Formwork is critical in concrete construction, requiring substantial time and financial resources. Traditional formwork methods encounter several challenges, such as prolonged construction timelines, substantial labor demands, and increased costs. This research investigates the application of 3D printing technology for formwork production, specifically focusing on its potential to advance lean construction principles through waste reduction and cost optimization. An experimental research design was employed to evaluate bio-based 3D printed formwork along with modular design for both standard and complex structures. Following a comprehensive literature review, Polylactic Acid (PLA) was identified as the optimal printing material due to its superior tensile properties, compressive strength, and cost-effectiveness. The study assessed the mechanical properties, printability, and durability of PLA material, along with the feasibility of integrating 3D printed formwork into existing construction workflows. As a biodegradable polymer derived from corn starch, PLA offers environmental advantages while maintaining suitable physical and mechanical properties that can be tailored through processing. The research findings contribute to the development of more sustainable and efficient concrete construction practices by addressing traditional formwork challenges including extended construction periods, high labor requirements, and elevated costs.