Complexity doesn't really add difficulty to 3d printing. My 3D printer doesn't much care whether a head is moving in a straight line or doing a zig-zag. It's gonna just keep extruding that concrete.
Kinda like how a 2D printer doesn't much care whether you're printing a detailed image or a very simple one.
I guess that there's a material cost. But, then, that's also true of existing buildings, and they clearly don't optimize for that to the exclusion of all else, else there'd be no aesthetic used in designing those buildings.
https://www.amazon.com/White-Corrugated-Paper-Sheet-Pack/dp/B08D2GT19P
A 10 pack of "20 x 30 x 0.16 inches;" cardboard weighs "6.4 Pounds".
10x30x10 is 6,000 square inches, or ~3.87 square meters. 6.4 lbs is 2.9 kg. So figure ~0.75 kg per square meter of corrugated cardboard.
https://en.wikipedia.org/wiki/Sun
Area is r² times pi.
So that's an area of about 1.52×10¹⁸ m² and a mass of about 1.14×10¹⁸ kg for the cardboard cutout.
https://en.wikipedia.org/wiki/Earth
Earth has about five million times as much mass, so the Sun cutout would have about a fifth of a millionth Earth's gravitational pull.
EDIT: In the grand spirit of what-if.xkcd.com I think it behooves us to take a humorously dark scientific look at this.
A larger problem would be 1.14×10¹⁸ kg of cardboard suddenly falling onto Earth's surface. Aside from any effects from it, like, directly impacting, you've just dumped 1.14×10¹⁸ kg of wood pulp onto Earth. Aside from any unpleasant effects from chemical additives, or blotting out the Sun's light to plants and causing biological collapse, I imagine that there could be some other unpleasant effects:
https://en.wikipedia.org/wiki/Atmosphere_of_Earth
Earth's atmosphere is mostly nitrogen and oxygen, and by volume about 20% oxygen, so we'll back-of-the-napkin it and say that about 20% of the mass is oxygen. So about 1×10¹⁸ kg of oxygen, fairly close to the mass of the cardboard cutout.
That cardboard is presumably flammable.
So if this vast expanse of cardboard ignites
like, from heat produced by falling through Earth's atmosphere, falling on any open flame in the world, or whatever, but seems like a pretty safe bet that something will touch it off
I'd assume that a considerable portion of Earth's oxygen supply would be converted to water and carbon dioxide in the resulting combustion reaction. Even aside from the global wildfire itself, that seems like it'd be pretty bad news for humans.