The goal of this demonstration is to validate a cost-effective approach in retrofitting the building envelope of an existing building in order to reduce heating and cooling energy consumption attributable to that envelope by over 65%. By making building envelope upgrades far less expensive, the Department of Defense (DoD) Energy Service Companies community can implement this solution at DoD sites to achieve greater energy efficiency and cost and energy savings.

This technology provides a streamlined envelope solution using a digital additive manufacturing approach for a mass-customizable, panelized wall retrofit. Technology provider, Branch Technology, has developed a cellular fabrication process that uses digital fabrication and a three-dimensional (3D) printing process optimized to produce façade panels and cladding systems. This digital fabrication and 3D printing process streamlines envelope design and the retrofitting process, therefore greatly reducing retrofit costs.

Whole building envelope retrofits have been identified as a key energy efficiency measure that can reduce carbon emissions by more than 50% and enable cost-effective electrification of heating loads. Yet traditional building envelope improvement methods (blown-in insulation, building out interior or exterior walls) are extremely disruptive to occupants, labor-intensive (and hence costly) to design and install, and typically not aesthetically pleasing. This project will demonstrate a novel approach to building envelope retrofits. A 50% savings in heating, especially when part of an all-electric heat retrofit, has the highest $/sq.ft. savings – about $0.37-0.45/ft²/year in energy cost savings. It is believed these metrics can be achieved within this project through both the insulation improvement and the infiltration reduction from this system. The panel retrofit system will increase the speed of the overclad installation process, reducing install costs and simplifying coordination at the street level. Also, the customizable overclad panel can meet specific aesthetic goals, including 3D shaping of panel surfaces to allow for custom fitment or compliance with street level right-of-way encroachment constraints. By demonstrating the cost and energy savings of this envelope retrofit technology, the project team seeks to enable more cost-effective packages for whole building retrofits and electrification for the DoD. (Anticipated Project Completion - 2027)