Embracing Digital Transformation in Themed Construction
3D Concrete Printing (Source: HeidelBerg Materials)
The New Frontier of Themed Construction
Themed construction has always been about innovation — pushing beyond the ordinary to craft immersive, story-driven environments. But now, a wave of digital transformation is reshaping how we design, document, and build these spaces from the ground up.
From Building Information Modeling (BIM) to digital twins, from real-time design collaboration to large-scale 3D printing, we’re entering a new era where creativity and constructability are no longer at odds — they’re allies.
To explore this evolution, we sat down with Jesse Hanson, PE, engineering designer, 3D concrete printing expert, and a Strategic Partner at CASTO Creative, to discuss how digital tools are transforming immersive design from both a creative and technical standpoint.
Q&A with Jesse Hanson, PE — On the Cutting Edge of 3D Printing & Digital Fabrication
“Creativity doesn’t end with the vision — digital tools help bring it to life exactly as imagined.”
— Jesse Hanson, PE
Can you tell us a bit about your background and how you became involved in 3D printing for themed construction?
“My background is in engineering design and construction. I started in 3D concrete printing about four years ago, working with one of the major 3DCP companies in the U.S. I helped develop their structural designs, systems, and code documentation.”
What role do you see digital fabrication playing in the future of immersive design?
“Digital fabrication isn’t just compatible with immersive design — it’s necessary to ensure the construction matches design intent. Whether it’s architectural walkthroughs, real-time modeling, or construction planning, digital tools optimize the entire process and ensure the vision is executed with accuracy.”
3D Concrete Printer (Source: Hal Robotics)
How 3D Printing Is Redefining Constructability
According to Jesse, one of the biggest impacts of 3D printing is the shift in what we mean by constructability. In traditional construction, feasibility is often determined by labor skillsets and material limitations. But with 3D printing?
“Your constructability is no longer bound by experienced boots on the ground or traditional square-box materials — it’s limited only by what your printer, materials, and designers can accomplish,” Jesse says.
3DCP enables direct model-to-fabrication workflows, which means imaginative forms and generative design elements can go straight from digital models to physical structures with far fewer translation errors. For themed environments, where unusual shapes and complex surfaces are the norm, this opens new doors in both speed and precision.
Digital Tools That Support the Creative Process
Beyond 3D printing, Jesse points to a range of digital tools that are changing the way creatives work:
BIM (Building Information Modeling): Helps identify design clashes and construction inefficiencies before they hit the field.
Digital Twins: Go a step further by modeling interactive use, maintenance, and lifecycle performance.
Direct Model Coordination: Cuts down on translation errors, improving confidence that what’s designed is what’s built.
This reflects broader industry momentum, as outlined in the Deloitte 2025 Engineering & Construction Industry Outlook. The report identifies digital transformation as a core driver of progress, with technologies like BIM, AI, digital twins, and robotics becoming critical tools for managing risk, accelerating timelines, and enabling smarter builds across every sector of the construction industry.
“Creativity goes beyond the initial vision,” Jesse explains. “These tools let that creativity persist through the process — not get lost along the way.”
Reality Check: Challenges & Misconceptions
“Creativity goes beyond the initial vision. These tools let that creativity persist through the process — not get lost along the way.”
Digital transformation brings huge benefits — but it's not without growing pains.
One of the most common misconceptions?
“People assume it’s unnecessarily complicated,” Jesse says. “But that’s the short view. Yes, learning the tools takes time, but that investment upfront saves major headaches later — especially in terms of cost, schedule, and design integrity.”
He also notes that digital fabrication demands more forethought in the design phase. “You’re not leaving details to be figured out in the field — the design needs to account for machine execution from the beginning. That requires full buy-in from everyone involved.”
Opportunities for Studios, Artisans, and the Next Generation
One of the most encouraging trends Jesse sees is how digital tools are leveling the playing field.
“These technologies disrupt the traditional methods big firms have used for decades. Small studios and agile operations actually have the advantage because they can adapt faster.”
For artisans, fabricators, and emerging design teams, this means more freedom to prototype, visualize, and execute highly detailed work — even with limited budgets.
How CASTO Creative Bridges Digital and Physical Worlds
3D Concrete Printed Architecture (Source: World Architecture)
At CASTO Creative, we’re passionate about constructability. That means more than just making pretty concepts — it’s about building them well, with intent, accuracy, and durability. We’re proud to collaborate with forward-thinking minds like Jesse Hanson — not only as a thought leader in 3D printing, but as a Strategic Partner helping us push the boundaries of constructability and creativity in themed environments.
Digital transformation aligns perfectly with that mission.
We partner with innovators like Jesse Hanson to explore what’s possible through digital fabrication.
We support our clients with detailed documentation, digital workflows, and constructability consulting.
We educate designers, architects, and contractors on how to align creative vision with the realities of construction — whether through 3D mockups, scenic finishes, or tech-integrated installations.
Key Takeaways
Digital tools are not optional — they’re essential for future-focused design and construction.
3D printing is enabling more imaginative, cost-effective, and structurally sound themed elements.
BIM and digital twins improve efficiency, reduce errors, and extend the value of creative design.
Small teams and creative studios can use these tools to compete — and win — in a rapidly changing industry.
3D Concrete Printing (Source: Sika Group)
