The initiative is supported by the Department of Defense’s Environmental Security Technology Certification Program (ESTCP) and marks one of the first large-scale military applications of custom 3D-printed insulation panels. These panels are designed using Branch’s Cellular Fabrication (C-Fab®) process, which begins with a digital scan of existing building surfaces and ends with precisely manufactured insulation components tailored to fit complex architectural details.
This kind of precision allows the Army to sidestep the inefficiencies of off-the-shelf insulation solutions, particularly in older structures where standard materials often fall short. The retrofit project at Detroit Arsenal will address approximately 6,250 square feet of building envelope, with estimated energy efficiency improvements of up to 50%. That’s not just a boost for operational performance—it also supports the military’s ongoing push to meet federal sustainability goals.
To validate performance, the National Renewable Energy Laboratory (NREL) is constructing a parallel 300-square-foot test installation at its research facility in Colorado. The monitored demo will collect real-world data on energy savings, installation complexity, and long-term value—key benchmarks that could guide future military infrastructure planning.
While the Detroit Arsenal retrofit is still in early stages, its inclusion in Ameresco’s 2025 federal project backlog signals growing momentum around these types of collaborative efforts. The company sees this as part of a broader trend: federal agencies are increasingly leaning on private sector innovation to address infrastructure challenges without the delays of traditional government contracting cycles.
