Affordable housing using sustainability-led C3DP: Tvasta

What makes your solution innovative?

Tvasta aims to automate the building process and improve productivity, customization, and sustainability. The innovation of C3DP lies in its ability to construct entire buildings using a 3D printer, eliminating the need for manual labor and allowing for faster and more accurate construction. This method is faster and more precise than traditional construction methods, reducing construction time and costs.

a. Our 3D Printer and Material delivery systems enable us to print at an affordable price and enable cost-effectiveness. For example, we can 3D Print concrete with larger aggregate size particles (up to 12 mm) which enables us to pump with cheaper concrete material than our competitors across the world. 

b. Ownership of the technology stack: this enables Tvasta to disrupt the market with minimal dependency on other players unlike those in India only importing printers, we constantly iterate and push our capabilities to even better serve Indian construction needs

c. We have an array of sustainable materials with lower carbon and environmental footprints (including geopolymer-based mixes, limestone calcined clay cement, GGBFS slag-based mixes, LD slag mixes, etc.) according to the needs of our customers. These mixes can reduce the embodied carbon footprint by 30-60% (depending on the mix) when compared to OPC-based mixes with equivalent grades. 

d. Another key innovation of C3DP is its ability to customize the construction process to meet specific design requirements. There have been multiple attempts to automate construction in the past, however, nothing comes close to C3DP when it comes to design customization This means that architects and engineers can design and construct buildings that are both aesthetically pleasing and functional without losing out on time for making formworks

What are your impact goals for the next year and the next five years, and how will you achieve them?

1. Affordable Housing: In the next year, our goal is to build 10 affordable 3D printed houses, increasing our production capacity and streamlining our processes. We aim to reach a target of 800 houses per year by the end of Year 5. We will achieve this by investing in R&D, enhancing our 3D printing technology, expanding our team, and partnering with real estate companies, governments, and NGOs. Furthermore, we will focus on improving our construction speed and lowering production costs, to make our houses even more affordable.

2. Sustainability with respect to Carbon Reduction: We will continue to improve our 3D printing technology to make it more energy-efficient and reduce carbon emissions. We will also work on developing and utilizing more eco-friendly construction materials. Our goal is to reduce our carbon footprint by 10% in the next year, and by 50% in the next five years. To measure our progress, we will conduct regular audits of our carbon emissions and make the necessary adjustments in our operations.

3. Job Creation: As we expand our operations, we expect to create more jobs directly within our company and indirectly in related industries. Over the next year, we aim to increase our full-time staff by 20% and our contract employees by 30%. By Year 5, we aim to employ at least 200 full-time employees and 50 contract employees. Additionally, by expanding our reach and building more structures, we will be indirectly creating jobs in sectors like real estate, design, logistics, and maintenance.

4. Disaster Relief Process Development and Deployment: We aim to develop a rapid response process for deploying our 3D printing technology in disaster-stricken areas, for the construction of temporary or permanent housing and facilities. In the next year, we plan to develop a prototype of this process and test it in simulated conditions. Over the next five years, we aim to have this process fully operational and tested in at least three real-world disaster relief scenarios.

5. Education and Training: Recognizing the transformative potential of 3D printing in the construction industry, we aim to create educational programs to train the next generation of architects, engineers, and builders in 3D printed construction. In the next year, we plan to develop a curriculum in partnership with educational institutions and offer training programs. Over the next five years, our goal is to train at least 1,000 professionals and students in 3D printed construction, thereby fostering innovation and growth in the industry.

These impact goals align with Tvasta’s mission of revolutionizing the construction industry through advanced 3D printing technology. They also contribute towards a more sustainable and inclusive future.

Which of the UN Sustainable Development Goals does your solution address?

• 4. Quality Education
• 8. Decent Work and Economic Growth
• 9. Industry, Innovation, and Infrastructure
• 11. Sustainable Cities and Communities
• 13. Climate Action

How are you measuring your progress toward your impact goals?

Tracking progress towards impact goals is crucial for understanding the effectiveness of Tvasta Manufacturing Solutions’ strategies and making necessary adjustments. Here are some specific indicators we are using to measure our progress:

1. Affordable Housing: We track the number of affordable 3D printed houses we build each year. This is a direct measure of our impact in addressing housing needs. We also monitor the cost of each house, aiming to reduce it over time, which would indicate improved affordability.

2. Sustainability and Carbon Reduction: We conduct regular audits of our carbon emissions to measure our environmental impact. We look at factors such as energy used in the manufacturing process, emissions from our operations, and the lifecycle emissions of the materials we use. We aim for a year-on-year reduction in our carbon footprint.

3. Job Creation: We track the number of jobs we create directly within our company and indirectly in related industries. We monitor both the number of jobs and the quality of these jobs, in terms of wages, benefits, and working conditions.

4. Disaster Relief Process Development and Deployment: We assess our progress in this area by tracking the development and successful deployment of our disaster relief process. Key indicators include the speed at which we can deploy in response to a disaster, the number of structures we can build in a given timeframe, and the feedback we receive from those using these structures.

5. Education and Training: We measure our impact in this area by the number of people we train in 3D printed construction each year. We also track the outcomes for these individuals, such as job placements or advancements in the field of 3D printed construction.

These indicators align with several of the UN Sustainable Development Goals (SDGs), including:

• SDG 11: Sustainable Cities and Communities (Indicator 11.1.1: Number of people living in slums, informal settlements, or inadequate housing)

• SDG 9: Industry, Innovation and Infrastructure 

• SDG 8: Decent Work and Economic Growth (Indicator 8.5.2: Unemployment rate, by sex, age, and persons with disabilities)

• SDG 13: Climate Action (Indicator 13.2.2: Total greenhouse gas emissions per year)

• SDG 4: Quality Education (Indicator 4.4.1: Proportion of youth and adults with information and communications technology (ICT) skills, by type of skill)

By tracking these indicators, we can ensure that we’re making measurable progress towards our impact goals and contributing to broader sustainability objectives.

What is your theory of change?

Goal: To provide affordable and sustainable construction solutions to meet global demand.

Assumptions:

1. There is a significant global demand for affordable and sustainable construction solutions.

2. The current construction industry practices are slow, costly, and unsustainable.

3. The C3DP technology has the potential to revolutionize the construction industry by improving productivity, customization, and sustainability.

Interventions:

1. Develop and refine C3DP technology by innovating next-generation construction 3D printers, and low-carbon materials to improve construction productivity, customization, and sustainability. 

2. Create awareness and interest among potential customers and stakeholders about the benefits of C3DP technology.

3. Establish strategic partnerships with key stakeholders such as R&D institutes, distributors, and franchise partners to expand market reach and enhance sustainability.

4. Understand end-user requirements and conduct research and development to continually innovate and improve C3DP technology to meet evolving customer needs and preferences.

Outcomes:

1.  Creation of a strong supporting ecosystem and Increased adoption of C3DP technology by customers and stakeholders. 

2. Improved construction productivity and sustainability leading to more affordable and sustainable construction solutions.

3. Enhanced brand awareness and reputation for Tvasta as a leader in innovative and sustainable construction solutions.

4. Increased revenue and profitability for Tvasta, enabling continued research and development and expansion into new markets. 

Impact:

1. Increased availability of affordable and sustainable construction solutions globally.

2. Reduced overall environmental impact of the construction industry.

3. Improved quality of life for individuals and communities through access to safe, durable, and sustainable infrastructure.

Describe the core technology that powers your solution.

Tvasta provides turnkey solutions for C3DP technology which is a combination of printers, software, and materials that enable the 3D printing of buildings. Here are some key points about the Our core technology:

1. Printers: C3DP uses a 3D printing machine that is programmed to lay down concrete layer by layer, allowing for the precise construction of buildings by a process called topological optimization. Our printers’ portfolio includes Off-site and On-site Gantry Printers, Robotic Arm-based printers, and Pole printers.

2. Material: The C3DP technology uses a material mix that is specifically formulated for 3D printing,

the material mix must exhibit the behavior of a solid and hold its shape (after deposition) or the behavior of a liquid to be able to flow and be transported (during pumping and extrusion).

3. Extrusion System: The extrusion system also known as the hopper mechanism is designed to ensure a consistent flow of concrete and enable the printing of complex geometries. This flow can be changed according to specific needs for the printing.

4. Control and Monitoring Software: The control software of C3DP is designed to interface with the printer and extrusion system, enabling precise control of material flow through the nozzle and movement of the hopper in the printing space. It ensures that the printing process is running smoothly and provides real-time data on the progress of the construction.

5. Design Software: The design software(e.g. Autocad Fusion, Rhino, and Grasshopper)  allows architects and engineers to design buildings in a 3D environment, enabling them to create complex shapes and structures, conduct operational analysis and studies, etc.

6. Auxiliary subsystems: This involves mixing and batching plants to prepare the material mix of a particular rheology, which is later fed by the pump system to the hopper mechanism. 

Overall, the C3DP as a technology is a quite sophisticated and integrated that combines hardware, software, and materials to enable the 3D printing of required structures. It is designed to be fast, precise, customizable, and sustainable, with the potential to transform the construction industry.

Which of the following categories best describes your solution?

A new application of an existing technology

Please select the technologies currently used in your solution:

• Imaging and Sensor Technology
• Internet of Things
• Manufacturing Technology
• Materials Science
• Robotics and Drones
• Software and Mobile Applications
• Virtual Reality / Augmented Reality

If your solution has a website or an app, provide the links here:

https://www.linkedin.com/company/tvasta/mycompany/

In which countries do you currently operate?

• India

In which countries will you be operating within the next year?

• India
• United States

What type of organization is your solution team?

For-profit, including B-Corp or similar models

How many people work on your solution team?

At Tvasta, currently we are a team of total 106 members, in which the number of full-time staff is 65 , part-time staff is 13, and contractors or other workers include 28 members

How long have you been working on your solution?

We have been working and Indigenously developing on construction 3D printing for roughly 7 years now.

What is your approach to incorporating diversity, equity, and inclusivity into your work?

At Tvasta Manufacturing Solutions, diversity, equity, and inclusivity are fundamental to our success and our impact. We're committed to fostering a culture that values diverse perspectives, promotes equal opportunity, and ensures every team member feels valued and included. Here's how we approach these principles in our work:

1. Diversity: We value diversity in all its forms, including gender, race, ethnicity, religion, age, sexual orientation, and abilities. We believe that a diverse team brings a range of perspectives, ideas, and experiences that can lead to innovative solutions. We strive to maintain a diverse workforce and leadership team, and we're committed to recruiting from a variety of backgrounds and experiences.

2. Equity: We are dedicated to providing equitable access to opportunities within our organization. We believe in a merit-based system where all employees have an equal chance to grow and advance, regardless of their background. We also address disparities and strive to eliminate barriers that may have historically prevented the full participation of marginalized groups. This includes fair compensation, opportunities for professional development, and transparent promotion processes.

3. Inclusivity: We aim to create an inclusive work environment where all team members feel welcomed, respected, supported, and valued. This means fostering a culture of open communication, mutual respect, and collaboration. We regularly conduct team-building activities and provide platforms for all voices to be heard.

We also understand that diversity, equity, and inclusivity are ongoing efforts. We regularly review our practices and policies to ensure they align with these principles. We also provide regular training and workshops to educate our team on the importance of these values and how to uphold them in our daily work.

Lastly, our commitment to these principles extends to our clients and partners. We believe that by promoting diversity, equity, and inclusivity in our work, we can help create a more equitable and inclusive construction industry.

What is your business model?

Tvasta is a turnkey provider for the construction 3D printing needs of its customer. Following are our key revenue streams

1. 3D Printer Sales (high margin sales)

2. 3D Printing Platform as a Service (high long-term revenue growth potential)

3. Material sales (the above two revenue streams are captive customers to this recurring revenue line)

4. Design for 3D Printing (this will enable us to retain customers in the long run and is not aimed as a major revenue generation line)

Our aim is to establish a revenue model that would pay per use similar to a subscription service.  Depending on the type of project, this could be a per hour, per square foot, or per module model. But this model, once established, will enable standardized scaling across various types of projects throughout the country and subsequently in Global Market. We would also lay maximum emphasis on avoiding the end contracting/execution work and will work with established construction companies to build and scale up our franchise centers. 

Our initial effort over the next year would be to work with our lead customers and lead adopters to prove the viability of the technology for various types of structures (affordable housing and Basic Infrastructure requirements). We would like to move to a Franchise based model in the future (in partnership with construction companies in various regions) where Tvasta works with them using a Pay per use model for the 3D Printers. In this Platform as a Service Model, Tvasta will provide the 3D Printing technology and the operational expertise for running them. The construction companies would manage the on-ground construction and pay Tvasta for the usage of its 3D Printers, material, and consultancy.

The larger end goal is to create a cohesive and collaborative ecosystem to enhance the adoption of C3DP technology by the customers and stakeholders. Through our core solution, we want to maximize construction productivity and sustainability leading to more affordable and greener construction solutions, which in turn will be impacting builders, governments, and the general public at large. Overall it will be Improving the quality of life for individuals and communities through access to safe, durable, and sustainable infrastructure.

Do you primarily provide products or services directly to individuals, to other organizations, or to the government?

What is your plan for becoming financially sustainable?

Tvasta Manufacturing Solutions has developed a diversified financial sustainability plan that ensures a steady flow of income from multiple sources, while also planning for strategic investments to fuel future growth. Here’s how we plan to achieve financial sustainability:

1. Revenue Generation: Our primary source of revenue comes from selling our products and services, which includes selling 3D Printers, providing 3D Printing Services, selling 3D Printable materials, and offering Architecture & Design solutions. We are already revenue positive and project-wise gross margin positive, which means that we are generating a profit on each project before considering company-wide operating expenses.

2. Scaling Revenue: We have a robust growth plan in place, aiming to increase our revenue from $2 million to $8 million in the next 12 months. This would be achieved through strategic marketing, sales expansion, and continued delivery of high-quality products and services that meet our clients’ needs.

3. Capital Raising: We plan to raise additional equity capital to fund our cash flow needs and tech development. This will allow us to invest in expanding our team, improving our technology, and scaling our operations. Additionally, we will seek grant capital for tech development and prototyping, leveraging non-dilutive funding sources to advance our innovation efforts.

4. Profitability: While we are currently not EBITDA positive, we aim to achieve profitability in 18 months. This will be achieved by optimizing our operations, improving our gross margins, and scaling our revenue while maintaining control over our operating expenses.

5. Long-term Financial Planning: Over the long term, we will continue to balance revenue generation with strategic investments in technology and growth. We will regularly review our financial performance and make necessary adjustments to ensure that our revenue streams adequately cover our expected expenses.

By executing this plan, Tvasta Manufacturing Solutions aims to not only become financially sustainable but also to create a strong financial foundation that enables us to continue advancing our mission of revolutionizing the construction industry through advanced 3D printing technology.

Share some examples of how your plan to achieve financial sustainability has been successful so far.

Our plan to achieve financial sustainability has already shown promising results. Here are some examples of our success so far:

1. Grants: We have successfully secured a grant of $1 million from the Ministry of Housing and Urban Affairs. This grant has helped us invest in technology development and prototyping, furthering our mission of revolutionizing the construction industry through advanced 3D printing technology.

2. Revenue Generation: Over the past 12 months, we have generated a revenue of $2 million. This revenue has come from various sources, including selling our 3D printers, providing 3D printing services, selling 3D printable materials, and offering architecture & design solutions.

3. Corporate Social Responsibility (CSR) Projects: We have received $300k through CSR projects. These projects allow corporates to fulfill their social responsibilities while enabling us to create positive social and environmental impact.

4. Projected Revenue: We have a robust plan for scaling our revenue, aiming to reach $8 million in the next 12 months. This will be achieved through strategic growth initiatives and the continued delivery of high-quality products and services.

5. Profit Margins: We have achieved a healthy profit margin of 50% on our 3D printer sales. On our construction services, we’ve managed a margin of 10% which we expect to increase as we streamline our processes and scale our operations.

These achievements validate our financial sustainability plan and demonstrate our ability to successfully generate revenue, secure funding, and deliver high-quality, profitable services. Moving forward, we will continue to leverage these strategies to achieve financial sustainability and support our mission of transforming the construction industry.