Ameresco, U.S. Army’s Detroit Arsenal harness cutting-edge 3D printing to transform building efficiency, sustainability

Ameresco, Inc., a leading energy solutions provider dedicated to helping customers navigate the energy transition, announced a significant new project with the U.S. Army’s Detroit Arsenal, a key facility in Warren, Michigan. This project is among the first within the Department of Defense to demonstrate the potential of 3D printing for large-scale energy efficiency upgrades, aiming to provide a model for future military and federal building retrofits. As part of the Department of Defense’s Environmental Security Technology Certification Program (ESTCP), this initiative aims to improve building insulation and energy performance through a state-of-the-art 3D fabrication process, contributing to the Department of Defense’s (DOD) broader sustainability and resilience goals.

Ameresco, in collaboration with Branch Technology and the National Renewable Energy Laboratory (NREL), will design and install a custom-made, energy-efficient envelope over cladding system using Branch Technology's Cellular Fabrication (C-Fab) process. This innovative approach digitally scans, designs, and manufactures insulation panels through advanced 3D printing, creating a tailored, cost-effective solution that significantly enhances the energy performance of the facility’s exterior.

“Partnering with the U.S. Army as they push the envelope on sustainable innovation is inspiring,” says 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.”

The project covers approximately 6,250ft² of Detroit Arsenal’s building envelope, and is expected to improve energy efficiency by 50%, resulting in reduced energy costs and a significant reduction in greenhouse gas emissions. As an innovative pilot project, NREL will host a 300ft² mockup installation at their research facility in Colorado, where energy savings and cost-effectiveness will be closely evaluated.