and CEO of American Air Liquide, said in an Energy Forum episode with Ed Emmett at Rice University’s Baker Institute, “The world is always looking to make sure that energy is first available, it’s affordable, and then it’s clean. And I see hydrogen over time evolving in that manner.” He also noted that “companies have produced hydrogen and utilized hydrogen for over 100 years, and they’ve done that very safely… I think we can continue that moving forward.”

China has doubled down on hydrogen as part of its industrial strategy, building massive electrolyzer manufacturing capacity and funding dozens of pilot projects across transportation and heavy industry. Japan and South Korea also stand out as examples of how sustained policy support can drive hydrogen progress.

Where Hydrogen Fits Today

To understand hydrogen’s role now, it helps to remember what it actually does. About 76 percent of global hydrogen is produced from natural gas and used in refineries, fertilizer plants, and chemical production. This so-called “gray hydrogen” is essential but carbon-intensive.

What’s new is the rise of low-carbon hydrogen, “blue” hydrogen made from natural gas with carbon capture, and “green” hydrogen produced by splitting water with renewable electricity. These methods are expensive, but they’re growing. According to the International Energy Agency, global low-emissions hydrogen output rose about 10 percent in 2024.

Hydrogen is also expanding beyond industry. As Graff explained, it already powers thousands of forklifts in warehouses across the U.S. and is beginning to appear in commercial trucking, locomotives, and even aviation prototypes. “You can now drive 600 to 800 miles on a hydrogen fuel-cell truck,” he noted, “and refuel in 30 minutes, just like you would refill for diesel.”

The Cost Challenge and a Gulf Coast Opportunity

So why the slowdown? One word: economics.

Even with generous tax credits, green hydrogen can cost two to three times more than conventional fuels. Electrolyzers are still expensive, though costs are falling as Chinese suppliers introduce low-cost alternatives.

Infrastructure is another hurdle. Pipelines, storage, and fueling networks need to be built from scratch.

But those same challenges point to opportunity, especially along the U.S. Gulf Coast. The region already has one of the world’s largest hydrogen pipeline systems and a well-established energy infrastructure. Texas, in particular, has a head start. It already hosts nearly 1,000 miles of hydrogen pipelines, about 64 percent of the U.S. total, and some of the world’s largest hydrogen storage sites at Moss Bluff, Spindletop, and Clemens. Out of 140 hydrogen plants operating nationwide, 43 are in Texas, supported by extensive refining and natural gas infrastructure. This combination of assets gives the Gulf Coast an unmatched foundation to scale low-carbon hydrogen and integrate production, storage, and end use across industries.

As Ken Medlock , Senior Director of the Center for Energy Studies at Rice University’s Baker Institute, explains in his report: Developing a Robust Hydrogen Market in Texas, Texas has all the critical elements needed to lead in a low-carbon hydrogen economy, including existing infrastructure, a skilled workforce, and proximity to industrial demand centers. That combination gives it a distinct advantage in scaling up hydrogen production and use.

Governments around the world are showing renewed confidence in hydrogen. The European Commission awarded nearly €3 billion to 13 major projects, while Japan and South Korea continue expanding fueling networks. China is leading one of the most ambitious buildouts, with more than 50 planned hydrogen projects and a rapidly growing fleet of fuel-cell vehicles. Despite recent setbacks, global investment has surpassed $100 billion, and projects in places such as Chile, where strong renewables and low-cost Chinese equipment help make projects feasible, are moving toward final investment decisions.

What Comes Next

Hydrogen’s future won’t depend on replacing every fuel, but on filling the gaps where batteries and biofuels fall short.

Transportation: This is where momentum is strongest today. Batteries dominate cars, but hydrogen fuel cells excel in heavy trucks, ships, and planes. As Graff noted, “You can design a commercial vehicle with the same utility as diesel but powered by hydrogen.” Airbus and Boeing are testing hydrogen propulsion concepts, and several ports are experimenting with hydrogen bunkering for cargo ships.

Industry: Steel, cement, and chemicals account for a quarter of global emissions. Hydrogen-based direct-reduced-iron (DRI) steelmaking is being piloted in Europe and Asia and could transform how these materials are produced at scale.

Storage: Hydrogen can store energy for days or weeks, serving as backup for renewables like wind and solar. But storage remains very costly and may only prove viable for the “last mile” of greenhouse gas reduction or grid stability.

These uses may sound niche, but that’s how technologies scale. They start small, gain an economic foothold, and expand as costs decline.

Conclusion

Hydrogen's early, perhaps irrational, exuberance may have cooled, but amidst the rubble of cancelled projects are the beginnings of an industry that could play a vital niche role on the journey towards a lower carbon intensity energy future. As costs fall and infrastructure around the world expands, hydrogen's role will expand into the nooks and crannies of the energy industry.

It won't replace every fuel, but it doesn't have to. Success will come from steady, project-by-project progress.

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Scott Nyquist is a senior advisor at McKinsey & Company and vice chairman, Houston Energy Transition Initiative of the Greater Houston Partnership. The views expressed herein are Nyquist's own and not those of McKinsey & Company or of the Greater Houston Partnership. This article originally appeared on LinkedIn.

Houston energy startup launches to power AI data centers with Microsoft agreement

power move

Buoyed by a purchase agreement from Microsoft, Houston-based Joulent recently launched to build power plants that meet the electricity demands of AI data centers and other computing-heavy industries.

Joulent builds dedicated power-generating facilities that feed directly into data centers and other power-dependent facilities, eliminating the need for companies to siphon power from grids. Joulent’s plants combine generation, storage and smart controls in a modular, scalable setup, according to a news release.

Investment firm Engine No. 1 established Joulent in collaboration with energy technology company GE Vernova.

Joulent’s first project, the Project Kilby natural gas facility in West Texas, will be co-located with a Microsoft data center. It’ll deliver about 2.67 gigawatts of power under a 20-year deal between Microsoft and Energy Forge One, a subsidiary of Houston-based Chevron. Engine No. 1 and Chevron teamed up to build the plant.

GE Vernova will supply most of the plant’s power capacity, with additional capacity coming from Solar Turbines, a subsidiary of Irving-based construction and mining equipment manufacturer Caterpillar.

“Leadership in the AI era will be determined by who can deliver energy and compute the fastest, most reliably, and at the lowest cost,” Chris James, founder and CEO of Engine No. 1 and Joulent, said in a news release.

“By building new power-generating facilities, Joulent enables customers across industries to power the next chapter of American innovation, while reducing pressure on existing grids and maintaining affordability for ratepayers.”

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