Robot-aided fabrication of interwoven reinforced concrete structures

Abstract

This paper describes the outcomes of ongoing research, conducted at the Architectural Association (AA) Summer DLAB Visiting School 2016, to develop an innovative strategy for the construction of three-dimensionally interwoven concrete composite structures. Research methods include the employment of computational design and robotic fabrication techniques that incorporate geometry rationalization and material constraints. Through the analysis of traditional rod bending strategies, this research aims to develop a novel approach by the reduction of mechanical parts for controlling the desired output geometries. This goal is addressed by devising a robotic tool-path, developed in KUKA|prc with Python scripting, where fundamental material considerations, including tolerances and spring-back values, are integrated in the bending motion strategies through a systematic series of mathematical calculations in line with physical tests. Correlations between custom-formed steel reinforcement bars and Polypropylene formwork within the agency of a concrete composite structure are verified through the large-scale prototype. This research serves to test the evolving complexity of embedding parameters related to generative form-finding, geometrical rationalization, material constraints, and robotic toolpath planning within the computational environment and simulation tools, thereby enabling the capacity to implement simple mechanical tools and cost-effective fabrication methods.