The Mobile Bay National Estuary Program (MBNEP), in collaboration with the U.S. Army Corps of Engineers (USACE), is advancing a pilot study to evaluate the feasibility and performance of 3D-printed artificial reef structures fabricated from dredged Mobile Bay sediments. This work builds on findings from the USACE Regional Sediment Management Program demonstrating that cohesive sediments from the Blakeley Island Confined Disposal Facility possess sufficient rheological and structural properties for direct 3D printing without additive binders. The pilot aims to characterize the mechanical stability and erosion resistance of sediment-based 3D printed substrates in estuarine conditions, along with their suitability for larval settlement and biofilm development. A test reef and reef shards were deployed on the western shore of Mobile Bay in October 2025; periodic monitoring of structural integrity, hydrodynamic interactions, and surface colonization is ongoing. Preliminary results suggest that the 3D printed reef remains structurally sound within the intertidal zone, and that the textured surface of the material is suitable for settlement of encrusting organisms like bryozoans, barnacles, and tube worms. Monitoring into spring and summer 2026 may yield more information about suitability of the material for oyster spat settlement.

By comparing durability and functional habitat performance to that of traditional reef materials, the project seeks to determine whether dredged-sediment structures can provide a viable, locally sourced alternative that simultaneously reduces material transport costs, supports ecosystem services, and contributes to confined-disposal capacity management. Results from this pilot will inform scalable design parameters and production pathways for regionally deployable, nature-inspired reef modules that integrate beneficial-use sediment management with estuarine habitat enhancement.