From balloons frame to CAD-tailored :From balloons frame to CAD-tailored :Japanese precut framing technology Japanese precut framing technology

comes to the U.S.comes to the U.S.

Presented By:Presented By:

Soad Zaki Abdel-TawabSoad Zaki Abdel-Tawab

By: Ted Smalley BowenBy: Ted Smalley Bowen

Web Address:Web Address:

http://archrecord.construction.com/features/digital/archives/0410dignews-1.asphttp://archrecord.construction.com/features/digital/archives/0410dignews-1.asp

Topic Number: 36Topic Number: 36

Date: Date: 10/0410/04

PREFASEPREFASE

Advances in manufacturing technology Advances in manufacturing technology are bringing mass customization closer to are bringing mass customization closer to reality for home building. reality for home building.

For a number years, building suppliers For a number years, building suppliers have manufactured made-to-order have manufactured made-to-order components with a high degree of components with a high degree of automationautomation

Now, a supplier called MF Technologies is Now, a supplier called MF Technologies is using a CAD-driven system called using a CAD-driven system called MasterFit, developed in Japan, to churn MasterFit, developed in Japan, to churn out custom-cut, engineered wood frames out custom-cut, engineered wood frames for single- and multifamily houses.for single- and multifamily houses.

MasterFit systemMasterFit systemcomes to U.S.comes to U.S.

The Minneapolis-based company opened its first fully automated The Minneapolis-based company opened its first fully automated U.S. plant in June 2004. Company officials tout the system’s frugal U.S. plant in June 2004. Company officials tout the system’s frugal use of materials, which makes for less factory waste, as well as its use of materials, which makes for less factory waste, as well as its ability to produce tighter frames and shells, reduce production and ability to produce tighter frames and shells, reduce production and assembly time, and simplify labor requirements.assembly time, and simplify labor requirements.

The MasterFit system consists of a proprietary The MasterFit system consists of a proprietary CADCAD tool (an tool (an AutoCAD add-on) to which data from standard CAD files, hard-copy AutoCAD add-on) to which data from standard CAD files, hard-copy drawings, or sketches are added. The tool then lays out the frame drawings, or sketches are added. The tool then lays out the frame and cuts studs, joists, rafters, and trusses from engineered wood and cuts studs, joists, rafters, and trusses from engineered wood using a computer numeric control using a computer numeric control CNCCNC system system

CAD/CAM/CNC Software OverviewCAD/CAM/CNC Software Overview

There are three main types of software programs that are used to There are three main types of software programs that are used to go from design to making a physical part using your Windows-based go from design to making a physical part using your Windows-based PC. PC.

MasterFit systemMasterFit system Frame components are labeled and shipped to Frame components are labeled and shipped to building sites as a kit of parts. Because they building sites as a kit of parts. Because they are assembled with interlocking metal pegs are assembled with interlocking metal pegs and plates, the frames can be erected by and plates, the frames can be erected by construction teams with minimal training, construction teams with minimal training, rather than skilled laborers. (Prefabricated rather than skilled laborers. (Prefabricated building panels used with the frames must be building panels used with the frames must be attached with nails or screws, however.)attached with nails or screws, however.)

The Albert Lea, Minnesota, factory can turn The Albert Lea, Minnesota, factory can turn around an order in about two weeks. Once around an order in about two weeks. Once components are on-site, the shell of a 1,500-components are on-site, the shell of a 1,500-square-foot house can be erected and square-foot house can be erected and enclosed within three days, according to MF enclosed within three days, according to MF

Technologies president Santos MartinTechnologies president Santos Martin..

MasterFit systemMasterFit systemhow it workhow it work

MasterFit delivers a superior framing MasterFit delivers a superior framing method that easily accommodates method that easily accommodates conventional mechanical requirements conventional mechanical requirements and finish work.and finish work.

While MasterFit represents a giant leap While MasterFit represents a giant leap forward in framing technology, once the forward in framing technology, once the framing and enclosing work is completed, framing and enclosing work is completed, no special methods are needed for no special methods are needed for plumbing, heating, electrical systems and plumbing, heating, electrical systems and interior finish work.interior finish work.

In fact, because MasterFit utilizes fewer In fact, because MasterFit utilizes fewer members to deliver stronger structural members to deliver stronger structural integrity, running mechanical and integrity, running mechanical and electrical systems is actually simpler than electrical systems is actually simpler than in traditional stick-built constructionin traditional stick-built construction

MasterFit systemMasterFit system The house was built The house was built

by seven women by seven women enrolled in a carpentry-enrolled in a carpentry-training program in training program in Duluth, Minnesota, who Duluth, Minnesota, who had only one week of had only one week of experience.experience.

MasterFit Frames MasterFit Frames are shipped to a site and are shipped to a site and assembled with joinery assembled with joinery included in the kit.included in the kit.

Photography:Photography:

Courtesy Courtesy Northern Northern

Communities Communities Land TrustLand Trust

lhb/Jeff Frey lhb/Jeff Frey PhotographyPhotography

ADVANTAGESADVANTAGES MasterFit delivers a lower building MasterFit delivers a lower building

cost while saving on material waste, cost while saving on material waste, time and labor time and labor

It’s a better way to buildIt’s a better way to build

1.1. Save Time: Because the MasterFit Save Time: Because the MasterFit system can be installed and enclosed system can be installed and enclosed in daysin days

2.2. Save Materials : Get an exact Save Materials : Get an exact materials delivery for every project. materials delivery for every project.

3.3. Save Labor: no need to skilled laborSave Labor: no need to skilled labor

4.4. Save the Environment: As a footnote Save the Environment: As a footnote to your building profitability, you’ll to your building profitability, you’ll have the confidence (and marketing have the confidence (and marketing advantage) of using products that advantage) of using products that more efficiently use precious natural more efficiently use precious natural resources. resources.

ENVIEROMENTAL PERFORMANCEENVIEROMENTAL PERFORMANCEBecause MasterFit’s superior Because MasterFit’s superior structural integrity enables structural integrity enables construction with fewer studs per construction with fewer studs per wall, the MasterFit home achieves wall, the MasterFit home achieves higher overall energy performance higher overall energy performance than a traditional stick-built home. than a traditional stick-built home. This fact, coupled with more precise This fact, coupled with more precise construction that results in smaller construction that results in smaller gaps, enables the MasterFit home to gaps, enables the MasterFit home to achieve a better thermal performance achieve a better thermal performance rating with the same R-value rating with the same R-value insulation.insulation.

Clear Wall Panel. Clear Wall Panel. Insulated Wall Panel. Insulated Wall Panel. Narrow line Structural Narrow line Structural Insulated Panel. Insulated Panel.

Exterior Panel OptionsExterior Panel Options

SELLING POINTSSELLING POINTSDespite these advantages, the growth of this market has been Despite these advantages, the growth of this market has been slow. While the number of engineered wood plants in the U.S. has slow. While the number of engineered wood plants in the U.S. has about doubled since 1989, engineered wood still represents only 5 about doubled since 1989, engineered wood still represents only 5 to 6 percent of the North American structural framing material to 6 percent of the North American structural framing material market, according to the Engineered Wood Association. market, according to the Engineered Wood Association.

It lacks well-conceived pathways for utilities such as pipes and It lacks well-conceived pathways for utilities such as pipes and wires and doesn’t address the integration of structure with interior, wires and doesn’t address the integration of structure with interior, non-load-bearing infill partitions and cabinetry.non-load-bearing infill partitions and cabinetry.

DISADVANTAGES DISADVANTAGES A process for making high-quality, mass-customized homes A process for making high-quality, mass-customized homes requires considering the whole system, from flashing to how air requires considering the whole system, from flashing to how air moves indoors.moves indoors.

inadaptable to late changes that invariably occur during custom inadaptable to late changes that invariably occur during custom building.building.