See inside a 600-square-foot 3D-printed tiny home in Maine made of recyclable materials

Brittany ChangApr 23, 2023, 16:34 IST

The BioHome3D in Maine was printed using bio-based materials.Brittany Chang/Insider

The University of Maine's Advanced Structures and Composites Center 3D-printed a tiny home in November 2022.
The recyclable home was printed using pellets made of wood waste and a plastic binder.

Most 3D-printed homes popping up around the world have been built using a concrete mix.

Anthony Vu

But the University of Maine's Advanced Structures and Composites Center (ASCC) has taken a more novel and sustainable approach to 3D printing homes.

Brittany Chang/Insider

Instead of using concrete, ASCC is printing homes out of wood waste.

Brittany Chang/Insider

The research and development center has its hands in diverse projects — from floating wind turbines to rebars — all with the goal of creating a sustainable future.

Brittany Chang/Insider

The research and development center has its hands in diverse projects — from floating wind turbines to rebars — all with the goal of creating a sustainable future.

But we're not here to talk about all of ASCC's various side quests.

Brittany Chang/Insider

Instead, on an overcast April afternoon, I visited the college campus to see one of its latest projects: the BioHome 3D.

Brittany Chang/Insider

ASCC unveiled this project in November 2022 as the first 3D-printed tiny home made of "bio-based" materials, making it completely recyclable.

Brittany Chang/Insider

To create the printing material, the center used bio-resins to encapsulate wood residuals from sawmills, creating a durable printing material that gives life to wood waste.

Brittany Chang/Insider

To create the printing material, the center used bio-resins to encapsulate wood residuals from sawmills, creating a durable printing material that gives life to wood waste.

To do this, ASCC works with various industrial partners that specialize in pallet production around the US.

Brittany Chang/Insider

We’re all familiar with sawdust. When sawdust is ground even further, it becomes a powder-like cellulose nanofiber.

Brittany Chang/Insider

When this is combined with a plastic binder, the nanofibers can turn into a collection of small pellets.

Brittany Chang/Insider

These pellets are then fed into ASCC's 3D printer, which is also the world's biggest polymer 3D printer, according to the university.

Brittany Chang/Insider

This printer essentially functions as a "glue gun with hundreds of settings," Habib Dagher, the founding executive director of the center and principal investigator of this project, told me when I visited …

Brittany Chang/Insider

This printer essentially functions as a "glue gun with hundreds of settings," Habib Dagher, the founding executive director of the center and principal investigator of this project, told me when I visited …

… turning the pellets into a printing material that acts like the "ink" of the printer.

Brittany Chang/Insider

Someday, Dagher wants to source the wood and create the pellets locally.

Brittany Chang/Insider

There's certainly enough supply to do so: He believes Maine produces enough wood waste to build 100,000 homes annually.

Brittany Chang/Insider

To create the home, ASCC took a modular and prefab approach to printing.

Brittany Chang/Insider

The floor, walls, and roof of the 600-square-foot home were printed as four separate, insulated, and pre-wired 200-square-foot modules in ASCC's manufacturing facility.

Brittany Chang/Insider

In comparison, many companies only print the walls of the home, often on-site.

Icon

Using a flatbed truck, these modules were then moved outside of the facility and installed onto a concrete foundation within half a day.

Brittany Chang/Insider

An electrician then spent another two hours powering the unit.

Brittany Chang/Insider

But because it's a prototype, the home is not connected to plumbing, the center told Insider in January.

Brittany Chang/Insider

Now, it's undergoing testing — including on the material and its ability to be recycled five times over — to determine what should be changed in the next home.

Brittany Chang/Insider

Now, it's undergoing testing — including on the material and its ability to be recycled five times over — to determine what should be changed in the next home.

But so far, it's fair to be optimistic: The home has successfully survived what Dagher called Maine's "very extreme" winter.

Brittany Chang/Insider

"This place is so much larger than I expected," I thought when I first walked into the 600-square-foot home.

Brittany Chang/Insider

The large windows brightened up the interior despite the overcast afternoon.

Brittany Chang/Insider

And while the ceilings weren't unusually high, they were tall enough to make the space feel open with the natural light.

Brittany Chang/Insider

The layout wasn't as open-concept as other tiny homes I've seen …

Brittany Chang/Insider

… which is to say the bedroom and desk were in their own room separate from the living room and kitchen.

Brittany Chang/Insider

The bedroom and bathroom were surprisingly spacious — significantly larger than ones I've seen in some city apartments.

Brittany Chang/Insider

The bedroom had large windows, rows of closets, and a desk ….

Brittany Chang/Insider

… while the bathroom around the corner had all the typical amenities including a large shower.

Brittany Chang/Insider

The entrance into the living room and kitchen was across the hall from the bathroom.

Brittany Chang/Insider

Here, the layout looked more like an open-concept living space.

Brittany Chang/Insider

There was a dining table, seating area, and a sprawling kitchen with a breakfast bar.

Brittany Chang/Insider

One of the most eye-catching features was the wall that curved into the ceiling. This curve is a signature of 3D printers no matter the printing material.

Brittany Chang/Insider

You might have noticed that the walls in the bedroom looked like they were printed on an angle …

Brittany Chang/Insider

… while the ones in the living room look more parallel.

Brittany Chang/Insider

Throughout the printing process, ASCC tested different printing techniques, creating different final products.

Brittany Chang/Insider

Some of the walls have also been covered with dry wall, appealing to traditionalists.

Brittany Chang/Insider

The bio-based printing material doesn't just make for a more sustainable home.

Brittany Chang/Insider

Its brown tone — similar to wood — gives the home a warm ambiance.

Brittany Chang/Insider

It's a stark contrast to concrete homes, which gave Icon's House Zero a more contemporary and sleek look.

Icon's over 2,000-square-foot House Zero in Austin.Brittany Chang/Insider

"[It's not] just the engineering of the home but the livability aspects," Dagher said, noting that people who have visited have "loved" the interior colors and the curve of the walls.

Brittany Chang/Insider

"[It's not] just the engineering of the home but the livability aspects," Dagher said, noting that people who have visited have "loved" the interior colors and the curve of the walls.

"Those kinds of livability and ergonomic aspects of the house are very interesting to us and we now have the tools to do it cost-effectively," he said.

Brittany Chang/Insider

This home is just the start of ASCC's printing venture.

Brittany Chang/Insider

The end goal is to print a home in 48 hours. This one took about 10 times longer.

Brittany Chang/Insider

The center is now putting together what will be the new largest polymer 3D printer, which will dwarf its current system.

Brittany Chang/Insider

And in a year, it'll begin building an extension of its current manufacturing site. The center has already raised over $80 million for this future facility.

Brittany Chang/Insider

The future factory's first project will be a development of nine homes.

Brittany Chang/Insider

There's an opportunity for ASCC to make substantial money off of this tech, especially if it sells it to a construction company. But that's not the goal.

Brittany Chang/Insider

Instead, Dagher says he wants to "franchise" it by building factories in various locations where homes are needed.

Brittany Chang/Insider

“Our number one priority is to alleviate the societal problems [like housing and sustainable construction] we are facing right now,” he said. “There’s an opportunity here to harness these biomaterials and help solve these problems.”

Brittany Chang/Insider

“Our number one priority is to alleviate the societal problems [like housing and sustainable construction] we are facing right now,” he said. “There’s an opportunity here to harness these biomaterials and help solve these problems.”

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See inside a 600-square-foot 3D-printed tiny home in Maine made of recyclable materials

Most 3D-printed homes popping up around the world have been built using a concrete mix.

But the University of Maine's Advanced Structures and Composites Center (ASCC) has taken a more novel and sustainable approach to 3D printing homes.

Instead of using concrete, ASCC is printing homes out of wood waste.

The research and development center has its hands in diverse projects — from floating wind turbines to rebars — all with the goal of creating a sustainable future.

But we're not here to talk about all of ASCC's various side quests.

Instead, on an overcast April afternoon, I visited the college campus to see one of its latest projects: the BioHome 3D.

ASCC unveiled this project in November 2022 as the first 3D-printed tiny home made of "bio-based" materials, making it completely recyclable.

To create the printing material, the center used bio-resins to encapsulate wood residuals from sawmills, creating a durable printing material that gives life to wood waste.

To do this, ASCC works with various industrial partners that specialize in pallet production around the US.

We’re all familiar with sawdust. When sawdust is ground even further, it becomes a powder-like cellulose nanofiber.

When this is combined with a plastic binder, the nanofibers can turn into a collection of small pellets.

These pellets are then fed into ASCC's 3D printer, which is also the world's biggest polymer 3D printer, according to the university.

This printer essentially functions as a "glue gun with hundreds of settings," Habib Dagher, the founding executive director of the center and principal investigator of this project, told me when I visited …

… turning the pellets into a printing material that acts like the "ink" of the printer.

Someday, Dagher wants to source the wood and create the pellets locally.

There's certainly enough supply to do so: He believes Maine produces enough wood waste to build 100,000 homes annually.

To create the home, ASCC took a modular and prefab approach to printing.

The floor, walls, and roof of the 600-square-foot home were printed as four separate, insulated, and pre-wired 200-square-foot modules in ASCC's manufacturing facility.

In comparison, many companies only print the walls of the home, often on-site.

Using a flatbed truck, these modules were then moved outside of the facility and installed onto a concrete foundation within half a day.

An electrician then spent another two hours powering the unit.

But because it's a prototype, the home is not connected to plumbing, the center told Insider in January.

Now, it's undergoing testing — including on the material and its ability to be recycled five times over — to determine what should be changed in the next home.

But so far, it's fair to be optimistic: The home has successfully survived what Dagher called Maine's "very extreme" winter.

"This place is so much larger than I expected," I thought when I first walked into the 600-square-foot home.

The large windows brightened up the interior despite the overcast afternoon.

And while the ceilings weren't unusually high, they were tall enough to make the space feel open with the natural light.

The layout wasn't as open-concept as other tiny homes I've seen …

… which is to say the bedroom and desk were in their own room separate from the living room and kitchen.

The bedroom and bathroom were surprisingly spacious — significantly larger than ones I've seen in some city apartments.

The bedroom had large windows, rows of closets, and a desk ….

… while the bathroom around the corner had all the typical amenities including a large shower.

The entrance into the living room and kitchen was across the hall from the bathroom.

Here, the layout looked more like an open-concept living space.

There was a dining table, seating area, and a sprawling kitchen with a breakfast bar.

One of the most eye-catching features was the wall that curved into the ceiling. This curve is a signature of 3D printers no matter the printing material.

You might have noticed that the walls in the bedroom looked like they were printed on an angle …

… while the ones in the living room look more parallel.

Throughout the printing process, ASCC tested different printing techniques, creating different final products.

Some of the walls have also been covered with dry wall, appealing to traditionalists.

The bio-based printing material doesn't just make for a more sustainable home.

Its brown tone — similar to wood — gives the home a warm ambiance.

It's a stark contrast to concrete homes, which gave Icon's House Zero a more contemporary and sleek look.

"[It's not] just the engineering of the home but the livability aspects," Dagher said, noting that people who have visited have "loved" the interior colors and the curve of the walls.

"Those kinds of livability and ergonomic aspects of the house are very interesting to us and we now have the tools to do it cost-effectively," he said.

This home is just the start of ASCC's printing venture.

The end goal is to print a home in 48 hours. This one took about 10 times longer.

The center is now putting together what will be the new largest polymer 3D printer, which will dwarf its current system.

And in a year, it'll begin building an extension of its current manufacturing site. The center has already raised over $80 million for this future facility.

The future factory's first project will be a development of nine homes.

There's an opportunity for ASCC to make substantial money off of this tech, especially if it sells it to a construction company. But that's not the goal.

Instead, Dagher says he wants to "franchise" it by building factories in various locations where homes are needed.

“Our number one priority is to alleviate the societal problems [like housing and sustainable construction] we are facing right now,” he said. “There’s an opportunity here to harness these biomaterials and help solve these problems.”