Enhancing Circularity, Sustainability, and Innovation
NERA
NERA: Future Proofing Built Environment with Biobased Materials
NERA transforms sawdust waste into high-performance, 3D-printed façade panels that store carbon, enhance energy efficiency, and reduce reliance on virgin materials. By integrating material intelligence, machine learning and digital fabrication, it offers a scalable, circular solution for sustainable retrofitting and new construction. These panels are lightweight, customizable, and low-impact, making buildings more resilient, beautiful, and part of the climate solution.
Spain
National
It addresses urban-rural linkages
It involves a physical transformation of the built environment (hard investment)
Prototype level
No
No
No
Individual
Project NERA develops bio based exterior insulation panels made from sawdust waste, designed and 3D printed to improve building energy performance while storing carbon and reducing construction emissions. The panels are particularly suited for building renovation and retrofitting.
Across Europe, many buildings are outdated and energy inefficient. Instead of demolition and reconstruction, citizens increasingly support renovation strategies such as the HouseEurope movement. At the same time, millions struggle with energy poverty, rising energy costs, and increasing pressure to renovate buildings under EU climate policies.
In parallel, the growing demand for timber construction is generating large volumes of by products such as sawdust. Despite being renewable, this resource is often burned or discarded.
Our concept, driven by the material intelligence, transforms this resource into low carbon architectural elements that help buildings consume less energy while storing carbon in the built environment. The project combines computational design and large scale 3D printing to produce lightweight, customizable, materially efficient panels designed for disassembly, supporting reuse or recycling.
The project is currently in development, with material research, prototyping, and collaborations with architects and local partners are ongoing. Early testing proved insulation potential (the panels maintained an interior temperature of 25°C while external temperature was 75°C), promising printability/finishing. We converted a commercial 3D printer into a paste printer, developed a machine learning algorithm for optimization/customization of panels based on building age, location, typology and created a scaling up methodology.
In the coming stages, the project aims to further develop the material and demonstrate the panels in real architectural applications, contributing to the renovation of buildings with solutions that are low carbon, aesthetically engaging, and accessible.
Across Europe, many buildings are outdated and energy inefficient. Instead of demolition and reconstruction, citizens increasingly support renovation strategies such as the HouseEurope movement. At the same time, millions struggle with energy poverty, rising energy costs, and increasing pressure to renovate buildings under EU climate policies.
In parallel, the growing demand for timber construction is generating large volumes of by products such as sawdust. Despite being renewable, this resource is often burned or discarded.
Our concept, driven by the material intelligence, transforms this resource into low carbon architectural elements that help buildings consume less energy while storing carbon in the built environment. The project combines computational design and large scale 3D printing to produce lightweight, customizable, materially efficient panels designed for disassembly, supporting reuse or recycling.
The project is currently in development, with material research, prototyping, and collaborations with architects and local partners are ongoing. Early testing proved insulation potential (the panels maintained an interior temperature of 25°C while external temperature was 75°C), promising printability/finishing. We converted a commercial 3D printer into a paste printer, developed a machine learning algorithm for optimization/customization of panels based on building age, location, typology and created a scaling up methodology.
In the coming stages, the project aims to further develop the material and demonstrate the panels in real architectural applications, contributing to the renovation of buildings with solutions that are low carbon, aesthetically engaging, and accessible.
The idea emerged from the applicant’s Master’s thesis project, developed at Institute for Advanced Architecture of Catalonia, observing two interconnected challenges shaping Europe’s built environment.
The construction sector is responsible for a significant share of emissions and resource consumption, while millions of buildings must be renovated to meet climate targets and millions of people are suffering from energy poverty. Rising energy prices have intensified the urgency to improve building efficiency.
On the other hand, the demand for mass timber construction is increasing due to legislation and reaching decarbonization goals while increasing wood by products such as sawdust. Currently, the large volumes of this waste is often downcycled, burned or landfilled where it decomposes and increases the CO2 emissions.
The concept then emerged as a response to the pressing global challenges and an exploration of material driven design, thinking how inherent properties of the wood waste can be enhanced and be transformed into a high-value material for climate-positive construction.
Initial experimentation focused on developing and iterating bio-based composite materials that could be manufactured using 3D printing technologies. In order to scale up the material for architectural applications a methodology based on design, fabrication and materiality was developed. These methods allow complex geometries to be produced with minimal waste while enabling architectural creativity.
Through prototyping and testing, the concept evolved into the development of exterior insulation panels designed to improve energy performance while acting as carbon-storing architectural elements. The panels are implemented to existing buildings as a retrofitting strategy.
Overall, the process has combined material experimentation, digital modelling, small and large scale prototypes, and feedback from professionals in architecture and innovation ecosystems.
The construction sector is responsible for a significant share of emissions and resource consumption, while millions of buildings must be renovated to meet climate targets and millions of people are suffering from energy poverty. Rising energy prices have intensified the urgency to improve building efficiency.
On the other hand, the demand for mass timber construction is increasing due to legislation and reaching decarbonization goals while increasing wood by products such as sawdust. Currently, the large volumes of this waste is often downcycled, burned or landfilled where it decomposes and increases the CO2 emissions.
The concept then emerged as a response to the pressing global challenges and an exploration of material driven design, thinking how inherent properties of the wood waste can be enhanced and be transformed into a high-value material for climate-positive construction.
Initial experimentation focused on developing and iterating bio-based composite materials that could be manufactured using 3D printing technologies. In order to scale up the material for architectural applications a methodology based on design, fabrication and materiality was developed. These methods allow complex geometries to be produced with minimal waste while enabling architectural creativity.
Through prototyping and testing, the concept evolved into the development of exterior insulation panels designed to improve energy performance while acting as carbon-storing architectural elements. The panels are implemented to existing buildings as a retrofitting strategy.
Overall, the process has combined material experimentation, digital modelling, small and large scale prototypes, and feedback from professionals in architecture and innovation ecosystems.
Energy Efficiency
Circular Economy
Decarbonization
Biobased Innovation
Inclusive Renovation
The concept addresses several urgent environmental and socio-economic challenges in Europe’s built environment.
Firstly, the project addresses energy efficiency and energy poverty. The panels are designed to improve building envelopes, reducing heat loss in winter and heat gain in summer. This can significantly lower heating and cooling demand, helping households reduce energy bills and become less vulnerable to volatile energy prices
Secondly, it contributes to decarbonising construction materials. Conventional exterior insulation systems often rely on carbon-intensive materials or toxic resins such as mineral/rock wool, foam, cement, aluminium, or petrochemical products. In contrast, the project combines sawdust with bio-based binders and natural additives to create a healthier and more environmentally responsible alternative.
The panels also act as carbon storage elements. By incorporating waste into durable building components, the project helps lock carbon into buildings for long periods. The project further promotes circular construction principles. The panels are designed to be modular, lightweight, and removable, enabling repair, reuse, and adaptation over time.
Finally, the concept strengthens local circular value chains by working with local woodworkers and sawmills who struggle with costly sawdust disposal and limited warehouse storage space. We help them dispose of the waste in a sustainable manner and avoid contamination of ecosystems.
Firstly, the project addresses energy efficiency and energy poverty. The panels are designed to improve building envelopes, reducing heat loss in winter and heat gain in summer. This can significantly lower heating and cooling demand, helping households reduce energy bills and become less vulnerable to volatile energy prices
Secondly, it contributes to decarbonising construction materials. Conventional exterior insulation systems often rely on carbon-intensive materials or toxic resins such as mineral/rock wool, foam, cement, aluminium, or petrochemical products. In contrast, the project combines sawdust with bio-based binders and natural additives to create a healthier and more environmentally responsible alternative.
The panels also act as carbon storage elements. By incorporating waste into durable building components, the project helps lock carbon into buildings for long periods. The project further promotes circular construction principles. The panels are designed to be modular, lightweight, and removable, enabling repair, reuse, and adaptation over time.
Finally, the concept strengthens local circular value chains by working with local woodworkers and sawmills who struggle with costly sawdust disposal and limited warehouse storage space. We help them dispose of the waste in a sustainable manner and avoid contamination of ecosystems.
Project NERA explores how sustainability can shape a new aesthetic language for the built environment. The panels are designed not only as functional insulation elements but also as architectural surfaces that respond to cultural and spatial contexts. Through computational design, machine learning algorithms and additive manufacturing, the material can be shaped into textures, patterns, and geometries that adapt to the identity of specific buildings or neighbourhoods.
This flexibility enables the panels to integrate into existing architectural contexts, particularly in renovation projects where preserving cultural identity and urban character is important.
The project also invites reflection on what we consider beautiful and valuable in architecture. By transforming sawdust (traditionally perceived as industrial waste) into expressive building elements, the concept challenges conventional hierarchies of materials and proposes a new aesthetic rooted in circularity, biological origin, and resource awareness.
Because the manufacturing method allows for high levels of customisation, the system also opens possibilities for co-design processes with architects, communities, and local stakeholders. When people participate in shaping the appearance of the spaces they live in, they are more likely to feel a sense of belonging, ownership, and care for those places. In this way, aesthetics becomes much more than a visual quality, it becomes a cultural and social process that connects materials, people, and places.
This flexibility enables the panels to integrate into existing architectural contexts, particularly in renovation projects where preserving cultural identity and urban character is important.
The project also invites reflection on what we consider beautiful and valuable in architecture. By transforming sawdust (traditionally perceived as industrial waste) into expressive building elements, the concept challenges conventional hierarchies of materials and proposes a new aesthetic rooted in circularity, biological origin, and resource awareness.
Because the manufacturing method allows for high levels of customisation, the system also opens possibilities for co-design processes with architects, communities, and local stakeholders. When people participate in shaping the appearance of the spaces they live in, they are more likely to feel a sense of belonging, ownership, and care for those places. In this way, aesthetics becomes much more than a visual quality, it becomes a cultural and social process that connects materials, people, and places.
The project addresses inclusion primarily through affordability, energy justice, and accessibility of sustainable renovation solutions.
Across Europe, many households struggle with energy poverty, where inefficient buildings lead to high heating costs and uncomfortable living conditions.
By improving the thermal performance of building envelopes, the project contributes to lower energy demand, reduced household energy expenses and increased thermal comfort, helping make homes more affordable and comfortable to live in.
The concept also promotes inclusion through resource efficiency and circular production. Using locally available sawdust waste can reduce reliance on imported materials and support regional economies. The project is planning to further explore distributed manufacturing models, including the potential to deploy production closer to where waste materials are generated. This approach could enable new opportunities for SMEs, local manufacturing, and skills development.
Finally, the machine learning algorithm allows for designing for creating and optimizing design options based on building typology, age, location and energy certificate supporting adaptable renovation strategies, which can make building upgrades more feasible in diverse contexts.
By combining environmental sustainability with social inclusivity, we aim to create a built environment that benefits both people and the planet.
Across Europe, many households struggle with energy poverty, where inefficient buildings lead to high heating costs and uncomfortable living conditions.
By improving the thermal performance of building envelopes, the project contributes to lower energy demand, reduced household energy expenses and increased thermal comfort, helping make homes more affordable and comfortable to live in.
The concept also promotes inclusion through resource efficiency and circular production. Using locally available sawdust waste can reduce reliance on imported materials and support regional economies. The project is planning to further explore distributed manufacturing models, including the potential to deploy production closer to where waste materials are generated. This approach could enable new opportunities for SMEs, local manufacturing, and skills development.
Finally, the machine learning algorithm allows for designing for creating and optimizing design options based on building typology, age, location and energy certificate supporting adaptable renovation strategies, which can make building upgrades more feasible in diverse contexts.
By combining environmental sustainability with social inclusivity, we aim to create a built environment that benefits both people and the planet.
The concept has been developed through a series of exchanges between architects, façade engineers, material scientists, waste suppliers, and wood industry experts.
These stakeholders played an important role in shaping the project’s direction. Architects and façade engineers have helped define the performance requirements, installation strategies, and integration of the panels within building envelopes, ensuring the system responds to real architectural and renovation needs. Material scientists and wood experts have contributed to optimising the bio-based composite and validating its material properties, while sawmills and wood-processing companies have provided insight into the availability, characteristics, and management of waste streams.
Their feedback has influenced key aspects of the concept, including panel dimensions, installation logic, material formulation, and circular design strategies such as modularity and design for disassembly.
Participation has therefore helped align the project with both academia (theory) and industrial realities (practice), ensuring that the concept can realistically integrate into construction workflows.
In the next stages, participation will expand further through pilot collaborations with architectural studios, municipalities, and building users. These collaborations will allow the project to test the panels in real renovation contexts and gather feedback from residents regarding comfort, energy performance, and aesthetic integration.
These stakeholders played an important role in shaping the project’s direction. Architects and façade engineers have helped define the performance requirements, installation strategies, and integration of the panels within building envelopes, ensuring the system responds to real architectural and renovation needs. Material scientists and wood experts have contributed to optimising the bio-based composite and validating its material properties, while sawmills and wood-processing companies have provided insight into the availability, characteristics, and management of waste streams.
Their feedback has influenced key aspects of the concept, including panel dimensions, installation logic, material formulation, and circular design strategies such as modularity and design for disassembly.
Participation has therefore helped align the project with both academia (theory) and industrial realities (practice), ensuring that the concept can realistically integrate into construction workflows.
In the next stages, participation will expand further through pilot collaborations with architectural studios, municipalities, and building users. These collaborations will allow the project to test the panels in real renovation contexts and gather feedback from residents regarding comfort, energy performance, and aesthetic integration.
The project interacts with and is planning to include stakeholders across several levels.
Currently at the local level, collaboration with wood-processing industries and furniture manufacturers helps source sawdust waste while strengthening circular material flows. For these partners, the collaboration provides a safe and sustainable pathway for managing sawdust waste, reducing disposal costs, minimising environmental contamination, and helping free up valuable storage space within their production facilities.
At the regional and national level, we are aiming to foster partnerships with architecture firms, innovation ecosystems, and research actors to support material development, testing, and architectural integration. Municipalities are particularly important partners, as many cities are currently implementing renovation strategies for public buildings and affordable housing in response to energy poverty and climate targets.
At the European level, the project aligns with policy frameworks such as the European Green Deal, Renovation Wave, and circular economy strategies, which call for the decarbonisation of construction and improved building energy performance.
Currently at the local level, collaboration with wood-processing industries and furniture manufacturers helps source sawdust waste while strengthening circular material flows. For these partners, the collaboration provides a safe and sustainable pathway for managing sawdust waste, reducing disposal costs, minimising environmental contamination, and helping free up valuable storage space within their production facilities.
At the regional and national level, we are aiming to foster partnerships with architecture firms, innovation ecosystems, and research actors to support material development, testing, and architectural integration. Municipalities are particularly important partners, as many cities are currently implementing renovation strategies for public buildings and affordable housing in response to energy poverty and climate targets.
At the European level, the project aligns with policy frameworks such as the European Green Deal, Renovation Wave, and circular economy strategies, which call for the decarbonisation of construction and improved building energy performance.
Project NERA is at the intersection of several disciplines:
- Material science and process engineering: Contribute to developing the bio-based composite and ensuring thermal performance and durability.
- Architecture and computational design: Shape how the panels integrate into buildings and how their surfaces contribute to aesthetic quality.
- Digital fabrication and manufacturing technologies: Enable efficient production with minimal waste while allowing architectural freedom.
- Machine learning algorithms: Enable optimized solutions for the environmental conditions, building typology, location, age and energy certificate; complimenting building performance and manufacturing workflow.
- Environmental science and sustainability research: Guides decisions related to carbon storage, life-cycle impact, material end of life strategies and circular material use.
- Social sciences: Fosters citizen participation, belonging and stakeholder activation through co-design processes
- Innovation and entrepreneurship: Support the development of a viable pathway for scaling the concept into real construction projects.
- Material science and process engineering: Contribute to developing the bio-based composite and ensuring thermal performance and durability.
- Architecture and computational design: Shape how the panels integrate into buildings and how their surfaces contribute to aesthetic quality.
- Digital fabrication and manufacturing technologies: Enable efficient production with minimal waste while allowing architectural freedom.
- Machine learning algorithms: Enable optimized solutions for the environmental conditions, building typology, location, age and energy certificate; complimenting building performance and manufacturing workflow.
- Environmental science and sustainability research: Guides decisions related to carbon storage, life-cycle impact, material end of life strategies and circular material use.
- Social sciences: Fosters citizen participation, belonging and stakeholder activation through co-design processes
- Innovation and entrepreneurship: Support the development of a viable pathway for scaling the concept into real construction projects.
The envisioned business model for our project would be a B2B2C model within the construction ecosystem.
In that context, the primary customers would be architects, real estate developers and contractors involved in building renovation or new sustainable construction projects, while end users would be property owners or tenants.
Revenue would come primarily from the sale of bio-based exterior insulation panels, complemented by design consulting and customisation services for architectural projects using our machine learning algorithm.
The manufacturing process would be initially only large scale robotic 3D printing adapting to different project scales while minimising material waste. In order to scale up the production, this technique could be combined with industrial extrusion technologies.
In early stages, development could be supported by innovation programmes, grants, awards and public funding. Over time, the aim is to transition toward a financially sustainable model based on product sales, partnerships within the construction sector and potentially private funding for scaling up.
In that context, the primary customers would be architects, real estate developers and contractors involved in building renovation or new sustainable construction projects, while end users would be property owners or tenants.
Revenue would come primarily from the sale of bio-based exterior insulation panels, complemented by design consulting and customisation services for architectural projects using our machine learning algorithm.
The manufacturing process would be initially only large scale robotic 3D printing adapting to different project scales while minimising material waste. In order to scale up the production, this technique could be combined with industrial extrusion technologies.
In early stages, development could be supported by innovation programmes, grants, awards and public funding. Over time, the aim is to transition toward a financially sustainable model based on product sales, partnerships within the construction sector and potentially private funding for scaling up.
There are several elements of the concept that have strong potential for replication and transfer across different geographies and sectors:
- Material Innovation: Transforming sawdust waste into a bio-based composite can be applied to different types of sawdust generated across wood-processing industries, regardless of tree species or specific industrial context. This makes the material adaptable to diverse regional waste streams.
- Machine Learning Enhanced Design: Enables the customisation of exterior insulation panels based on building age, typology, and climatic location. This allows the panels to adapt to different architectural contexts while maintaining material efficiency and thermal performance, making the solution transferable to diverse building stocks across Europe.
- Methodology Developed: Enabling scaling the bio-based composite through computational design and additive manufacturing, which can also be applied to other bio-based waste streams beyond sawdust. The design and fabrication strategies explored in the project provide a framework for upcycling agricultural or forestry residues into high-value architectural materials.
- Circular Value Chain Model: Connects waste producing industries with construction and manufacturing. This approach can be replicated in different regions by linking local material streams with architectural production.
- Material Innovation: Transforming sawdust waste into a bio-based composite can be applied to different types of sawdust generated across wood-processing industries, regardless of tree species or specific industrial context. This makes the material adaptable to diverse regional waste streams.
- Machine Learning Enhanced Design: Enables the customisation of exterior insulation panels based on building age, typology, and climatic location. This allows the panels to adapt to different architectural contexts while maintaining material efficiency and thermal performance, making the solution transferable to diverse building stocks across Europe.
- Methodology Developed: Enabling scaling the bio-based composite through computational design and additive manufacturing, which can also be applied to other bio-based waste streams beyond sawdust. The design and fabrication strategies explored in the project provide a framework for upcycling agricultural or forestry residues into high-value architectural materials.
- Circular Value Chain Model: Connects waste producing industries with construction and manufacturing. This approach can be replicated in different regions by linking local material streams with architectural production.
Over the next year with the support of this prize, project NERA could be further developed in the following areas:
- Advancing Material and Production Development (Months 1-3): Further improvements on the material durability and production process for increasing scalability and consistency. (20% of funding)
- Producing Additional Exterior Panel Prototypes (Months 1-3): To refine installation systems and architectural integration.
- Multi-disciplinary Focus Group (Month 4): Validating technical development, design and building envelope system through a multi-disciplinary focus group composed of architects, contractors/developers, facade engineers and municipalities enabling easy integration for building codes/regulations (6% of funding)
- Third Party Laboratory Testing (Months 4-6): Conduct laboratory tests for fire safety, thermal insulation, and durability to meet EU building standards. (27% of funding)
- Community and Stakeholder Engagement (Months 6-9): Capacity building and co-design workshops with citizens, municipalities, and SMEs showcasing results and co-designing adoption pathways. (20% of funding)
- Pilot Production (Months 6-12): Developing pilot collaborations with architects and building stakeholders to explore real-world applications. (17% of funding)
- Communication and Dissemination Activities (Continuous): Throughout all months document and share the project progress, increase visibility through publications, conferences, social media (10% of funding)
- Advancing Material and Production Development (Months 1-3): Further improvements on the material durability and production process for increasing scalability and consistency. (20% of funding)
- Producing Additional Exterior Panel Prototypes (Months 1-3): To refine installation systems and architectural integration.
- Multi-disciplinary Focus Group (Month 4): Validating technical development, design and building envelope system through a multi-disciplinary focus group composed of architects, contractors/developers, facade engineers and municipalities enabling easy integration for building codes/regulations (6% of funding)
- Third Party Laboratory Testing (Months 4-6): Conduct laboratory tests for fire safety, thermal insulation, and durability to meet EU building standards. (27% of funding)
- Community and Stakeholder Engagement (Months 6-9): Capacity building and co-design workshops with citizens, municipalities, and SMEs showcasing results and co-designing adoption pathways. (20% of funding)
- Pilot Production (Months 6-12): Developing pilot collaborations with architects and building stakeholders to explore real-world applications. (17% of funding)
- Communication and Dissemination Activities (Continuous): Throughout all months document and share the project progress, increase visibility through publications, conferences, social media (10% of funding)
