The onsite wood frame method of constructing new buildings has been the norm for residential and basic commercial structures for more than a century. In this review study, we consider investment into plastic composite structures to supplement or replace wood frame home construction. Previous developments in this field often centralize on using a classic composite sandwich panel design: a polymer-based core material adjoined to layers of synthetic fiber-reinforced polymer (e.g. fiberglass). The

more »

... ore of the composite panels is designed to meet demands toward low cost, light weight, and structural rigidity. Different varieties of plastics, including thermosets and thermoplastics, are discussed. Factors that need to be considered in the fabrication of composite modular residential buildings include, but are not limited to, energy consumption (both in building heating and cooling, and fabrication energy usage), fire resistance, resource use, environmental impact, human impact, and cost. Basic fabrication principles and techniques for composite modular panels are reviewed, wherein mechanical and electrical work can be incorporated into the building during panel manufacturing. Methods in which panels can be fabricated in high volumes that enable economies of scale are described. Thusly, recent progress in the application of plastics forming and machining that is applicable to the construction industry, and the feasibility of this type of residential construction are elucidated and discussed holistically.