Robotic Fabrication of Segmented Shells: Integrated Data-Driven Design

Abstract

This paper proposes a strategy for constructing unreinforced segmented shells with the aspiration to bring together several related research fields. By incorporating data from structural analysis and digital simulations into a continuous workflow, an automated building system is introduced. The research aims to provide a methodology of translation between digital form-finding, optimisation strategies and physical materialisation by persisting through the interdependent stages of design and robotic assembly. Through an integration of structural analysis data, a force- driven form-finding process is determined, accompanied by a custom tessellation pattern. System stereotomy is developed as an integrated interlocking system, derived from material properties and robotic fabrication constraints. Assembly process is developed as an automated construction 'pick and place system' capable of customized, on-site fabrication of architectural-scale structures. The system consists of multiple six-axis robotic arms, carried on mobile platforms with scissors lifts. The complexity of robotic manufacturing is addressed through developing a custom robotic toolpath. Correlations between these steps of the process are verified through developing a large-scale prototype, tested with proposed robotic assembly logic.