MIT spinout turns plastic waste into resilient building materials

The world needs more homes. The world also has too much plastic. Perhaps the only thing those two problems have in common is that they’re hard to solve.

Atlas Building Composites, a spinout of MIT, is on a mission to address both problems with a single solution. The company has developed an AI-powered robotic manufacturing platform capable of turning single-use plastics into durable building materials.

The company emerged from MIT HAUS, a research effort in the MIT Department of Mechanical Engineering that’s short for “Home Architecture for Universal Sustainability.” Atlas uses waterless plastic recycling and large-scale composite additive manufacturing technology to make parts like home foundations, decks, and trusses for walls, floors, and roofs.

“Our mission is to convert waste plastic pollution into durable composites to build 1 billion homes,” says Atlas chair and co-founder A.J. Perez ’13, MNG ’14, PhD ’23, who is also an MIT research scientist. “You can’t divorce these things from each other. We’re not here just to build homes, and we’re not here just to recycle plastic. The conventional way of building homes involves cutting down trees, mining, refining, and a bunch of other dirty activities. We want to avoid all that and address all the plastic bound for our oceans and landfills. We’re turning bottles into buildings.”

Atlas’ parts are already being used to support barns, sheds, decks, and docks. Most recently, the company supplied the U.S. Army Corps of Engineers with American-made recycled composite trusses to construct a 40-foot bridge in a Massachusetts wetland.

Perez and Atlas co-founder Matt Pouliot envision deploying thousands of their AI robotic production systems around the world. A key enabler for that scale is the company’s ability to recycle low-grade plastic into building components without water.