In a pilot project at the Detroit Arsenal in Warren, Michigan, the US Army is testing the use of 3D-printed façade elements to improve the building envelope for the first time. The aim is to significantly increase the energy efficiency of existing infrastructures using digitally manufactured insulating structures. The project is part of the US Department of Defense’s Environmental Security Technology Certification Program (ESTCP) and is intended to serve as a model project for energy-efficient renovations in existing public buildings.
The project is being implemented by Ameresco in cooperation with the National Renewable Energy Laboratory (NREL) and Branch Technology. The latter is contributing its Cellular Fabrication (C-Fab) technology – a process that makes it possible to adapt complex insulation structures to the respective building contour using an additive manufacturing process. The basis for this is a digital scan of the existing building, which is then used as the basis for manufacturing individualized cladding elements. The process should not only improve the thermal quality of the building envelope, but also reduce manufacturing costs and assembly work.
The new building envelope covers around 580 square meters and is expected to increase energy efficiency by up to 50 percent. In addition, a test installation on the NREL campus in Colorado is being evaluated to test energy savings and economic metrics under controlled conditions.
“Partnering with the U.S. Army as they push the envelope on sustainable innovation is inspiring,” said Nicole Bulgarino, President of Federal Solutions and Utility Infrastructure at Ameresco. “This pilot project isn’t just about lowering energy costs; it’s about rethinking how we approach building retrofits across large institutions. Using 3D printing to bring energy efficiency to Detroit Arsenal is a bold step, and we’re proud to be part of the Army’s journey toward a greener future.”
With this project, the Ministry of Defense is positioning itself as a potential pioneer in the integration of additive manufacturing into the energy-efficient refurbishment of buildings. If the process proves to be efficient and scalable, it could also be used in other areas of civil and military infrastructure in the future.
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