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The construction industry is currently undergoing an increasing demand to boost productivity and improve system efficiencies. Clients are demanding increasingly more customised products at a more competitive cost, speed, and quality. Yet current design systems and existing literature largely overlook the use of automated decision-making tools for supporting mass-customisation for prefabricated buildings. To address this gap, a method for using automated tools to optimise the modularisation of prefabricated light-weight structures is investigated. This study’s primary contributions include a multi-variable Modularisation Index, which offers a novel framework for characterising the “optimal” solution, and a recursive Slack-distribution algorithm, which offers a novel method for modularising customised architectural designs. The core insight is that an optimal modularisation solution may be found using a Greedy …