Insulated, load bearing wall panels are machined from a raw foam slab of foam material. The raw foam slab is loaded into a Turcotte sculptor. The Turcotte sculptor is an elegant 36-axis machine that machines the raw foam slab into one or more insulated foam wall panels. The Turcotte sculptor, in particular, may accept very large 18x4x2 feet slabs of foam material. The Turcotte sculptor then individually commands and actuates any of 36 linear actuators to produce the one or more insulated foam wall panels. The Turcotte sculptor, within minutes, simultaneously machines the raw 18x4x2 foam slab into two (2) 9-feet tall wall panels for 9-feet ceilings. The Turcotte sculptor may easily machine other wall sizes. The Turcotte sculptor thus efficiently and quickly volume produces entire one-piece, single-height insulated wall panels at reduced cost and with outstanding energy performance.

A system and method for manufacturing, assembling, and installing an extruded aluminum wall panel frame by manufacturing an extrusion profile that comprises a stud, a sole plate, and a sill plate and other components used to configure the extrusion profile into a frame either fully or partially assembled prior to transport and installation at the building site where the frame may be installed as a single-level structure or multi-level structure of varying lengths, widths, and floorplans.

A modular building system, includes a modular building assembly, including a base mounting structure with first and second base angle brackets; a left receiving wall assembly, including a left primary wall assembly, and left front and left rear corner brackets; a right primary wall assembly, and right front and right rear corner brackets; and front and rear wall assemblies; and a platform with legs; such that the modular building assembly is positionable on a top surface of the platform.

A building system and a method for constructing a building, the system (100) comprising plurality of prefabricated elements (I), the element (1) comprising: a self-supporting insulation panel (2) comprising a rigid insulation material, —a metal frame (3), comprising a pair of sub-frames. The length of the sub-frame (7a, 7b) has a cross-section comprising an attaching arm (10) extending along the corresponding edge surface (6a, 6b), and an intruding section (11) arranged in the attaching arm (10), the intruding section (II) intruding into the insulation element (5). A box-type structure (12) is arranged distally from the intruding section (11) and comprising a closed or partly open construction. The building system further comprises a connecting element (4), having a cross-section basically a shape of a U-profile. The connecting element (4) is arranged on sub-frames (7a, 7b) of two adjacent elements (1).

Described herein is a wall assembly for use in walls of energy efficient residential or commercial buildings which can provide improved thermal resistance, moisture resistance and structural capacity. The wall assembly includes a frame assembly; a laminated outer sheathing layer; and a closed cell inner foam layer for coupling the layer to the frame assembly. Also described herein is a method of manufacturing the wall assembly.

Light weight fiber-reinforced polymeric structural building panels and methods; sized, configured for fabrication of non-portable wall structures permanently fixed to natural base. The panel main body, and studs, can be fabricated separately, then assembled to each other to complete panel fabrication. Methods for making the main body are hand lay-up, or pultrusion. Studs are typically pultruded, and subsequently prepared having consistent thickness, flat surface, across the width of the stud end wall which is to be mounted to the main body. Foam blocks are between inner and outer layers of the panel. Foam blocks can be prepared in block clusters before assembly to the main body. In the main body, a fibrous layer is between each pair of next adjacent foam blocks. Intercostals extend “y” and “z” dimensions transverse to the length of the main body. Studs can be mounted to the main body using adhesive, mechanical fasteners, or both.

A facade assembly for a vehicle parking structure comprising a facade panel arranged to form part of an exterior of the structure. The facade assembly includes at least one support member extending inwardly of the panel and into the structure in use for connection with a floor of the structure. The support member is arranged to include one or more attachments.

A construction system utilizes a post-and-beam structure that supports major gravity loads of a building in combination with prefabricated exterior and/or interior wall panels that are not required to support gravity loads beyond self-weight. Studs within the prefabricated wall panels are oriented such that a widest face thereof is other than normal to the wall surfaces attached thereto. Such an orientation of the wall studs reduces or eliminates thermal bridging in the structure without adding materials, thereby reducing embodied carbon and embodied energy content. The orientation of the wall studs also maximizes the available space within the wall panels to accommodate electrical and plumbing utilities and insulation material and utilizes the studs along their strong axis to resist lateral loads.

The invention relates to a panel and a method for producing a panel. The panel is in particular a floor, wall or ceiling panel, and comprises at least one core layer, the core layer comprising an upper core surface and a lower core surface and at least one pair of opposite side edges; wherein the core layer comprises magnesium oxide cement; wherein the core has a density which is substantially homogenous over its entire volume, and wherein at least one decorative top layer is attached to an upper core surface of the core layer.

An article of manufacture is disclosed comprising a 3D-printed wall panel having an interior side and an exterior side. The exterior side comprises a textured surface formed by 3D printing the wall panel onto a textured form. In certain embodiments, the textured surface mimics at least one of natural stone, brick, and wood siding, and the medium printed onto the textured form is concrete. The interior side has 3D printed structural elements printed thereon designed to mimic conventional wood-stud framing in at least one of dimensions and spacing. A method for fabricating the 3D printed wall panel as described above is also disclosed.