Building and construction are responsible for 39% of global carbon emissions, with 28% coming from operational emissions—energy used to heat, cool, and light buildings. The remaining 11% stems from embodied carbon emissions, or "upfront" carbon associated with materials and construction processes throughout a building's lifecycle. The Carbon House Project aims to introduce a groundbreaking building technology tailored for second-world markets, where the demand for housing is urgent.

Working alongside Prof. Mark Goulthorpe from MIT Architecture, I developed innovative material-processing logic for his Automated Composite Housing project. This initiative, funded by ExxonMobil through the MIT Energy Initiative, explored the potential of redirecting hydrocarbons from their primary use as fuels to their macro use in building materials. The project focuses on creating lightweight, thin-skin, energy-efficient housing solutions.

To reduce lead times and make the manufacturing process more cost-effective, I devised fabrication logic that processes all joinery details using a multi-head CNC milling machine. This logic can later be algorithmically optimized to streamline large-scale manufacturing with minimal manual labor. Given its excellent stress resistance and lightweight properties, we proposed using prefabricated glass fiber-polymer composite sandwich panels to rebuild housing, schools, customs houses, beach restaurants, and even luxury villas on the hurricane-damaged islands of the British Virgin Islands.

We proposed a polymer-composite house plan for the staff housing on Richard Branson's Necker Island. Conventional building techniques and materials have proven inadequate in withstanding the devastating impact of hurricanes, such as Hurricane Irma, which caused significant damage across the Caribbean. The design utilizes composite panels of varying thicknesses and finishes, indicated by different colors, to enhance structural integrity and resilience against extreme weather conditions.

To reduce lead time and make the manufacturing process more cost-effective, I developed a fabrication logic system to process all joinery details using only a multi-head CNC milling machine. This logic can be further algorithmized to streamline large-scale manufacturing with minimal manual labor. Different sets of tool heads were modeled and integrated into cutting strategies, enabling automated tool path generation.

Overview of a composite panel processed into a prefabricated housing component and a close-up of the fabrication process with the required set of tool heads.

A section view of a joint assembly featuring “Biscuits” (colored orange), which are inserts used between the prefabricated panels to connect them. The panels are assembled on-site and infused with adhesive.

Completed panels are sized and split to fit into a 40-foot-long container using an optimized stacking algorithm (PackRat) to facilitate transportation to the Caribbean Islands (and around the world)

A layout study for a fully-automated  
composite panel production site


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