Foundry One
First production deployment of the gantry extruder: autonomous survey to sealed 1,800 ft² shell in 41 hours, geopolymer mix, two-person finishing crew. Sonoran Corridor, AZ.
Overview
We don't build. We deploy.
Segal Development designs, prints, and deploys autonomous 3D-printed buildings and self-sustaining communities — on Earth and in space. A building is treated as a print job: surveyed, modeled, and extruded by autonomous machines from material found on site.
One algorithm, different boundary conditions. Earth and Mars are the same problem with different gravity, atmosphere, and feedstock — solved once, re-skinned per environment. The only number that matters is time-to-habitation, compressed from years to days.
The Ten Fold acquisition adds the second deployment mode: pre-engineered buildings that transport at trailer size and unfold under their own power into full facilities in minutes — no foundations, no crane, one operator. Print where you stay; unfold where you move.
5
Core technologies
4
Solution classes
5
Ten Fold system variants
41h
Foundry One shell, print to seal
60%
Embodied carbon vs. cast concrete
Capabilities
TECHNOLOGY
Concrete printing
Gantry- and arm-mounted extruders lay low-carbon walls contour by contour at architectural scale, with closed-loop quality control on every layer. ±3 mm layer placement tolerance.
TECHNOLOGY
Geopolymer
Site-blended geopolymer binders replace Portland cement at strength parity — 60% less embodied carbon, zero batch plants trucked to site.
TECHNOLOGY
LiDAR → BIM → toolpath
Autonomous LiDAR and photogrammetry resolve the site to millimeters; constraints compile to a structural model and straight to machine toolpath. No manual redraw between survey and machine.
TECHNOLOGY
Swarm robotics
Coordinated multi-machine fleets print, place, and finish in parallel across a single footprint — the path from one structure to a community. In validation at Greywater Commons.
TECHNOLOGY
ISRU / regolith
In-situ resource utilization fuses local regolith into structure and shielding; sulfur-concrete binders set in vacuum and cold. Nothing load-bearing is launched from Earth.
SYSTEMS
Ten Fold deployable systems
Five unit classes, TF-MICRO to TF-80: buildings that transport at trailer size and unfold into ~3× their footprint in under 10 minutes. No foundations, no crane, one operator.
Case Studies
Aftershock
Containerized printer fleet validating time-to-habitation under field conditions: 6-unit permanent shelter cluster with no fixed power, no batch plant, no site office.
Greywater Commons
24-home off-grid community in the Nevada high desert — swarm sequencing across a shared footprint with closed-loop water and solar designed in, not bolted on.
Regolith Bench
Lunar-analog sintering testbed: simulant feedstock in vacuum-chamber conditions, de-risking binder chemistry, layer adhesion, and shielding density before flight.
First Light
Reference architecture for a cislunar habitat that lands, surveys, and prints itself — a pressurized, shielded shell standing before the first crew leaves Earth.
Other divisions
01
Aerospace
Orbital systems and launch. Space infrastructure and exploration.
02
Aeronautics
Autonomous aircraft and airships.
03
Shipyards
Maritime hulls and offshore systems.
04
Defense
Cross-domain defense systems.
05
Intelligence
Quantum intelligence and analytics.
06
Robotics
Autonomous robotics.
07
Compute
The operating system for the network.
08
Electronics
Hardware and components.
09
Energy
Sustainable energy.
10
Fabrication
Advanced manufacturing.
11
Agriculture
Food and land systems.
12
Health
Longevity and biofabrication.
13
Supply
Every part, one keystroke away.
14
Media
Story and signal.