BioHome-3D, the first 100% bio-based 3D-printed home, is proving to be a viable solution to the growing housing crisis after a year of rigorous outdoor testing. Developed at the University of Maine’s Advanced Structures and Composites Center (ASCC), this innovative prototype is set to establish new benchmarks for structural integrity, carbon footprint reduction, and advanced manufacturing techniques.

This 600-square-foot home, designed specifically to meet Maine’s affordable housing requirements, is crafted entirely from wood residuals, bio-resins and wood fibre insulation. The use of renewable materials not only ensures that the home is fully recyclable but also positions it as a carbon sink, effectively sequestering carbon dioxide.

With the construction industry responsible for 39% of global carbon emissions, BioHome-3D offers a pivotal solution by sequestering 46 tonnes of CO2 per unit. This approach addresses both operational and embodied carbon, setting new precedents for sustainable construction.

Resilience, performance

Throughout its inaugural year, BioHome-3D faced one of Maine’s most volatile weather periods, with sensors monitoring temperatures ranging from 1°F to 105°F, along with extreme windstorms and several snowstorms.

The home performed exceptionally well under these conditions, demonstrating its resilience to rain, snow, temperature fluctuations and hail.

Engineered in accordance with ASCE-7 loadings, it meets the design requirements of the International Code Council (ICC), showcasing its structural integrity.

Looking ahead, the ASCC plans to break ground on the green engineering and materials (GEM) ‘Factory of the Future’ later this year, marking a significant step in scaling up the production of BioHome-3D technology.

This new research centre, expected to be completed in 2026, will incorporate ‘Industry 4.0’ technologies, AI-enabled large-scale additive manufacturing, and collaborative robotics. It aims to revolutionise production processes while providing valuable learning opportunities for future workforce development.

New neighbourhoods

“The data collected over a year of outdoor exposure in Maine has proved that the technology is sound,” states ASCC Executive Director Habib Dagher. “Now, our focus is to scale up the production process. With the ‘Factory of the Future’, our goal is to produce one of these 600-square-foot homes every 48 hours. We’ve created a house. Now it’s time to create neighbourhoods.”

As the initial production speed for BioHome-3D started at a rate of 20 pounds per hour, advancements have now ramped it up to nearly 500 pounds per hour, significantly driving down costs and enhancing competitiveness with traditional stick-built homes.

The plans for the world’s first bio-based 3D-printed neighbourhood, featuring nine homes in the Greater Bangor area, are underway, aiming to provide housing for individuals experiencing or at risk of homelessness.

Maine faces a significant housing deficit, with nearly 80,000 homes needed to meet affordable housing demand by 2030. BioHome-3D stands to address this urgent need effectively.

Supporting industries

By utilizing locally sourced wood residuals, BioHome-3D also bolsters Maine’s forest products industry. The state’s sawmills generate nearly a million tonnes of wood residuals annually, previously used by now-closed pulp and paper mills.

Each 600-square-foot unit requires about 10 tonnes of these materials, suggesting the potential for producing 100,000 units per year, given the available resources. This innovative technology also addresses labour shortages and supply chain issues that hinder affordable housing construction.

By using abundant, renewable and locally sourced wood fibre, it reduces material costs and enhances sustainability. These locally produced materials are more resilient to global supply chain disruptions, helping ensure steady production.

With approximately 41% of Maine’s construction workforce nearing retirement, this approach significantly mitigates labour shortages while leveraging next-generation manufacturing technologies to minimize waste and accelerate production.

BioHome-3D has garnered international recognition, receiving awards such as the Aubin AM Case Study Award from the Society of Manufacturing Engineers and the Combined Strength Award at the 2023 CAMX Conference.

Comments