Prior single-family deep-energy retrofit projects have found adding high levels of exterior wall insulation to be very challenging and costly due to the extensive, high-skill labor required to effectively manage control layers at wall penetrations and terminations. We apply digital processes to simplify the design, production, and installation of a complete set of lightweight insulated panels customized for each building. We will present our system comprising the following features:
•    Pre-fabricated four-inch thick insulated panel blocks (PBs) with integral cladding. 
•    Scan-to-BIM software that extracts building features from building scans and calculates their dimensions with high accuracy.
•    Panelization algorithms generate the complete set of PBs and trim pieces to clad each building, feeding a computer-aided manufacturing process.
•    Augmented reality guides installation of the PB system on each façade, eliminating on-site cutting and greatly decreasing the skill and time required to reclad the building.