Overview

We developed a vertical business in which all elements of a residential building could be componentized, made to fit most residentially-zoned sites, assembled into modules in our factory, then assembled on site using robotic technology. This is in addition to assisting with local permitting and working with any locale-specific contractors and trades.

Test-Fit

The process starts by first analyzing whether or not a site qualifies for one of our projects. From there, thenature of the lot is determined, including how each boundary relates to local rules on set-backs, lot coverage, and general FAR considerations. The data is then processed to auto-generate an array of possible 3D floor plans & layouts which would adhere to fixed modularized/panelized rules, as well as keeping in accordance with building codes.

Auto Panelization of Building

Once a layout is selected by the lot owner, and customized further, internally-developed software is deployed to convert the test-fit model into detailed architectural & structural components in Revit/BIM. The most key components are the wall, floor, ceiling & shaft panels. There are additional modules for the Kitchen, Bathrooms, and casework. The panels would have all of the required mechanical ductwork, plumbing, and most of the electrical conduits/wiring auto-generated, and hosted within, and ready for connection to adjacent panels.

Detail Creation

Upon architectural & structural review, an internal script is ran to analyze the resultant BIM model, and generate permit & construction drawings, with annotations.

Shop Drawing Creation

In addition to the construction & permit drawings, shop drawings are generated for all components/modules; alongside detailed Quantity takeoffs, which are fed into the purchase order system. Additionally, general assembly instruction code is sent to various machine stations in the factory to enable the components/modules to be assembled with minimal human labor (though human labor is still very crucial in the beginning stages of assembly).

Construction Sequencing

Combining previous site information, jurisdictional restrictions, and component information, the construction sequencing is able to be planned. Once site work has been completed, the components are shipped to the site from the Ontario factory. The site assembly ‘robotic crane’ is also shipped to the location, where the carefully packed modules are removed from their pallets, and positioned into place, and interlocked by on-site workers. With most of the finishing also done in-factory, there is minimal touching up of the interiors; which completes the project.

Model Conversions to Unreal

There was a process developed to extract Revit data & geometries, and convert into a photorealistic Unreal 5 model, to enable clients to better visualize, then customize their home’s finishes, fixtures, casework, and other design elements.