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According to the 2016 Mckinsey report, the global construction industry is one of the least productive (The Construction Productivity Imperative, McKinsey Report, 2016), which can be attributed to a minimal implementation of digital and automation technology (Berger Digtization in the Construction industry—Building Europe's road to "Construction 4.0 THINK/ACT—BEYOND MAINSTREAM, 2015). This research argues that this relates to the skill base of construction workers since very few, if any, can operate digital fabrication systems. Here, a digital model is considered foundational knowledge and is used to communicate with a fabrication unit. The difficulty lies in communicating the digital model to the fabrication machine, which arguably requires a level of specialist knowledge. However, history shows that other methods of communicating complex construction information have existed, such as 1:1 on-site drawing, which used to be made by architects or construction workers to communicate complex information related to constructing jigs or building components (The Tracing Floor of York Minster.” In Studies in the History of Civil Engineering, 1:81–86. The Engineering of Medieval Cathedrals. Routledge, 1997). We propose an alternative where we learn from history and amalgamate that knowledge with a robotic framework. We present the calibration process behind a parametric visual feedback method for robotic fabrication that detects on-object hand-drawn markings and allows us to assign digital information to detected markings. The technique is demonstrated through a 1:2 prototype that is fabricated using an ABB IRB 120 robot arm.

The global construction industry is one the least productive sectors over a 30-year period, which arguably could be related to virtually no implementation of digital and automation technologies within the construction industry. Construction processes arguably consist of expensive manual labor or manual operation of mechanized processes, where hand-drawn markings on work-objects or partly build structures are used to inform and steer the construction process or allows for ad hoc adjustments of elements. As such, the use of on-object, hand-drawn information is considered integral to the modus operandi of a plurality of construction trades, where timber construction and carpentry are of special interest. In contrast, emerging methods of digital production in timber construction implicitly or explicitly seek to eliminate the interpretive component to the construction work, imposing a top-down paradigm of file-to-factory execution. While such systems offer a performance increase compared to manual labor, it is notoriously sensitive to construction tolerances and requires a high level of specialism to be operated, which could alienate craft-educated workers. This research argues that developing methods for digital production compatible with on-site human interpretation and adaptation can help overcome these challenges. In addition, these methods offer the opportunity to increase the robustness and versatility of digital fabrication in the context of the construction site. The article reports on a new method titled “augmented drawn construction symbols” that through a visual communication system converts on-object hand-drawn markings to CAD drawings and sends them to a robotic system. The process is demonstrated on a full-scale prototypical robot setup.

Visual Programming Language (VPL) is utilized with increasing frequency in Architectural, Engineering and Construction (AEC) industries to accomplish tasks relating to advanced geometry and complex designs. In recent developments, VPLs have gained traction in robotic research, where they are being explored as a good tool for robotic programming. While visual programming holds several key advantages justifying this attention, it comes with key limitations for developing commercial-grade robotic applications. Such applications need to be easily maintainable, stable and performance optimal to be able to succeed in the market. In this paper, we argue that the situation with regard to visual programming is similar to that of textual programming from 1960s. The universally adopted strong abstraction mechanisms vastly improved the condition for the latter. We then proceed to propose the utilization of software design patterns as a method to overcome some of the existing challenges faced by adopters of VPLs. Six novel design patterns are introduced, and their application is exemplified by industrial software development case studies.

Despite a well-understood potential to increase productivity of the global construction industry and sustained, international research efforts in recent years, wide-scale adoption of robotic technology currently remains elusive in the industry. As part of a larger industrial research effort to increase the efficiency of automation technologies within construction, this paper proposes a novel multi-layered knowledge encapsulation model to enable low-cost development of highly diverse robotic control applications within a parametric manufacturing paradigm. The effectiveness of proposed theoretical framework has been validated by developing multiple industrial applications and resulted in almost 40% reduction in development time.

This paper presents a new method for industrial manufacturing of topology-optimized, ultrahigh performance concrete structures using robotic abrasive wire cutting of polymerized styrene formwork systems. Topology optimization is a well-established procedure within disciplines of aeronautic, automotive and naval engineering. However, while recent developments have highlighted a significant potential for structural innovation and reduction of material consumption in topology-optimizing concrete structures, an effective method for large-scale manufacturing of such structures remains to be found. We argue that the prohibitive factor for large-scale adoption is the non-availability of mechanical processes capable of performing high-speed, high-volume manufacturing of advanced non-standard formwork and, consequently that this inhibition can be overcome through integrating ruled surface rationalization and robotically controlled abrasive wire cutting of three-dimensional formwork systems in polymerized styrene foams. The viability of the proposed method is demonstrated through the production of a 21 m spatial concrete structure, using abrasive wire cutting of EPS formwork via a containerized robotic work cell with an ABB IRB 6700 industrial manipulator, extended with external rotary axis.

This paper presents four key developments that are leading to the scalability of the fabrication processes of mycelium material. We develop a biological and digital fabrication pipeline for (1) growing large mycelium composite blocks, (2) on-site robotic wire-cutting, (3) using mycelium materials as a multi-functional formwork, and (4) implementing the self-healing of fungal organisms. The purpose of the research is to investigate the processing approaches, variable material handling and materials properties of large biohybrid (composed of biological and non-biological material) foam blocks. The robotic tool provides the freedom to shape and structure this novel biological material and opens the possibility of making unique architectural modules. For the first time, mycelium materials are robotically wire-cut in situ, which results in two demonstrators. Departing from an application-based intention, we test the compatibility of thermal insulating mycelium formwork with a concrete slab. As such, we combine two different materials with hybrid physical and architectural properties. Additionally, we investigated the self-healing and living properties of mycelium components after robotic implementation. The combination of microbiological systems and fibrous substrates creates a unique class of bioactive composite materials, with potential applications at in the construction sector.

This paper presents a new method for cost-effective realization of topology optimized structures using robotic abrasive wire-cutting of expanded polystyrene formwork. Topology optimization has shown potential for generating material efficient designs and increasing performance in architectural structures. However, the method results in complex, structural morphologies which frustrate efficient construction of said structures. To overcome this, and make the realization of the potential of topology optimization feasible in general construction, new approaches are needed. We propose an integrated method of ruled surface rationalization and robotically controlled abrasive wire-cutting of formwork parts in Expanded Polystyrene. The method is demonstrated through robotic production of EPS formwork using a pilot abrasive wire-cutting end-effector on a containerized robotic work cell with an ABB IRB 6700 industrial manipulator, extended with external rotary axis. The usability of the formwork is demonstrated through the construction of a 21 m, prefabricated demonstrator structure using Ultra High Performance Concrete.

This paper presents a novel method for integrated topology optimization and fabrication of advanced timber space-frame structures. The method, developed in research collaboration between ETH Zurich, Aarhus School of Architecture and Israel Institute of Technology, entails the coupling of truss-based topology optimization with digital procedures for rationalization and robotic assembly of bespoke timber members, through a procedural, cross-application workflow. Through this, a direct chaining of optimization and robotic fabrication is established, in which optimization data is driving subsequent processes solving timber joint intersections, robotically controlling member prefabrication, and spatial robotic assembly of the optimized timber structures. The implication of this concept is studied through pilot fabrication and load-testing of a full scale prototype structure.

This paper presents a novel method for cost-effective, robotic production of double curved formwork in Expanded Polystyrene (EPS) for in situ and prefabricated concrete construction. A rationalization and segmentation procedure is developed, which allows for the transliteration of double curved NURBS surfaces to Euler elastica surface segments, while respecting various constraints of production. An 18 axis, tri-robot system approximates double curved NURBS surfaces by means of an elastically deformed and heated blade, mounted on the flanges of two manipulators. Re-orienting or translating either end of the blade dynamically deforms the blade’s curvature. The blade follows the contours of the rationalized surface by continuous change in position and orientation of the end-effectors. The concept’s potential is studied by a pilot production of a full-scale demonstrator panel assembly.

This paper addresses both the architectural, conceptual motivations and the tools and techniques necessary for the digital production of an architecture of volume. The robotic manufacturing techniques of shaping volumetric materials by hot wire and abrasive wire cutting are discussed through a number of recent projects. A comparative analysis between milling and hotwire cutting is presented and a number of case studies and tool development studies are considered. Finally, the specifics of toolpath generation for robotic wire cutting are introduced.