Eco-voxels: Building blocks for sustainable, load-bearing structures

The housing and climate crises are intertwined: climate change increases housing costs through increased damage and insurance premiums, while resource-intensive construction boosts greenhouse gas emissions. Emerging alternative construction methods aim to reduce the environmental impact but often rely on materials with questionable sustainability benefits. In this study, we build on the concept of digital metamaterials—lightweight, reconfigurable building blocks—by introducing eco-voxels: modular, mass-producible construction units made from an in-house-developed polymer composite of partially sustainably sourced polymer and rCFs. By assessing the structural performance of an eco-voxel wall, we illustrate the suitability of this construction method for residential buildings. In parallel, by comparing the carbon footprint of a 1 m² eco-voxel wall with traditional concrete, three-dimensional-printed concrete, and CLT, we demonstrate 20%–40% reduced greenhouse gas emissions. Our analysis demonstrates that eco-voxels meet load-bearing requirements and offer a reduced carbon footprint aligned with eco-conscious construction demands.