Efficient robotic assembly of shell structures

Digital design and fabrication has revolutionized architecture, enabling rapid exploration of complex forms through computer-aided design (CAD) software. Robot manipulator arms are additionally fast becoming useful construction hardware, being able to be adapted to a wide variety of tasks. However, the transition from digital models to physical fabrication and assembly remains predominantly manual, leading to inefficiencies and limitations in digital manufacture. Particularly in the manufacture and construction of thin element structures, CAD and digital manufacture tools are fast becoming able to realise a wider array of complex designs.

Slender structures come with additional pitfalls, however. Supporting falsework structures for thin panel systems construction constitute a high proportion of material waste, due to their often single-use and highly custom nature. Additionally, such segmented structures often rely on adhesives or fixtures to constrain parts, reducing potential for disassembly and reuse. This work presents a design approach developed to demonstrate the use of integral joints for maintaining structural stability through robotic assembly without falsework. An approach is proposed based on stability assessments and funicularity measures to understand the behaviour of designed structures during and after assembly. The integration of sensor technologies, such as low-cost cameras for process feedback, further enhances this automated workflow. Feedback is crucial for maintaining the alignment and integrity of structures during robotic assembly, where minor discrepancies can significantly impact success. While these features can be implemented in robotics middleware ROS, it is relatively inaccessible to the architectural designer.

To address these challenges, this research outlines a comprehensive approach to automating aspects of design, manufacture, and assembly of segmented shell panel structures with parametric CAD software. Through this automation, considering robot manipulator capabilities at early design stages, this research aims to enhance the capabilities of the designer in construction with robotic technologies. With integration of algorithmic design, structural analyses, robot kinematics modelling and real-time feedback mechanisms, this work seeks to streamline the design process with feedback for architectural structures, and ultimately contribute to the robotic assembly of disassemblable systems that align with the evolving demands for sustainability and efficiency in the AEC sector.