AEC Print Technology: A Time of Innovation and Change

Why, When and How to bring Printing In-house

The global AEC industry is booming with a forecasted annual growth rate of 10.3%, and it is expected to reach $24 billion in revenue by 2032. Additionally, non-residential construction grew by nearly 20% in 2023 — a growth rate not seen since before the Great Recession. This growth is attributed to infrastructure demand, government stimulus, energy transition and new post-COVID customer demands.

However, along with this growth, the AEC industry has also experienced some significant challenges, including the rising costs of energy, materials and wages, as well as labor shortages and economic uncertainty. Despite these obstacles, executives say they’re optimistic and are proactively preparing their firms to operate more efficiently.

Trends Affecting the Industry as a Whole

Against this landscape, firms face four key industry trends:

1. The increasing adoption of BIM solutions and rapid advancements in virtual tools. These trends are revolutionizing the AEC design process. As a result, firms are scrambling to adopt and master new printing technologies that enhance collaboration, visualization and efficiency to bring blueprints, technical drawings, schematics and site plans to life.


2. The industry’s move toward off-site construction of modular and prefabricated techniques. This approach involves the manufacture of building components in a controlled factory environment with assembly done at the job site, with the subsequent need to have the latest versions of printed blueprints on hand.


3. Substantial government infrastructure funding via the Inflation Reduction Act (IRA) and other federal legislation. This has triggered an uptick in construction activity nationwide, leading to a higher volume of large-format printing that’s essential for guiding project teams in the field.


4. Sustainability initiatives, including via the IRA: These are also driving increased print volume. Nearly $350 billion in clean energy investments were announced after the IRA passed. As clients become more driven by the need to reduce their environmental impact, firms are also becoming more focused on resource-saving technologies, including finding ways to lower energy consumption and reduce paper waste in the production processes.

Why Traditional Printing Still Matters in a Digital-first Era

Since AEC firms must convey various design iterations, traditional 2D printing of these materials remains a key component of project workflows, especially in fieldwork. On-site teams still need hard copies of schematics for precise measurements and mark-ups or to review site plans in areas without reliable internet. Firms also need printed materials for contractual purposes, recordkeeping and regulatory compliance.

The volume of printing required depends on the size, scale and timeline of projects and workflows. Projects can span months or years, with many moving parts. Firms often need to produce hundreds or even thousands of large-format blueprints, schematics and drawings for every stage of a complex project.

Frequent project changes and cost overruns are another factor in print volume. A survey of senior AEC executives found that construction projects typically exceed their budgets and schedules by as much as 30% to 45%. In another survey, contractors said that managing cost volatility was their top priority. Inaccurate or delayed printing of large-format materials can exacerbate these problems and lead to costly errors and further project delays.

Breakthroughs in Print Technology

Choosing the right print technology can help firms meet challenges. Here are seven technological breakthroughs that have made large-format printing more energy- and cost-effective:

1. Consolidation of black and white to full-color printing: This eliminates the need for multiple printers since one device can switch from monochrome to full color for high-quality CAD lines and graphics on various paper types and other media.


2. Compact printer designs: Today’s large-format printers are up to 20% more compact, so they’re easily portable and can be used either in the office or on a job site.


3. One-click continuous, high-speed printing: Equipment can print with one click from a PC or Mac from a variety of formats including PDF, TIFF and DWF files.


4. Energy efficiency: Modern printers are designed and built with energy efficiency in mind. They include features like automatic power-off and sleep modes and some are ENERGY STAR® certified.


5. Advanced scanning capabilities: Integrated scanning enables seamless digital-to-print workflows and features like post-screen retouch with automatic background removal.


6. Enhanced security against data breaches: Printers are now embedded with features that defend against cyber-attacks, reduce risk and improve compliance. Everything is monitored from a centralized dashboard.


7. Easy maintenance: Routine maintenance is performed automatically to optimize printer performance.

Bringing it Home: Key Advantages of In-house Print Capabilities

Although AEC firms have traditionally outsourced printing of large-format materials such as technical drawings and blueprints, the digital transformation of large-format printing has resulted in innovations that make producing these materials in-house easier and more accessible than ever before.

As technology matures and users’ technical know-how increases, it has become easier to harness the speed and cost savings of in-house printing. The typical cost to outsource printing of large-format materials is $2 to $5 per square foot for monochrome blueprints and even more for color prints. Revisions, which are inevitable, drive up the cost further. For a medium-size firm, this could amount to tens of thousands of dollars per year.

In-house printing offers tremendous potential for long-term cost savings. Outsourcing this printing to reprographic vendors can often cost thousands of dollars per project, depending on the complexity, volume and number of revisions. It also requires dedicated staff to manage coordination, pick up new prints and ensure timely delivery to stakeholders. According to customer data, AEC firms can save 46% or more when switching from outsourced to in-house printing.

Firms can reap a number of benefits by switching from outsourced to in-house printing of large-format materials:

• Cost savings: Investing in large-format printers can reduce long-term printing costs by as much as 400% compared to outsourcing. Firms also save on mark-up costs, rush fees and delivery costs associated with outsourcing the print function to a reprographic vendor.

• More control and flexibility:  In-house printing offers ultimate control by eliminating the possibility of over-ordering or running short of critical materials. Total control over production makes it easy select the color, size and other output factors. It’s also easy to pivot a project or handle change requests without extra layers of communication (or possible miscommunication) with the print vendor.

• Faster turnaround: With anytime printing capabilities, firms eliminate wait times and rush requests. Streamlined project workflows also make it easy to share documents internally and externally while improving productivity.

• Greater document precision:  Having a wide-format printer on site allows firms to generate high-resolution renditions that meet all specifications on the media of choice. With the migration from laser to inkjet, printers produce finer details, especially in color-rendered drawings or when blueprints include color-coded elements.

• Faster response time:  In-house printing makes it easy to respond quickly and impress clients or project partners. It’s much easier to print isolated pages for mark-ups or signoffs with equipment that handles both printing and scanning of drawings or mockups. Professionally printed pieces often bring a vision to life better than digital images.

• Lower cybersecurity risk:  A recent survey found that 59% of design and construction firms experienced a cybersecurity threat in the last two years. Confidential designs and blueprints are less vulnerable when they’re only being routed internally for printing. With built-in security software, an in-house printer reduces the risk of intellectual property theft or data leaks.

Implications of Modern Print Technology

Modern print technology has long-term implications for AEC firm growth and competitive advantage. The hardware now features improved ink formulations and is optimized for high-speed, high-volume output while still maintaining exceptional detail. They are also faster, more reliable and can support a wide range of media including bond paper, technical paper and presentation boards.

Here are a few questions to explore when considering bringing your large-format printing function in-house:

• Here are a few questions to explore when considering bringing your large-format printing function in-house:


• How many square feet per month are you currently printing?


• How often do you currently outsource printing of large-format plans or drawings?


• What are your current outsourced printing costs on a monthly and annual basis?


• Do you currently use two different devices to print black and white versus color materials?


• Are you printing duplicates and, if so, how many pages are they?


• Do you need to scan in drawings that are redlined or marked up?


• Do you need multiple rolls for printing varied size materials without changing paper?


• Do you offset any printing costs through client billing?


• Have you had any security breaches in the past year or two?

Finding the Right Balance

Bringing print capabilities in-house by investing in the latest technology could be a smart move. The key is understanding the technology that is available and running an analysis as to how it can increase speed and efficiency while lowering costs for your firm. When comparing outsourcing your production to handling it in-house, it is important to assess the total cost of equipment ownership over its lifecycle, along with equipment acquisition costs, operating expenses and maintenance. The decision ultimately hinges on balancing up-front costs with ongoing operational needs.

About the Author

With over 25 years of experience in the printing and imaging industry, Mark Villari serves as the National Director of Wide Format for Flex Technology Group. Bringing a proven track record in both sales and service leadership, his career spans a range of experience that reflects deep technical knowledge and a passion for innovation. Mark is committed to delivering cutting-edge technology and tailored solutions to customers that drive growth by aligning the latest advancements with real-world business needs.

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