S1Ep112 From F16s to Composite SIPs with Evan Mai

Composite SIPs might not sound like battlefield tech—but for Evan Mai, they’re the future of building smarter, faster, and stronger. After logging over 2,300 hours in an F-16 and leading combat missions in Desert Storm, Evan’s new mission is on the ground: disrupting construction with a material most builders haven’t even touched yet.

Evan’s story isn’t your typical builder bio. He grew up on a Kansas farm, got hooked on flying, and ended up as a mission commander in the U.S. Air Force. After active duty, he spent years in the defense world, working with Raytheon on billion-dollar modernization programs for U.S. allies around the world. But the itch to build never left.

He started buying land, building custom homes, and even tackled condo conversions across California—900 units over five years. But when the 2008 recession hit, the financial crash wiped out his projects and forced a hard reset. “We thought we had our backside covered,” he says, “until the FDIC seized our two major banks.”

That sting pushed him back toward familiar ground—military and defense contracting. But it also got him thinking about how inefficient and fragile the construction world still was. Watching investors lose money and homeowners lose properties lit a fire under him. He started asking a question his dad once posed: “Why are we still building with sticks and stones?”

That question led him to composite SIPs—foam core panels wrapped in composite shells, the same kind of materials used in aerospace, marine, and automotive industries. After testing his own prototype in a garage (where all good ideas start), he discovered JD Composites in Nova Scotia. They were building homes from recycled plastic bottles and composite panels—homes that could take 325 mph wind in a test tunnel with less than a quarter-inch of deflection.

But the U.S. code compliance wasn’t there yet. Testing was expensive and slow. That’s when Evan connected with MDLR Brands and saw they already had composite SIPs approved for use in all 50 states. They had the scale, testing, and factories to take this material from concept to jobsite.

Now, as a business development executive at MDLR, Evan is helping builders see the light. These aren’t just “green” panels. They’re rugged, energy-efficient, hurricane-rated, and fast to assemble. In some builds, walls and roofing systems go up in just two days, with 50–70% less labor than traditional framing. That’s not theoretical. That’s field-tested reality.

Unlike traditional SIPs or stick-built homes, composite SIPs don’t rely on trusses, felt paper, or shingles. They reduce thermal bridging, eliminate drywall in some cases, and cut down on HVAC loads. That translates into real savings—not just on the build, but over the life of the home. For developers, that means lower maintenance and operating costs. For homeowners, it’s comfort and cost control.

Still, Evan knows builders are slow to adopt anything new. The big names won’t switch unless it’s 20% cheaper across the board. But the real value isn’t just in raw materials. It’s in time, simplicity, and fewer trades. “You can build a stronger, quieter, more energy-efficient home and cut your labor in half,” he says. “You just have to be willing to try something new.”

Evan isn’t waiting for the industry to catch up. He’s out partnering with builders, funding small projects, and showing what’s possible with composite SIPs. His goal is to build model homes, ADUs, even multifamily projects—then open the books and let the numbers speak for themselves.

He’s not looking for IPOs or Wall Street exits. This is mission-driven. “I’m retired Air Force. I’m retired Raytheon. This is the thing I want to do,” he says. “Let’s build better, faster, and smarter.”

And for anyone still doubting if this fighter pilot knows what he’s doing on a jobsite—just remember, he’s been solving high-stakes problems since the day Saddam invaded Kuwait. Figuring out how to frame a house faster? That’s just another mission.

Watch the full episode on YouTube.

About Evan Mai
Evan Mai is a former U.S. Air Force Lieutenant Colonel, F-16 Weapons School Instructor, and defense industry leader turned construction innovator. With a background in mission-critical operations and global modernization projects, Evan now leads national business development at MDLR Brands—bringing next-gen building materials like composite SIPs to forward-thinking builders across the U.S.

He’s on a mission to help contractors build stronger, faster, and smarter without the headaches of traditional methods.

Learn more at MDLRBrands.com.

About Michael Krisa
Michael Krisa is the creator and host of Builder Straight Talk, a no-fluff podcast built for serious builders, remodelers, and tradespeople who want to grow, scale, and simplify their businesses. With a background in marketing and a passion for real builder stories, Michael cuts through the noise to spotlight the people and ideas driving real results in construction today.

If you’re ready for straight talk, smart strategies, and the occasional hard-earned lesson, this is your corner of the internet.

Learn more at BuilderStraightTalk.com.