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Houston startup constructs eco-friendly 3D printed homes

seeing green

HIVE 3D is bringing science fiction to reality with this Texas project. Photo courtesy of HIVE 3D

A Houston company has teamed up with a Utah-based sustainable cement alternatives producer to construct eco-friendly homes made from 3D-printed pieces.

HIVE 3D was already revolutionizing the home-builder industry with its lightweight gantry system and mobile robotic arm system to 3D print its homes, but it took a giant leap further with its partnership with Eco Material Technologies.

Together, they are building the world’s first near-zero-carbon, 3D-printed homes. Using Eco Material’s cement mixture called PozzoCEM Vite, which has 92 percent lower emissions than traditional concrete that can set in just a few minutes, they are focusing on providing a sustainable, cost-efficient and affordable housing solution.

“We want our homes to last 1,000 years,” Timothy Lankau, CEO, Hive 3D CEO, tells InnovationMap. “We want archaeologists to dig them up and wonder what they were. I mean, you go to the Parthenon in Rome, and it looks similar today to how it did 2,000 years ago because the materials are so stable.

“Concrete's just a very stable material. It doesn't change over time, and that's also why building with stone and masonry is important for the future. We think it's more sustainable because it's ultimately going to be better in terms of longevity.”

Key collaboration

Eco Material Technologies and HIVE 3D’s collaborative mission began through a mutual desire to develop sustainable and eco-friendly solutions for the construction industry.

“Both companies recognized the pressing need to reduce the environmental impact of traditional construction materials and processes and the need for affordable, high-quality housing,” says Grant Quasha, CEO of Eco Material Technologies. “The partnership between the two companies began when Eco Material Technologies reached out to HIVE 3D to explore the potential of incorporating their eco-friendly materials into 3D printed construction.

“HIVE 3D recognized the opportunity to combine their expertise with sustainable material solutions. The finished product of this collaboration is an eco-friendly construction material that can be 3D printed into various structural elements like walls, floors and columns.”

Proof of concept

Photo courtesy of HIVE 3D

HIVE 3D’s first full project, a 3,150-square-foot home located in Burton, Texas, was printed with a rotating team of just four people using PozzoSlag, which replaces 50 percent of the portland cement in concrete and has been used in roads and bridges in Texas for over a decade.

The home used several innovations that hadn’t been used in a 3D printed house before, including parametric wall designs, foamcrete wall insulation, and pigmented concrete layers.

“Our product is more sustainable because it utilizes proprietary technology that allows for the use of alternative materials to replace the clinker and processes from traditional cement that contribute to its high emissions,” says Quasha. “It is estimated that the portland cement industry contributes to 8 percent of global emissions annually, but by utilizing Eco Material Technologies' cement replacement solutions ... builders can significantly decrease their carbon emissions without compromising on the product's setting time or long-term strength."

Each ton of portland cement replaced by a ton of Eco Material's products, PozzoSlag or Pozzocem, reduces emissions by close to one ton, Quasha explains.

The Calais project, located in Round Top, Texas, behind the Halles, an antique shopping and design destination, broke ground in March 2023 and will feature a collection of tiny homes known as casitas, including studio, single-bedroom and two-bedroom models, ranging from 400 to 900 square feet.

“These small homes will serve as a model for affordable and eco-friendly housing throughout the country,” says Lankau. “We plan to build them at a speed and cost point that is unprecedented in the affordable housing space.

“Ultimately, we want to build houses at a disruptive price point. We want to be vertically integrated and put our homes on the market at a significant discount to market wherever they are. And by significant, we're talking 20 or 30 percent. That's our goal.”

The right resources

Photo courtesy of HIVE 3D

HIVE 3D worked with CyBe Construction to create a mobile construction 3D printer and mixing system that allows the printing mortar to be mixed onsite, which eliminates a significant amount of labor and time, which means those savings can be passed on to the consumer.

“We worked with a company called CyBe in the Netherlands to build a robotic arm, and that arm has about an 11-foot reach, and it can go all the way in a circle around itself,” says Lankau. “So, it drives around the foundation of the house, printing sections of the house at a time. So, it'll print a section, drive to the next section, and print the next section.

“So instead of having this many different materials and these many different traits, people that do all these different things, we have a machine that just uses one material and prints the wall.”

HIVE 3D has an internal engineer that works through all of the structural issues that may come up on projects and helps them build homes with monolithic, foot-thick concrete walls with rebar and steel supported in them.

According to Lankau, their 3D printed homes are tornado-proof, hurricane-proof, pest-proof, bullet-proof and can virtually withstand anything because of the sustainable materials used to build them.

“They're everything-proof,” says Lankau. “Just because of the natural strength of the concrete and the steel we use to create them, they can support millions of pounds. So, it's actually a stronger material than a typical house. By a factor of 100. Like I said, it's bulletproof and tornado-proof. You could drive a car into it, and it would total the car. I mean, it's a very, very sturdy structure.”

A bright future

Photo courtesy of HIVE 3D

Moving forward, HIVE 3D would like to continue to innovate and advance its 3D printing technology by leaps and bounds.

“The science fiction goal here, which is maybe a five-year goal, is to be able to drive onto a site, press a button, and watch the robots work,” says Lankau. “We want to be a significant home builder. So, in five years, we want to be building a lot of houses quickly and affordably and we want to continue to automate more and more of the process.”

Right now, there is no formal process for commissioning a HIVE 3D printed home. Perspective customers are directed to the website, then put in a request to build a home, go through a screening process and if the project is a good fit, they'll put that project into their pipeline.

“We can build them quickly. It's just a matter of getting to them,” says Lankau. “We're also going to be doing some developments in Texas probably to start. We also have some international things that we'll be looking into next year. But right now, it's mostly in Texas. We'll be building some developments and putting those homes on the market. We hope to have some out this year and then a bigger chunk next year as we get more machines working. Those will be announced on our website.”

As HIVE 3D continues to find ways to scale its business model, there is a laser focus on the diminishing idea of the “American Dream,” where young families are able to purchase their first home. With the rising costs of supplies and labor, those families have been priced out of the market.

“That’s almost all we think about,” says Lankau. “Homeownership and that part of the American Dream is really struggling right now because the affordability gap between what the average person makes and what the average house on the market costs is just getting wider and wider.

According to Lankau, there are a lot of options to address the supply gap, but there aren’t an equal number of options to solve the affordability issue. Their goal is to find the best ways to deliver real cost savings over both traditional construction and other automated technologies.

“About three weeks ago, we kind of hit the inflection point in our current project where we printed a little house in three days. The cost of the house was what we wanted the cost to be, which is a disruptive amount less than what you could do traditionally or with any other construction technique. And we said, okay, now we're far enough along. We have this system. It's a scalable system. So, we're right now putting some capital together to go out and buy, build more of these machines and get out and start doing these truly affordable housing projects. Because that's where our heart is. Our heart's on the affordable side.”

HIVE 3D’s project in Burton, Texas isn’t available for sell yet, but it will be listed on Airbnb for interested customers to go and experience when it’s completed.

Additionally, the Casitas units in Round Top will be short-term rentals for festival patrons.

“We’ll go directly to market with our next projects,” says Lankau. “And then we'll sell that big house property in Burton at the end of this year.”

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This article originally ran on InnovationMap.

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Houston geothermal startup adds former bp, Calpine execs to C-suite

new leaders

XGS Energy, a Houston-based developer of geothermal power systems, has added several energy industry veterans to its C-suite this summer.

The company named Al Vickers as its new chief operating officer earlier this month. Vickers will replace Ghazal Izadi in the role, as she moves into the chief growth officer position.

Vickers previously served as CEO of bp's U.S. Low Carbon Energy business and most recently was COO of Houston-based Grid United, which develops next-generation transmission infrastructure.

“I have spent my career developing, building, and operating large, complex energy infrastructure, and I am excited to work with XGS’s proven technology, which is ready to deliver clean, round-the-clock power at the scale the grid and customers need,” Vickers said in a news release. “XGS sits at the intersection of innovation, affordability, demand growth, responsible infrastructure development, and long-term energy resilience. I’m excited to roll up my sleeves and apply best practices from both oil and gas and infrastructure development to deliver gigawatt-scale geothermal projects.”

Kurt Fricker, who most recently held leadership roles at Hess Corporation, was also announced as XGS's new chief procurement officer.

The hires come shortly after XGS announced Richard Chong as its new chief financial officer in May.

Chong joins XGS from Houston-based power producer Calpine, where he most recently was vice president of finance. His work there included leading $2.25 billion in financing for Geysers, the world’s largest geothermal power complex.

Chong says XGS’ proven technology and the rising demand for clean power will help the company execute on its multi-gigawatt pipeline.

“I look forward to applying the experience I’ve built over two decades in energy finance to help XGS deliver clean, reliable power to customers and unlock the massive development opportunity ahead for next-generation geothermal,” Chong said in the release.

XGS’ first project is a 150-megawatt geothermal facility in New Mexico. It will supply around-the-clock electricity to the grid operated by Public Service Co. of New Mexico in support of Meta data centers.

XGS recently tapped Houston-based energy technology company Baker Hughes to provide engineering services for the New Mexico project.

XGS’ geothermal system uses thermally conductive materials to deliver affordable energy anywhere hot rock exists — without the need for water resources or specific geological conditions. This results in lower-risk projects, more site options, easier permitting and faster deployment.

Since 2023, XGS has raised nearly $57 million in venture capital.

XGS launched in 2008 in Palo Alto, California, as Geothermic Solution. In conjunction with its Series A round in 2023, the company rebranded to its current name. The company recently moved its headquarters to Houston, according to the Houston Business Journal.

Woodlands-based Lancium teams up on West Texas data center campus

coming soon

The Woodlands-based Lancium Technologies, which designs, develops, and manages gigawatt-scale data center campuses, has teamed up with Denver-based data center builder and operator Crusoe Energy Systems on a new grid-connected campus more than 100 miles east of Wichita Falls.

Construction on the 1-gigawatt Childress County campus, being built for an unidentified tech company, is expected to start in Q3 of this year.

Lancium owns the 270-acre site where the data center campus will be located and will set up and manage the campus’ energy infrastructure. Crusoe will design, build, and operate the campus.

The two companies already are working together on data centers in Abilene. Their first data center has already expanded to a capacity of 1.2 gigawatts, and a 900-megawatt data center is planned for adjacent land owned by Lancium.

The Abilene project is the first site of the Stargate initiative, an AI infrastructure program backed by MGX, OpenAI, Oracle, and Softbank to create a U.S. network of hyperscale AI data centers. The four-year initiative has earmarked $500 billion to build the network.

“Childress is a natural next step in our partnership with Crusoe,” Lancium CEO Michael McNamara said in a news release. “Crusoe has been a great partner to build alongside in Abilene, and we’re glad to bring that same model — and the jobs and investment that come with it — to the community of Childress. We are deeply committed to working with local stakeholders to advance a model of development that addresses the broader needs of the community we will share for a very long time.”

Last year, Lancium appeared at No. 43 on Time and Statista’s list of America’s top greentech companies.

Lancium has raised $1.25 billion in funding since its founding in 2017, according to PitchBook and CB Insights.

In 2021, Lancium closed $150 million in funding led by Hanwha Solutions, with participation from SBI Holdings, Novawulf and other investors. Four years later, the company arranged $600 million in debt financing to advance development of “clean” data center campuses.

New York energy firm scoops up Houston’s Infinity Power Partners

m&a activity

Houston-based energy management and consulting firm Infinity Power Partners has been acquired by New York City-based Environ Energy, which also offers energy management and consulting services.

The deal creates a new “anchor segment” for Environ in the multifamily market. With the addition of Infinity Power’s roughly 2,000 clients in the multifamily sector, representing more than 1 million multifamily units under contract, Environ now has more than 8,000 U.S. clients in the commercial real estate, healthcare, manufacturing, education and government sectors.

“This acquisition continues to solidify our presence in key energy markets while aligning with founders who share our deep commitment to client success,” Environ CEO Chris Sternberg said in a news release.

Infinity Power co-founders and managing partners Nick Altman and Peter Selber have joined Environ, a portfolio company of investment firm 424 Capital. Altman and Selber founded Infinity Power in 2011.

“We built our business one relationship at a time,” Selber said, “with a strong commitment to the communities we serve. That same dedication is reflected in Environ’s approach — now delivered at scale.”

Altman says the acquisition is part of the “next chapter” in energy management. Energy management services help commercial customers reduce utility bills, improve equipment life, achieve green energy goals, and decrease risk tied to fluctuating energy prices.

“Energy management is a culture for continual improvement of energy performance and efficiency that’s integrated within an organization’s normal business practice,” according to the U.S. Office of Energy Efficiency & Renewable Energy.

In all, Environ has made six acquisitions in the past 17 months.

Last year, Environ acquired another Houston-based energy management and consulting firm, CSD Energy Advisors. In that deal, Environ gained nearly 1,000 clients, including several Fortune 500 companies and three large industrial energy users in Texas. As part of the deal, CSD co-founders Andrew Barth and JB Sowyrda joined Environ.

Also last year, Environ purchased Carrollton-based energy advisory firm Rapid Power Management (RPM).

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