Design, Manufacture, and Assembly of Structural Building
Components Produced via Large-Scale Additive Manufacturing of
Recycled Polymer Composites
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godfrey-tgod-smme-meche-2026-thesis.pdf
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38.46 MB
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Checksum (MD5)
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Author(s)
Godfrey, Tyler
Advisor(s)
Hardt, David E.
Date Issued
February 2026
Publisher
Massachusetts Institute of Technology
Abstract
This thesis evaluates the feasibility of using large-scale additively manufactured, recycled glass fiber–reinforced polymer components in building systems. The MIT HAUS group seeks to mass-produce affordable housing through large-scale additive manufacturing (LSAM) using recycled polymers. To support this objective, the thesis presents the design, manufacture, and assembly of building components fabricated from recycled polymers using the Cincinnati BAAM 603 system. Building on prior MIT HAUS work on foundations and trusses, this work began with the design, manufacture, and testing of a printed floor system. Experimental results showed that the floor met International Building Code (IBC) deflection limits, exhibiting a measured stiffness of 3,825 lb/in. The system was subsequently loaded to failure at 4,480 lb and retained the ability to support 2,000 lb after fracture. Finite element analysis (FEA) simulations conducted in Fusion 360 predicted the measured stiffness within 5% and were subsequently used to guide design optimization of several building components. Based on these results, a building was designed with a floor area of 64 ft² and a vertical clearance of 8 ft between the floor and roof. A stick-framed construction approach was employed, with joists, joist hangers, wall studs, and roof trusses designed and printed on the BAAM system, while plywood and OSB were used for sheathing. In total, the building comprised 50 printed parts across 14 SKUs. Production required 788 minutes and 675 lb of material, achieving a 97.6% material yield and a total printed part weight of 660 lb. Dimensional measurements indicated that the BAAM system exhibits low variance but limited dimensional accuracy for certain features, depending on geometric orientation. No post-processing was initially performed on the printed components. A transport kit incorporating plywood sheathing and fasteners was developed to enable forklift transport of the components to the MIT Bates Research and Engineering Center. On-site assembly required 11.7 hours, corresponding to just under 36 total labor hours. Based on the observed challenges and limitations of the demonstrated building, an integrated frame concept was proposed to better leverage the capabilities of BAAM and LSAM processes. The frame comprises floor joints, wall studs and roof joints into a single part. This approach eliminates approximately 86% of structural joints in a building of similar size, reduces tolerance stack-up effects and greatly simplified assembly.
MIT Department
Massachusetts Institute of Technology. Department of Mechanical Engineering
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