Kansas State Researcher Tests 3D-Printed Concrete Modules for Storm Shelters

The problem with storm shelters

Manufactured home communities face a gap in severe weather protection. Most shelters are expensive, and retrofitting existing neighborhoods is difficult. Reese Greenlee, an assistant professor of architecture at Kansas State University, is testing whether 3D-printed concrete modules can offer a practical middle ground.

The project focuses on a single full-size module measuring four by four feet. Rather than building an entire house with a large gantry printer, the team prints structural panels off-site in a controlled environment, ships them, and assembles them on location. That approach sidesteps the logistics of moving a giant printer to a job site.

Testing for tornado conditions

The printed geometry is not arbitrary. Greenlee's team is testing how print orientation, infill patterns, and wall thickness affect performance under extreme wind pressure and debris impact. Storm shelters must meet ICC 500 and FEMA P-361 criteria, including the ability to withstand a two-by-four traveling at 100 mph.

The next phase moves to an Intertek facility in Minnesota, where the full-scale module will face tornado wind speeds and debris-impact testing. The team is paying special attention to joints, corners, and penetrations, because those are the weak points in most shelter designs.

Why 3D printing fits

Concrete 3D printing gives designers more freedom to shape geometry for specific loads. You can vary wall thickness, add internal reinforcement channels, and optimize infill without the constraints of traditional forming. The trade-off is material behavior. Concrete behaves differently when deposited in layers than when poured in a form, and the team is still learning how those differences affect strength.

If the module passes certification, the technology could offer a faster, cheaper path to code-compliant shelters for vulnerable communities. Greenlee says the social angle matters as much as the technical one. Manufactured housing residents often face stigma and limited access to safe infrastructure. A 3D-printed shelter that meets the same standards as conventional construction could help close that gap without drawing attention to the home's affordability.