U.S. Army Retrofits Detroit Arsenal Building with 3D Printed Panels

A new collaborative pilot project at the U.S Army’s Detroit Arsenal, located in Warren, Michigan, is set to showcase how large-scale 3D printing can be utilized to upgrade aging infrastructure with minimal disruptions. The project will bring together the National Renewable Energy Laboratory (NREL), Ameresco, and Branch Technology to retrofit the 1940-era building using robot-printed insulation panels.

Specifically, the project will target Building 25 of the Arsenal, which is around 16,250 square feet and currently suffers from outdated insulation and inefficient thermal performance. The U.S Army stated in a press release that by adding new 3D printed exterior panels, they will be able to reduce the building’s heating and cooling load by nearly 65%. The project will also be a cost-saving measure by reducing the load on the current HVAC system.

An example of Branch Technology’s Cellular Fabrication (C-Fab®) Process for design, printing, and application. (Credit: Branch Technology)

Unlike other traditional retrofit methods, which often have extensive interior modifications or demolition, Branch Technology announced that it will utilize off-site fabrication and on-site installation. The company plans to use precision laser scans to ensure each panel is tailored to the building’s surface. Afterwards, the company will print each panel using their C-Fab system, a large-scale robotic extrusion process that will create fiber-reinforced polymer lattice structures. These eight-inch panels will then be filled with cellulose foam and installed as a new high-performance envelope on the building.