A Home Like No Other
The University of Maine’s Bio-Home Technology is Opening Doors in Affordable Housing By Carole VanSickle Ellis The oldest prefabricated home on record is the “Manning Portable Cottage,” which was created by British carpenter John Manning, who, in 1830, offered buyers the opportunity to commission house components that could be built in London, then shipped around the country or internationally and assembled upon receipt. The concept spread like wildfire due to the relatively inexpensive production process and the added benefit that the properties could be assembled by individuals with less training, on the whole, than would otherwise be needed for home construction. Kit houses gained popularity over the course of the century following Manning’s invention, and, during World War II, prefabricated homes for labor crews were invaluable in providing fast, effective shelters that could be both erected quickly and transported relatively easily. By the end of the war, public demand for this type of house was rampant and remains so today. However, like almost any other form of housing, prefabricated housing comes with some inherent issues that add costs — financial, time-based, environmental, and on resources — that can make even this dynamic housing option difficult for many residents to access. The multifaceted issue of cost of production is one that Habib Dagher, executive director of the Advanced Structures and Composites Center (ASCC) at the University of Maine, and his team hope to solve with a groundbreaking bio-based printing tool that could revolutionize the construction industry and affordable housing. An Innovative Application for Existing Technology Dagher and his team, which includes chief operating engineer in additive manufacturing at ASCC Evan Gilman, have spent nearly two decades working on projects in development of biobased materials suitable for additive manufacturing. Gilman explained that although additive manufacturing itself has been used in a variety of fields for years, the manner in which the ASCC scientists apply the principles in this field to everyday problems such as creating comfortable, affordable, long-term housing for the roughly 7 million Americans who do not currently have access to such habitations at this time is very new. Traditionally, Gilman explained, additive manufacturing with polymers has been used to create relatively small-scale objects rather than something big like a fully functional residence capable of housing multiple residents on a permanent basis. “The basic technology has existed for a long time, but we are pushing the boundaries of how large a format we can use with additive manufacturing,” Gilman said. “We are printing, layer by layer, the floors, the walls, and the roof all together in one complete shape.” Dagher added, “We are using a technology very similar to what is used on small 3D printers, but we are melting a polymer with wood fiber in it and depositing that bio-based material using a nozzle — and at a much faster rate than a small printer.” That speed is increasing all the time as the team continues to refine the process; by the end of the first prototype’s print run, the machinery was printing almost six times faster than the speed at which it had begun. “The other thing that makes this technology different — and the most important element — is that the materials are 100% bio-based and 100% recyclable,” Dagher said. “That means the entire house is recyclable.” Bio-based materials are products that mainly consist of one or more substances derived from living matter, also referred to as biomass. In the case of the ASCC home, the bio-based construction materials that are used to “print” the structures are primarily bio-resins and sustainably sourced wood fibers. Maine has a particularly accessible source for this material in its forest products industry, which creates a great deal of wood fiber and other wood byproducts that fit the bio-home bill perfectly. Historically, the state’s papermill industry has purchased and used large volumes of this “waste,” but the papermill industry has struggled in recent years and all but six of Maine’s paper mills were closed by the start of 2023. “There is an excess of wood fiber in the northeast that is currently looking for a home,” Gilman observed. If we can use those excess materials or residue to produce a home, it makes them useful again and creates a valuable structure like a house.” He added, “Housing is a good potential application for the technology because there is a big need. We have excess material available and a real need for housing.” Dagher noted that the bio-homes also function as “carbon storage and sequestration facilities” because they are made from trees that have captured carbon from the air and that are then converted into bio-based homes that retain that locked-in carbon. “This makes the entire process and product very unique because of its recyclability and environmental friendliness,” he said. Next Steps: Weathering the Storms, Literally In late 2022, Dagher and his team revealed the culmination of their bio-based printing project: the world’s first bio-based, 3D-printed home. The prototype boasts 600 square feet of living space and architectural features largely created from recycled and repurposed materials. In the future, Dagher noted, other elements like kitchen cabinets, could be printed along with much of the rest of the structure. Already, the sleek model is being compared to work by famous architect Frank Lloyd Wright, who also had a passion for affordable, visually attractive housing. Wright’s efforts in this arena were a valiant precursor to the Maine team’s bio-homes, but they, like most prefabricated options prior to the ASCC’s prototype, had one prevailing handicap that limited universal applicability to the problem of affordable housing: They were made of ready-cut pieces composed of traditional building materials that had to be transported to the building location and then assembled. Other creative minds have attempted to solve this problem by bringing 3D printers to the construction site and printing out concrete walls that may be topped with traditional roofs once assembled, but the process is still costly and not particularly efficient. By using bio-based materials, the entire structure
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