Mexico-based design practice MANUFACTURA has developed a bio-based construction material called CORNCRETL, combining limestone aggregates, dried corn residues, and recycled nejayote — the calcium-rich wastewater produced during nixtamalization, the ancient Mesoamerican process of soaking corn in an alkaline solution.
The material’s name merges “corn” and “concrete,” and its development drew references from pre-Hispanic Mayan construction techniques that relied on lime-based materials. MANUFACTURA came to our attention a couple of years ago when it innovated a technique for using 3D printing to create bioceramics from used eggshells, combining them with sustainable aggregates.
To prepare the mixture for fabrication, nixtamal waste is collected, dried, shredded, and pulverized to a consistent particle size before being blended with mineral aggregates and organic binders.
Printability testing used a WASP Concrete HD Continuous Feeding System integrated with a KUKA robotic arm, enabling precise and repeatable deposition.
Manufacturing on Demand
Compared to standard concrete, CORNCRETL achieved up to a 70% reduction in carbon emissions, according to MANUFACTURA.
Unlike Portland cement, lime-based systems harden at room temperature and require lower calcination temperatures during production, reducing energy consumption and greenhouse gas output. The material also naturally regulates humidity and carries self-healing properties for minor surface cracks.
The project targeted two intersecting problems in Mexico’s construction sector. Organic waste represents 64% of all waste generated in the country, with corn contributing significantly to that figure.
Construction labor conditions in Mexico also remain difficult, with limited access to technical training and elevated occupational risk. MANUFACTURA has therefore positioned CORNCRETL as a circular material strategy aimed at reducing organic waste while introducing more automated fabrication methods to the industry.
A full-scale prototype using the material was built at the Shamballa open-air laboratory in Northern Italy, the country’s first certified 3D printed residential structure.
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Author: Joseph Caron-Dawe
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