Developing Feedback Based Robotic Manufacturing Method for Earth-Based Materials

Abstract

Although earth-based materials have the advantage of being locally sourced and have low embodied emissions, they can have an unpredictable material behavior due to their heterogeneous composition which potentially limits their use in manufacturing. As a result, it becomes challenging to standardise and maintain quality outcomes. Moreover, current industry methods are labour-intensive and require a high level of traditional knowledge. This research explores and develops a fabrication methodology for earthen materials that is location-agnostic. It involves an array of fabrication approaches, including the development of a robotic 'Impact Printing' setup using a UR10 robot and a custom tool to pick, place, and mechanically compact earth blocks. The 'Feedback System' employs Kinect 2.0 to scan the deformation of earth materials observed during fabrication and a computational algorithm to generate accurate and adapted toolpaths for the position and compaction of earthen blocks in real-time. To push the boundaries of architectural design for traditional building materials, the study investigates the construction of a closed Nubian vault using the aforementioned techniques and tools. Through the optimization of material behavior and manufacturing processes, the research opens up a pathway for automated onsite earth construction.