UTK professor launches sustainable start-up to rethink how walls are built
After decades designing iconic structures, UT professor Maged Guerguis is now building something new: OTTO Prefab, a start-up born from biomimicry, additive manufacturing, and a vision for cleaner construction.
Maged Guerguis has decades of stories from his work as a skyscraper architect.
Stories about buildings overlooking multi-level parks in Manila, stories about designing all-electric RVs, stories about starting his own architectural design firm and lab called Soft Boundaries.
One of his favorite stories is how he ended up in Knoxville.
He first came to the University of Tennessee, Knoxville (UTK) through a collaboration with Oak Ridge National Laboratory (ORNL) and Skidmore, Owings & Merrill on a project called AMIE 1.0. It was the world’s largest 3D-printed building enclosure, capable of wirelessly sharing energy with a 3D-printed vehicle.
And soon, Guerguis will have a new tale to tell, this time, one that’s hidden inside the walls of homes, hotels, and commercial spaces.
That story, however, is still being written.
A new company and a new mission
Amidst full-time jobs in professorship, architecture, and as a family man, Guerguis became curious about the amount of waste generated from the construction industry.
Projects use more material than necessary, which causes adverse financial and environmental implications.
Guerguis sees additive manufacturing (AM) as a faster, safer, cost-effective, and environmentally sustainable solution, particularly in large-scale construction.
Let’s look at the makeup of a wall, for example. There are studs, all made of wood, and several of them are placed throughout the structure of the home. On top of that, there are top rails, bottom rails, and all the noggins in between.
In addition to the wood, home builders also add panels, insulation, electrical wires, etc.
A lot is going on inside our walls.
Guerguis said there’s a more efficient and sustainable way to do this. He’s spent the past two years developing it.
“We can design and print the insides of walls to be structurally sound under stress and use less material,” he said.
His theoretical research at UTK revealed a process through which material could be uniquely designed for high-stress areas in a structure. Guerguis said this design is based on “biomimetic principles found in nature,” which maximize structural performance, minimize weight, and drastically reduce waste.
“It could be the future of how we sustainably build structures,” he said. “I see this as an efficient option for sustainable housing, hotels, and commercial structures.”
Seeing that his research extended beyond theory and had practical, real-world applications, Guerguis decided to take the bold step in pursuing it as a business.
He reached out to the UT Research Foundation (UTRF), which gave him funding to further explore commercialization.
He also connected with Autodesk in the Boston Technology Center, which provided him the opportunity to spend a summer testing different materials, working with 3D printing robots, and proving his concept.
At this point, he has small-scale samples with a variety of materials, as well as a partial large-scale sample that he developed at Autodesk, using a concrete 3D printer.
Now, about a year later, he’s ready to begin commercializing what he’s calling “Otto Prefab.”
OTTO Prefab joins Spark program
Bringing something from theory to practice and then from laboratory to market is no easy task. There’s a lot to consider: from customer discovery and financial projections to applying for grants and identifying decision makers, and marketing the product.
“UTRF had recommended I apply to the Spark Cleantech Accelerator program,” Guerguis said. “I am so glad I did. It helped me bridge the gap between research and entrepreneurship, and understand how to bring an innovation to market.”
The Spark Innovation Center was founded in 2020 and is headquartered at the UT Research Park. Through its Cleantech Accelerator, Scholars, and Incubator programs, Spark has supported 40 companies that have collectively raised $137.6 million, hired 196 full-time employees, and supported 52 interns. 77 percent of companies served still have an active presence in Knoxville.
The cohort is currently at its halfway point, with about six weeks of programming remaining.
In addition to participating in Spark, Guerguis has renewed his residency at Autodesk in Boston to continue materials discovery and full-scale prototyping of high-performance building panels.
Reflecting on the past year
There’s been a lot of change for Guerguis, his students, and his family. Working in a full-time professorship while also starting a business is not for the faint of heart.
“How do you do it all?” we asked, to which he responded, “With balance.”
Guerguis detailed how, through decades of building stories, he’s also been somewhat of an architect in his own life and with his own family.
“I asked ChatGPT one day to define what quality of life really means,” he said. “From there, our family went through each area to see which of those qualities we already have, and where we could grow to create a life that brings fulfillment.”
Areas like family relationships, health and wellness, environmental sustainability, fulfilling careers, and spiritual practices. Guerguis said just about every minute of his day is spent intentionally – even the time he eats, which is noon and five in the evening.
He has that same sort of intentionality with OTTO Prefab, and feels a sense of fulfillment and passion in knowing that he’s developed something with a large potential for impact.
Now, he’s focused on getting it into the hands of businesses and builders who need it.
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