The Wood House
3D Printer
A revolutionary additive manufacturing system that transforms sawdust waste into structural-grade composite materials, enabling the 3D printing of complete residential homes at a fraction of the cost and carbon footprint of traditional construction.
About the Wood House 3D Printer
The Wood House 3D Printer represents a paradigm shift in residential construction. By combining advanced additive manufacturing techniques with novel sawdust-based composite materials, this technology addresses three of the most pressing challenges facing the construction industry: sustainability, affordability, and speed.
Every year, the global lumber industry produces over 150 million metric tons of sawdust and wood waste. Currently, a significant portion of this byproduct is either burned — releasing stored carbon back into the atmosphere — or deposited in landfills where it decomposes anaerobically, generating methane. The Wood House Printer transforms this waste stream into a valuable construction feedstock.
The system operates on a modified gantry-style 3D printing platform scaled to architectural dimensions. A heated extrusion head deposits a precisely formulated mixture of processed sawdust, bio-derived binding agents, and performance-enhancing stabilizers in continuous layers. Each layer bonds chemically and mechanically to the one below, creating monolithic wall structures that are thermally efficient, structurally sound, and environmentally responsible.
Unlike concrete-based 3D printing approaches, the Wood House Printer leverages the natural properties of lignocellulosic biomass — inherent thermal insulation (thermal conductivity of 0.12–0.18 W/m·K compared to concrete’s 1.0–1.8 W/m·K), carbon sequestration potential, and acoustic damping — to produce homes that are both high-performance and ecologically aligned.
Waste to Walls
Repurposes millions of tons of sawdust and wood waste generated annually by the lumber industry into a high-performance building material.
Automated Fabrication
A gantry-mounted extrusion system precisely deposits sawdust composite in programmed layers, building walls, structural elements, and architectural features autonomously.
Material Innovation
Proprietary composite blends of sawdust, bio-based binders, and stabilizers achieve compressive strengths rivaling concrete while remaining biodegradable.
Affordable Housing
Projected to reduce per-square-foot construction costs by up to 60% by 2030, making homeownership accessible to billions worldwide.
How the Wood House Printer Works
From raw sawdust to a finished, habitable structure — the Wood House 3D Printer follows a seven-stage additive manufacturing pipeline. Each stage is optimized for material consistency, structural integrity, and environmental performance.
Raw Sawdust Collection
Sourced from lumber mills, furniture factories, and forest management operations. Softwood and hardwood species are segregated by particle density.
Grinding & Sieving
Hammer mills reduce particle size to 40–200 mesh (0.074–0.42 mm). Vibratory screens ensure uniform particle distribution for consistent extrusion flow.
Chemical Mixing
Pre-dried sawdust is blended with MDI resin, PVA binders, calcium stearate, UV stabilizers, fire retardants, and fungicides in a high-shear ribbon mixer at 60–80°C.
Heated Extrusion
The composite is fed into a heated barrel (140–180°C) with a progressive-pitch screw that plasticizes the mixture. A variable-aperture nozzle (20–80 mm width) controls bead geometry.
Layer Deposition
The gantry system deposits layers at 8–15 mm height with ±0.5 mm positional accuracy. Each layer bonds to the previous via thermal welding and chemical crosslinking of partially cured resin.
UV / Thermal Curing
Integrated UV-C lamps (254 nm) initiate surface crosslinking immediately after deposition. Ambient curing continues for 48–72 hours, with optional accelerated curing at 60°C in enclosed chambers.
Finished Structure
The completed wall system achieves full mechanical strength within 7 days. Post-processing includes window/door framing integration, surface finishing, and weatherproof coating application.
Raw Sawdust Collection
Sourced from lumber mills, furniture factories, and forest management operations. Softwood and hardwood species are segregated by particle density.
Grinding & Sieving
Hammer mills reduce particle size to 40–200 mesh (0.074–0.42 mm). Vibratory screens ensure uniform particle distribution for consistent extrusion flow.
Chemical Mixing
Pre-dried sawdust is blended with MDI resin, PVA binders, calcium stearate, UV stabilizers, fire retardants, and fungicides in a high-shear ribbon mixer at 60–80°C.
Heated Extrusion
The composite is fed into a heated barrel (140–180°C) with a progressive-pitch screw that plasticizes the mixture. A variable-aperture nozzle (20–80 mm width) controls bead geometry.
Layer Deposition
The gantry system deposits layers at 8–15 mm height with ±0.5 mm positional accuracy. Each layer bonds to the previous via thermal welding and chemical crosslinking of partially cured resin.
UV / Thermal Curing
Integrated UV-C lamps (254 nm) initiate surface crosslinking immediately after deposition. Ambient curing continues for 48–72 hours, with optional accelerated curing at 60°C in enclosed chambers.
Finished Structure
The completed wall system achieves full mechanical strength within 7 days. Post-processing includes window/door framing integration, surface finishing, and weatherproof coating application.
The Science Behind Wood Composites
Wood-plastic composites (WPCs) have been commercialized since the 1990s for decking and cladding, but the Wood House Printer takes the science to structural-grade performance. The key innovation is a precisely controlled particle size distribution combined with a multi-component binder system that achieves both thermoplastic processability and thermoset final properties.
At a molecular level, the composite derives its strength from three interacting mechanisms: mechanical interlocking between irregular sawdust particles, chemical bonding via MDI (methylene diphenyl diisocyanate) resin that reacts with wood hydroxyl groups to form urethane linkages, and hydrogen bonding through PVA (polyvinyl alcohol) chains that bridge cellulose fibers.
The particle size distribution follows a bimodal curve optimized through computational modeling: coarse particles (200–420 \u03bcm) provide bulk structure and reduce shrinkage, while fine particles (74–150 \u03bcm) fill interstitial voids, increasing packing density from 62% (random packing) to 85%+ (optimized bimodal). This dense packing is critical for achieving the target compressive strength of 25–30 MPa.
During extrusion at 140–180\u00b0C, the MDI resin undergoes partial polymerization, creating a semi-crosslinked network that maintains the bead shape during deposition. Full curing occurs over 48–72 hours as ambient moisture completes the isocyanate reaction, transforming the initially thermoplastic material into a rigid thermoset composite with a glass transition temperature (Tg) exceeding 120\u00b0C.
Lignocellulosic Matrix
60%The composite's primary phase consists of cellulose fibers (40–50% of dry wood mass), hemicellulose (25–35%), and lignin (15–30%). When processed to 40–200 mesh and combined with polymeric binders, this matrix forms a rigid, interconnected microstructure. The cellulose fibers act as natural reinforcement — analogous to rebar in concrete — while the lignin provides inherent hydrophobic character and serves as a natural adhesive between fibers.
Thermal Performance
0.15 W/m·KThe composite's thermal conductivity ranges from 0.12 to 0.18 W/m·K, approximately 8–10 times lower than concrete (1.0–1.8 W/m·K) and 3 times lower than standard brick (0.6–1.0 W/m·K). This stems from the cellular structure of wood particles, which trap air in microcellular pockets. A 300mm-thick printed wall achieves an R-value of R-2.0 m²·K/W without additional insulation, meeting passive house standards in temperate climates.
Moisture Engineering
<5% absorptionUntreated wood absorbs 20–30% moisture by weight, leading to dimensional instability and biological decay. The WHP composite addresses this through MDI resin crosslinking (creating hydrophobic polyurea bonds), calcium stearate surface coating of individual particles, and acetylation of hydroxyl groups during the heated extrusion process. The result: water absorption below 5% after 24-hour immersion, comparable to high-density polyethylene lumber.
Biological Resistance
Class 1 DurabilityIncorporated boron-based fungicides and zinc pyrithione provide broad-spectrum resistance to wood-decay fungi (brown rot, white rot, and soft rot), termites, and wood-boring insects. The encapsulated delivery system ensures fungicides remain active for 25+ years. In accelerated aging tests (EN 113), the composite achieves Class 1 durability — the highest rating under European standards, typically reserved for tropical hardwoods like teak and ipe.
Chemical Composition Breakdown
The WHP composite is a precisely engineered multi-component system. Each ingredient is selected for its contribution to processability during extrusion, structural performance after curing, and long-term durability against environmental degradation.
Composition by Weight
Component Summary
Detailed Chemical Composition Table
Complete formulation breakdown with typical percentages and functional roles
| Component | Range | Typical | Category | Role / Function |
|---|---|---|---|---|
| Sawdust / Wood Fiber | 55–65% | 60% | Matrix | Primary structural matrix. Cellulose fibers provide tensile reinforcement; lignin contributes natural binding and hydrophobicity. Particle size: 40–200 mesh. |
| MDI Resin (Methylene Diphenyl Diisocyanate) | 8–12% | 10% | Binder | Primary thermosetting binder. Reacts with wood hydroxyl groups to form urethane crosslinks. Provides water resistance and structural rigidity. |
| PVA (Polyvinyl Alcohol) | 3–5% | 4% | Binder | Secondary binder and rheology modifier. Improves fiber-to-fiber bridging and layer adhesion during printing. Biodegradable. |
| Lignin (Technical Grade) | 2–4% | 3% | Binder | Bio-derived supplemental binder recovered from kraft pulping. Enhances UV resistance and reduces dependence on synthetic resins. |
| Water | 8–12% | 10% | Processing | Processing aid and plasticizer during mixing/extrusion. Activates MDI crosslinking reaction. Evaporates during curing phase. |
| Calcium Stearate | 2–3% | 2.5% | Stabilizer | Internal lubricant and moisture barrier. Coats individual wood particles, reducing hygroscopicity by 40–60%. |
| UV Stabilizers (HALS + UVA) | 1.5–2.5% | 2% | Stabilizer | Hindered Amine Light Stabilizers (HALS) scavenge free radicals; UV Absorbers (benzotriazole type) absorb 290–400 nm radiation. Prevents photodegradation. |
| Zinc Stearate | 1–2% | 1.5% | Stabilizer | Thermal stabilizer and processing aid. Prevents oxidative degradation during high-temperature extrusion (140–180°C). |
| Ammonium Polyphosphate (APP) | 1.5–2.5% | 2% | Additive | Intumescent fire retardant. Forms insulating char layer at >250°C, achieving Class B fire rating (EN 13501-1). |
| Boron Compounds (DOT) | 0.5–1% | 0.8% | Additive | Broad-spectrum biocide effective against fungi, termites, and wood-boring beetles. Low mammalian toxicity. |
| Zinc Pyrithione | 0.2–0.5% | 0.3% | Additive | Supplemental fungicide targeting mold and mildew. Synergistic with boron compounds for extended durability. |
| Maleated Polyethylene (MAPE) | 1–2% | 1.5% | Additive | Coupling agent that improves interfacial adhesion between hydrophilic wood fibers and hydrophobic polymer binders. |
Stabilizer Science & Protection Systems
Long-term durability of the WHP composite depends on a multi-layered stabilization strategy targeting the four primary degradation pathways: ultraviolet photodegradation, thermal oxidation, moisture-induced swelling, and biological attack. Each stabilizer system is selected for synergistic interaction with the others.
UV Stabilizers
| Compound | Type | Mechanism of Action | Dosage | Test Standard |
|---|---|---|---|---|
| Hindered Amine Light Stabilizers (HALS) | Radical Scavenger | HALS (e.g., Tinuvin 770) operate through the Denisov cycle: nitroxide radicals capture carbon-centered free radicals generated by UV photolysis of lignin chromophores. The regenerative mechanism provides long-term protection (10,000+ hours UV exposure equivalent). | 0.8–1.5% | ASTM G154 |
| Benzotriazole UV Absorbers (UVA) | UV Absorption | Absorbs UV radiation (290–400 nm) through intramolecular proton transfer, converting photon energy to harmless thermal energy. Prevents photocleavage of β-aryl ether bonds in lignin that causes yellowing and surface erosion. | 0.5–1.0% | ASTM D4329 |
Thermal Stabilizers
| Compound | Type | Mechanism of Action | Dosage | Test Standard |
|---|---|---|---|---|
| Zinc Stearate | Metal Soap | Acts as an acid scavenger during high-temperature extrusion (140–180°C), neutralizing HCl and organic acids released from thermal decomposition of hemicellulose. Also serves as an internal lubricant, reducing screw torque by 15–20%. | 1.0–2.0% | ISO 305 |
| Antioxidant (Irganox 1010) | Phenolic Antioxidant | Primary antioxidant that donates hydrogen atoms to peroxy radicals, terminating autoxidation chain reactions. Prevents thermal oxidative degradation during processing and extends outdoor service life. | 0.1–0.3% | ASTM D3012 |
Moisture Stabilizers
| Compound | Type | Mechanism of Action | Dosage | Test Standard |
|---|---|---|---|---|
| Calcium Stearate | Hydrophobic Agent | Long-chain fatty acid salt that coats individual wood particles with a hydrophobic monolayer. Reduces equilibrium moisture content from 12–15% (untreated wood) to 3–5%. Prevents dimensional swelling/shrinking cycles that cause cracking. | 2.0–3.0% | ASTM D1037 |
| Silane Coupling Agent (A-171) | Surface Modifier | Vinyl trimethoxysilane undergoes hydrolysis and condensation with wood surface hydroxyl groups, creating a covalent Si–O–C bridge. Improves fiber-matrix adhesion and reduces moisture wicking along fiber-matrix interfaces. | 0.3–0.5% | ISO 62 |
Biological Stabilizers
| Compound | Type | Mechanism of Action | Dosage | Test Standard |
|---|---|---|---|---|
| Disodium Octaborate Tetrahydrate (DOT) | Inorganic Biocide | Boron compounds disrupt metabolic pathways in wood-decay fungi and insects. Effective against brown rot (Postia placenta), white rot (Trametes versicolor), and subterranean termites (Reticulitermes flavipes). Non-volatile, so remains in the composite indefinitely. | 0.5–1.0% | EN 113 / AWPA E10 |
| Zinc Pyrithione (ZPT) | Organic Biocide | Chelates metal ions essential for fungal enzyme function, particularly targeting surface mold species (Aspergillus, Penicillium, Trichoderma). Provides rapid-onset antifungal activity complementing the slower-acting boron compounds. | 0.2–0.5% | ASTM D4445 |
Synergistic Stabilization
The stabilizer package is designed for synergistic interaction. HALS and phenolic antioxidants operate through complementary radical scavenging mechanisms — HALS targets alkyl and peroxy radicals generated at the composite surface, while Irganox 1010 terminates chain propagation in the bulk material. Similarly, the combination of boron compounds (systemic, long-lasting) and zinc pyrithione (contact, rapid-onset) provides dual-mode biological protection that exceeds the efficacy of either component alone by a factor of 2.5–3x. The calcium stearate moisture barrier further enhances all stabilizer systems by limiting water-mediated transport of degradation products and biological agents into the composite core.
Mechanical Properties Comparison
The WHP composite achieves a remarkable balance of structural, thermal, and acoustic properties. While its elastic modulus is lower than concrete (making it more flexible and less brittle), its compressive strength closely matches standard concrete grades, and its tensile and flexural strengths significantly exceed both concrete and masonry.
Strength Comparison (MPa)
Key advantage: Ductile failure mode. Unlike concrete, which fails catastrophically through brittle fracture, the WHP composite exhibits progressive fiber pullout and matrix yielding before ultimate failure. This ductile behavior provides valuable warning time in structural overload scenarios and is particularly beneficial in seismic zones where energy dissipation is critical.
Complete Mechanical Properties Table
WHP composite compared against traditional construction materials
| Property | Unit | WHP Composite | Concrete | Brick | Wood Frame | Adobe |
|---|---|---|---|---|---|---|
| Compressive Strength | MPa | 25–30 | 25–40 | 10–20 | 8–15 | 2–5 |
| Tensile Strength | MPa | 7–10 | 2–4 | 1–2 | 8–12 | 0.3–0.5 |
| Flexural Strength | MPa | 10–14 | 4–6 | 2–3 | 12–16 | 0.5–1 |
| Elastic Modulus | GPa | 3.5–5.0 | 20–30 | 5–15 | 9–14 | 0.5–1.5 |
| Thermal Conductivity | W/m·K | 0.12–0.18 | 1.0–1.8 | 0.6–1.0 | 0.12–0.16 | 0.5–0.7 |
| Density | kg/m³ | 850–1050 | 2300–2500 | 1600–2000 | 400–600 | 1200–1700 |
| Water Absorption (24h) | % | <5 | 5–8 | 10–20 | 15–30 | 15–25 |
| Fire Rating | Class | B (EN 13501) | A1 | A1 | D | A1 |
| Sound Transmission Class | STC | 45–52 | 50–58 | 45–50 | 33–40 | 40–48 |
| Service Life (Projected) | Years | 50–75 | 80–100 | 100+ | 40–60 | 25–40 |
Environmental Impact Analysis
The environmental case for the Wood House Printer is compelling across every lifecycle metric. By replacing energy-intensive materials (cement, fired bricks, steel) with a bio-based composite manufactured at relatively low temperatures, the WHP process achieves dramatic reductions in carbon emissions, embodied energy, water consumption, and construction waste.
Impact: Traditional vs WHP
Lifecycle Carbon Analysis
Cradle-to-gate emissions: The production of Portland cement releases approximately 0.9 tons of CO\u2082 per ton manufactured (calcination + kiln energy). For a typical 150 m\u00b2 concrete house requiring ~40 tons of cement, this equals ~36 tons of process CO\u2082 alone. The WHP composite, manufactured at 140–180\u00b0C using electric heating, generates only 0.08 tons CO\u2082 per ton of composite — a 91% reduction per unit mass.
Biogenic carbon storage: Each ton of sawdust composite permanently sequesters approximately 0.45 tons of CO\u2082 (as biogenic carbon locked in cellulose and lignin). For a 150 m\u00b2 house requiring ~18 tons of composite, this represents 8.1 tons of stored CO\u2082 — effectively making the wall system carbon-negative.
End-of-life: Unlike concrete (which requires energy-intensive crushing and typically downcycles to aggregate), the WHP composite can be reground and re-extruded with minimal property loss (\u226415% strength reduction after three recycling cycles), or composted in industrial facilities where the cellulose fraction biodegrades within 12–18 months.
Cost Analysis & Projections
The economic proposition of the Wood House Printer improves rapidly with scale. While early-stage costs slightly exceed traditional construction (reflecting printer amortization and small-batch material procurement), the technology reaches cost parity in 2025 and achieves substantial savings by 2027 as production scales and supply chains mature.
Cost per Sq Ft Over Time
Projection based on 50% annual production scaling, sawdust feedstock price stability, and progressive printer technology improvements. Traditional costs assume 5% annual inflation in materials and labor.
Key Economic Drivers
Material Cost Advantage
Sawdust is a waste byproduct priced at $50–$150/ton, compared to Portland cement at $120–$180/ton and structural lumber at $400–$800/MBF. As demand grows, long-term supply agreements with lumber mills could reduce feedstock costs below $80/ton. The binding agent cost (primarily MDI resin at $3.20/kg) represents the largest single material expense, but ongoing R&D into bio-based alternatives (cashew nut shell liquid-derived isocyanates) promises a 40% reduction by 2028.
Labor Reduction
The WHP system requires a 3-person crew (1 printer operator, 1 material handler, 1 quality inspector) compared to 8–12 workers for traditional construction. This 60–75% reduction in labor hours translates to significant savings in regions with high construction labor costs ($35–$80/hour in North America and Europe).
Speed to Occupancy
Complete wall systems for a 150 m\u00b2 house print in approximately 72 hours of continuous operation. Including curing time and finishing, a fully habitable home can be delivered in 4–6 weeks versus 6–12 months for traditional construction. This compressed timeline reduces financing costs, temporary housing expenses, and project overhead by an estimated 15–20%.
Cost Breakdown: 150 m\u00b2 Residence
Side-by-side comparison of traditional vs. WHP construction costs (2026 projections)
| Item | Traditional | WHP Method | Notes |
|---|---|---|---|
| Sawdust Feedstock (kiln-dried) | — | $1,800 | 18 tons @ $100/ton delivered. Sourced from local lumber mills within 50 km radius. |
| Binding Agents (MDI + PVA + Lignin) | — | $4,200 | MDI resin: $3.20/kg, PVA: $2.80/kg, Technical lignin: $0.80/kg. |
| Stabilizers & Additives | — | $2,100 | HALS, UV absorbers, calcium stearate, fire retardants, biocides, coupling agents. |
| Foundation & Site Prep | $18,000 | $14,000 | WHP uses lighter structure (40% less weight), allowing reduced foundation. |
| Wall System (Material + Labor) | $45,000 | $12,000 | WHP automated printing vs. traditional block/frame + labor crews. |
| Roof System | $22,000 | $20,000 | Conventional roof trusses. Future: partial 3D printed roof panels. |
| Electrical & Plumbing | $18,000 | $17,000 | Similar scope. WHP integrates conduit channels during printing. |
| Insulation | $8,000 | $0 | WHP walls inherently insulated (R-2.0/300mm). No additional insulation needed. |
| Interior Finishing | $15,000 | $12,000 | Smooth WHP surfaces require minimal prep. Natural wood aesthetic. |
| Equipment Amortization | — | $5,000 | Printer ($800K) amortized over 160 houses. Maintenance included. |
| Total Estimated Cost | $126,000 | $88,100 | Per 150 m² (1,615 sq ft) single-story residence. 30% savings. |
Future Vision & Development Roadmap
The Wood House Printer is not merely a construction tool — it is the seed of a fundamentally new paradigm for how humanity builds shelter. The convergence of materials science, robotics, artificial intelligence, and biotechnology positions this technology for exponential advancement over the coming decade.
By 2035, we envision a world where a complete, code-compliant, energy-efficient home can be 3D printed from locally sourced sawdust in under 48 hours for less than $30,000. This is not speculative — it is the logical extrapolation of current material science trajectories, manufacturing cost curves, and regulatory trends.
The global housing deficit stands at 1.6 billion people lacking adequate shelter. Traditional construction methods cannot close this gap within any plausible timeline. The WHP approach, with its minimal labor requirements, low-cost feedstock, and rapid deployment capability, offers the most credible pathway to addressing this humanitarian crisis at scale.
AI-Driven Optimization
Machine learning algorithms will continuously optimize composite formulations in real-time based on ambient conditions (temperature, humidity), sawdust batch variability, and structural requirements. Neural network-controlled extrusion parameters will achieve ±0.1 mm dimensional accuracy — surpassing human-supervised processes by an order of magnitude.
Bio-Engineered Binders
Ongoing research at institutions including MIT, ETH Zürich, and the University of British Columbia is developing fully bio-derived isocyanate alternatives from cashew nut shell liquid (CNSL), soy-based polyols, and mycelium-based adhesives. These next-generation binders promise to eliminate all petroleum-derived components by 2032, achieving a 100% bio-based composite.
Multi-Story Capability
Current WHP technology is validated for single-story structures. Phase 2 development (2027–2029) targets two-story buildings through enhanced composite formulations with glass fiber reinforcement, achieving compressive strengths of 40+ MPa. Phase 3 (2030+) aims for three-story structures using hybrid WHP-steel systems with embedded structural steel connectors printed in-situ.
Global Deployment Network
The WHP system is uniquely suited to regions with abundant forestry waste: Southeast Asia (palm oil plantations), Sub-Saharan Africa (sawmill waste), South America (eucalyptus plantations), and Northern Europe (softwood forestry). Modular, container-shipped printer systems will enable rapid deployment to disaster relief zones and developing regions with housing deficits.
Space & Extreme Environments
The additive manufacturing principle underlying the WHP system is being explored for extraterrestrial construction applications. NASA and ESA have identified in-situ resource utilization (ISRU) — building from local materials — as a key enabler for lunar and Martian habitats. Cellulose-based composites from bioengineered plant matter could potentially serve as feedstock for off-world WHP systems.
Integrated Smart Homes
Future WHP iterations will embed sensors, wiring conduits, and smart home infrastructure directly during the printing process. Strain gauges printed into wall layers will enable real-time structural health monitoring. Phase-change materials (PCMs) integrated into the composite matrix will provide passive thermal regulation, reducing HVAC energy consumption by an estimated 30–40%.
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Wood House Printer
🏗️ Discover the future of sustainable construction — 3D printing entire houses from sawdust composites. Full scientific breakdown inside! 🌲
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Wood House 3D Printer | Sawdust Composite Homes
Explore the revolutionary Wood House 3D Printer that builds sustainable homes from sawdust composites. Discover the science, materials, and future of eco-construction.
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| og:title | Wood House 3D Printer | Sawdust Composite Homes |
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| og:site_name | Wood House Printer |
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