This Houston company is 3D printing homes with eco-friendly materials

future of construction

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

While it may be true that the mother of invention is necessity, in today’s startup market, a more important factor is disruption. That’s where HIVE 3D, a Texas-based leader in constructing eco-friendly 3D printed homes, flourishes.

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 Utah-based Eco Material Technologies, North America’s leading producer of sustainable cement alternatives.

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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UH, Baylor researchers make breakthrough with new pediatric leukemia treatment device

childhood cancer

A team of Houston researchers has developed a new microfluidic device aimed at making treatments safer for children with hyperleukocytosis, a life-threatening hematologic emergency often seen in patients with leukemia.

Dr. Fong Lam, an associate professor of pediatrics at Baylor College of Medicine and a pediatric intensive care physician at Texas Children’s Hospital, partnered with Sergey Shevkoplyas, a professor of biomedical engineering at UH, on the device that uses a large number of tiny channels to quickly separate blood cells by size in a process called controlled incremental filtration, according to a news release from UH.

They tested whether performing cell separation with a high-throughput microfluidic device could alleviate the limitations of traditional conventional blood-filtering machines, which pose risks for pediatric patients due to their large extracorporeal volume (ECV), high flow rates and tendency to cause significant platelet loss in the patient. The results of their study, led by Mubasher Iqbal, a Ph.D. candidate in biomedical engineering at UH, were published recently in the journal Nature Communications.

“Continuously and efficiently separating leukocytes from recirculating undiluted whole blood — without device clogging and cell activation or damage — has long been a major challenge in microfluidic cell separation,” Shevkoplyas said in a news release. “Our study is the first to solve this problem.”

Hyperleukocytosis is a condition that develops when the body has an extremely high number of white blood cells, which in many cases is due to leukemia. According to the release, up to 20 percent to 30 percent of patients with acute leukemia develop hyperleukocytosis, and this places them at risk for potentially fatal complications.

The new device utilizes tiny channels—each about the width of a human hair—to efficiently separate blood cells through controlled incremental filtration. According to Lam, the team was excited that the new device could operate at clinically relevant flow rates.

The device successfully removed approximately 85 percent of large leukocytes and 90 percent of leukemic blasts from undiluted human whole blood without causing platelet loss or other adverse effects. It also operates with an ECV that’s about 1/70th of conventional leukapheresis machines, which makes it particularly suitable for infants and small children.

“Overall, our study suggests that microfluidics leukapheresis is safe and effective at selectively removing leukocytes from circulation, with separation performance sufficiently high to ultimately enable safe leukapheresis in children,” Shevkoplyas said in the release.

Greentown Labs adds 5 new Houston startups to climatetech incubator

Going Green

Greentown Labs announced that it added five startups to its Houston community in Q1 of 2025.

The companies are among a group of 19 that joined the climatetech incubator, which is co-located in Houston and Boston, in the same time period. The companies that joined the Houston-based lab specialize in a number of "green" applications, from converting plastic waste into sustainable materials to developing energy-storage solutions.

The new Houston members include:

  • Concept Loop, a project of Pakistan-based Innova8e Inc., aims to repurpose post-industrial and post-consumer plastic waste into sustainable building materials.
  • GeoFuels, a Sugar Land-based company that produces hydrogen by using baseload geothermal power and methane pyrolysis.
  • PLASENE, a Houston-based company with an innovative platform that converts plastic waste into liquid fuel and low-carbon hydrogen through its proprietary catalysts and modular, scalable, pre-engineered units platform. The company was named to Greentown's ACCEL Year 3 cohort earlier this year.
  • RepAir Carbon, an Israeli company with a fully electric, zero-heat carbon-removal technology that consumes minimal energy, operates without liquids or solvents, and produces no hazardous materials or waste.
  • RotorVault from Pasadena, California, is commercializing energy-storage and load-following solutions that are containerized, modular, and field-deployable systems built on flywheel technology.

Fourteen other companies will join Greentown Boston's incubator. See the full list here.

PLASENE and five other new members—Thola, Respire Energy, Andros Innovations, FAST Metals and Tato Labs—join Greentown Labs through its most recent Advancing Climatetech and Clean Energy Leaders Program, or ACCEL, cohort. ACCEL, which works to advance BIPOC-led startups in the climatetech space, announced its third cohort last month.

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A version of this story originally appeared on our sister site, EnergyCapitalHTX.

Houston startup unveils its innovative leather alternative at the rodeo

sustainable fashion

Last month’s Houston Livestock Show and Rodeo stirred up another rootin’ tootin’ time for Houstonians and beyond.

But before the annual event galloped into the sunset, there were quite a few memorable innovations on display, with one notably coming from Rheom Materials.

The Houston-based pioneer of next-generation materials presented its scalable, bio-based alternative known as Shorai, a 93 percent bio-based leather, through two custom, western-inspired outfits that showed off cowboy flair through a sustainable lens.

“I'm a Houstonian, I love the rodeo,” Megan Beck, Rheom’s business development manager, recalls. “We're sitting there talking about it one day and we're like, ‘Okay, we've got to do something with this leather to show people how good it can look in apparel, how easy it is to wear.’”

Buoyed by the idea that their materials are meant to “change your impact, not your life,” Rheom captured the real-life energy of their bio-leather outfits under the rodeo’s neon lights in a short commercial video and photo shoot with models donning the samples, while dancing and enjoying the festivities. Rheom created a skirt, a leather jacket, and then a leather top for the look.

“Houston is such a vibrant city,” Beck says. “There's so much innovation here. I think the rodeo is just a really, really great example of that. And so we wanted to take this opportunity to take some of these garments out there and go on the slide, go on some of the rides, go into the wine garden and go dancing, because if you've ever felt some of the materials in the market in this space, they're very stiff, you can't really move in them, they're a little fragile, they kind of fall apart.”

Not only do the models in the video look fashionable, but they also look comfortable, and the leather looks natural and supple. And to the naked eye, Shorai appears to be like the leather most wearers are accustomed to.

“What we really wanted to showcase in this is the energy and the movement of the leather, and to show people how good it can look in apparel, and how easy it is to wear, which I think we were able to accomplish,” Beck says.

Next up, Beck says Rheom wants to scale production of Shorai, the Japanese word for “future,” at a competitive price point, while also reducing its carbon footprint by 80 percent when compared to synthetic leather. According to Beck, Rheom plans to see Shorai products come to market sometime this year.

“We have companies globally right now that are testing materials, that are prototyping, that are making garments, making handbags and footwear, and making eyewear because we have a plastic, as well,” Beck says. “So, this year, I do believe we'll start seeing those products actually come to market, which is very, very exciting for us.”

And with their large-scale production partner already set up for Shorai, Rheom plans to start its first production run of the product soon.

“In April, we'll actually be starting our first production run,” Beck says. “We'll be doing it at full scale, full width, and a full run of materials. So over the next five years, we're only going to just try to increase that capacity.”

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