Strategies for Adaptive Design and Fabrication with Bio-Based and Reclaimed Building Materials

Bio-based and waste-sourced materials are emerging as sustainable alternatives to reduce resource extraction and construction waste in the Architecture, Engineering, and Construction (AEC) industry. Unlike conventional materials such as brick, concrete, or steel, they are renewable, locally available, and support circular economy principles. Agricultural fibers like hemp offer high carbon uptake and frequent harvest cycles but exhibit variability due to environmental factors. Similarly, reclaimed materials are influenced by prior use, residual performance, and inconsistent availability. These properties contrast with current manufacturing standards, which prioritize uniform materials suited for standardized fabrication. While data-driven modeling and in-line sensing offer solutions for material variability, existing workflows remain optimized for mass production and lack flexibility to integrate bio-based and reclaimed resources. This paper examines how bio-based and reclaimed materials impact design and fabrication, focusing on the capabilities and limitations of current CAD and CAM workflows. Through architectural case studies, it explores: Capabilities: How well can CAD, CAM, and simulation tools accommodate material variability? Limitations: What barriers hinder large-scale adoption, and at what stages? Opportunities: What workflow modifications can enhance adaptability? The case studies cover timber, agricultural fibers, and biopolymer-based materials, analyzed alongside their fabrication methods—milling, fiber winding/kitting, and 3D printing. Insights from these studies inform the Adaptive Production Chain (APC), a new methodology for integrating material characterization with design and fabrication. APC fosters adaptive, circular workflows, aligning material properties with production processes to promote sustainable innovation in the AEC industry.