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Citations
... and six-axis milling of EPS foam serves to understand machine tolerances and cutting toolpaths of ruled surface geometries and joints, suitable for prototyping and enabling digital sculpting that emulates traditional craftsmen (Burry, 2016). Research projects directly exploring material options included the subtractive cutting of modules in sandstone and marble with bespoke abrasive diamond saws (Feringa, Søndergaard, 2014;McGee, Feringa, & Søndergaard, 2012), as self-supporting, compression only, mortar-less sandstone structures (Block Research Group, 2016;Rippmann, 2016) or for example as multi-axis waterjet cutting of masonry for thin shell vaulting (Kaczynski, McGee, & Pigram, 2011). Research projects investigating modular elements and customized joint systems include robotic deposition of standard modular systems (Gramazio, Kohler, 2014;Trummer, 2012), optimized segments of the funicular-shaped RDM Vault (McGee et al., 2012), or discrete developable surface segments (Yuan, 2014). ...
In a context of stereotomy, robotic subtractive cutting enables design-to-production processes that integrate craftsmanship with advanced manufacturing technology. This paper discusses empirical research into the fabrication of complex and custom-designed geometries by means of robotic subtractive cutting, with a specific focus on modular elements and joint typologies that form an essential condition for self-supporting stone structures. The paper presents research findings in two parts. In the first part, four case studies for jointing techniques and a cross-comparison between these are introduced to derive strategies for multiple criteria, including macro-and-micro geometries, modules and joints, structural performance, material variations, machine cutting methods and end-effectors, and robotic workspace. In the second part, the paper focuses on the structural performance of the joint geometry typologies, expanded towards material constraints and robotic fabrication process. The paper concludes with a discussion on these varied subtractive cutting methodologies and a resulting design-to-fabrication workflow, and indicates future research work.
Highlights Demonstrates applications of stereotomic practice for robotic subtractive cutting. Reports on comparative case studies for four different module and joint structures. Discusses structural performance for Interlocking base block geometries. Provides a multi-criteria framework for structural, material/machine cutting methods. Develops a design-to-fabrication workflow in robotic subtractive cutting.
... While vaulted structures are usually considered to be manufactured from stone, masonry blocks, or tiles, the novel form-finding and manufacturing tools extended the design possibilities to light-weight materials, including plywood. Structurally informed shell designs in plywood have been used to explore differing goals, including variable-volume and mass solutions [4], advanced manufacturing with industrial robots [5][6][7], as well as connection and assembly strategies [8][9][10]. ...
The use of production systems based on CNC manufactured integral joinery has been increasing in many design fields including architecture, construction and industrial design. In many cases, such production systems are based on connectors that utilize interlocking mechanisms between components for assembly, sustained only by friction. Assembly systems based on friction-fit connections are low-cost, easy to manufacture and can be flat packed, shipped for construction and assembled with no special tools, fasteners or adhesives. In this paper, we propose a design to fabrication method based on a 2D tool path CNC production system with the friction-fit connection assembly logic that can be easily manufactured and assembled. The presented method provides extended groundwork for architectural design exploration based on tessellation procedures. It can be used for the design of discrete thin shells and applied to different scenarios in architecture. The method combines construction and manufacturing constraints, along with architectural and aesthetic requirements, in order to achieve a visually balanced pattern of panels and connectors. Due to this, parametric design of construction details with multi-criteria design optimization was used. The design to fabrication method proposed was tested on two models with different form generation approaches, size and scale illustrating that the method can successfully fulfil all necessary constraints.
... Multi-axis waterjet cutting of masonry has been used for Thin Shell Vaulting (Kaczynski et al. 2011). This project uses a 7 axis Kuka KR 100 HA (high accuracy) robot to manipulate a custom built abrasive water jet nozzle for cutting twisted planar surfaces in sandstone. ...
In the context of stereotomic practice, advanced fabrication with waterjet and wire-cutting of interlocking wave geometry has opened up new possibilities for crafting stone modules with precision and efficiency. This paper discusses the utilization of machined cutting techniques, the processes and workflows of fabricating joint systems for arched and vaulted surface geometries. It presents a comparative study with multiple criteria; such as geometry, method, material, machine and workflow. Furthermore, this paper presents research into the comparison between abrasive waterjet cutting and wire cutting of modules in stone and foam.
... Several other projects have combined the use of stone or brick with state-of-the-art digital design and fabrication techniques (Bechthold, 2009; Fallacara, 2009; Gramazio and Kohler, 2008; Kaczynski et al., 2011; Pedersen et al., 2012; Wendland, 2009). However, the design for the majority of these projects was driven by visual, tectonic and ornamental considerations. ...
Recently, the interest of architects and designers in contemporary applications of masonry has increased considerably. Motivated by the elegance of historic masonry structures, mostly decorative stone and brick applications have been developed, driven by new possibilities in fabrication technology and the increasing relevance of sustainable building materials. In contrast, the use and potential of structural masonry has rarely been addressed in these developments. This paper presents novel methods for structural stone masonry, focusing on the possibilities of approaches closely interrelating form-finding and material-driven fabrication. Thanks to newly developed structural form-finding methods for the design of unreinforced masonry shells, new, “free-form” vaulted structures in stone are now imaginable. These new structural design tools have been integrated into a digital process, which is informed by relevant construction and fabrication parameters. The paper focuses on this interrelation, linking expressive structural form to its real-world demands in stone construction by considering appropriate and efficient fabrication technology. The design for the MLK Jr Park Vault in Austin, Texas, USA is used as a proof-of-concept case study for the process, taking full advantage of modern stone-cutting technology and using the compression strength and weight of stone masonry to efficiently combine construction material and structural form.
Keywords:
shells, brickwork & masonry, design methods & aids
Hotwire cutting of Styrofoam or Polystyrene has been a popular tool for developing fast prototypes by the architectural community. The introduction of multi-axis industrial robots in the architectural curriculum, and the enhancement of the design to fabrication process by software bridging the gap, provided an alternative meaning to the traditional mostly representational process of hotwire cutting. This paper sets out to document and assess the procedural methodology and the results of a series of integrated design to fabrication experiments that took place in the Institut für Experimentelle Architektur-Hochbau. By channelling design intention towards a component assembly for a translucent effect, students were asked to utilise industrial robots to fabricate and prototype via hotwire cutting, designs that refer to architectural elements. These elements, mainly due to their scale and the commercial availability of bulk Styrofoam panels, can lead to functional or ornamental representations of discrete elements, which can be assembled together as part of a greater design.
The project for an acoustic shell in the Italian city of Matera was looked as an opportunity to explore an alternative stereotomic approach. The semi-vaulted space was initially thought to be built with discrete blocks of stone following a structural system in compression bounded by tie-rods, but practical and economic sustainability issues led to a different approach to that of classic cutting and carving raw stone. The collaboration between two different research teams led to the incorporation of a reusable mold technology; with the help of robotic technology and flexible moulding, it became possible to create customized heavy blocks discarding the need for disposable one-off moulds for casting voussoirs. By surveying stereotomy as a classic discipline within the scope of this project, this paper extrapolates and reflects on the validation of a different production process facing the classic ones that have defined stereotomy in architecture and construction.
This paper describes a novel method for constructing complex concrete structures from small-scale individualized elements. The method was developed through the investigation of laser cutting, folding and concrete casting in PETG plastic sheets and funicular grid shell simulations as a generator of complex geometry. In two full-scale experiments, grid shell structures have been designed and built at Aarhus School of Architecture and the University of Technology, Sydney, in 2011 and 2012. The novel design method is described as an iterative process, negotiating both physical and digital constraints. This involves consideration of the relations between geometry and technique, as well as the use of form-finding and simulation algorithms for shaping and optimising the shape of the structure. Custom-made scripts embedded in 3D-modeling tools were used for producing the information necessary for realising the construction comprised of discrete concrete elements.
Traditional artistic stone processing techniques offer vast possibilities for finishing stone products. However, stone processing is physically highly demanding work requiring stamina as well as skill. This makes products expensive to produce and the detailed design only accessible for skilled masons as an efficient communication between designers and masons is difficult. We introduce a robot-based approach to produce “artistic” surfaces for individualized stone products. First, distinctive traditional, manual processing techniques will be introduced and analyzed towards enabling us to specify the necessary requirements of an adaption to an industrial robot. These requirements are then implemented in an automated tool and an automated path planning algorithm. Building upon a visual programming environment we will present an accessible interface that allows the user to apply customizable stone structuring patterns to an individual stone product.
The paper discusses the advancement in the mass-customization of building components referring to Robot-Assisted Manufacturing. It is presented how the contemporary employment of Robotics offers a perspective of flexible alternative to traditional serial production system. Different Robot-Assisted fabrication methods are discussed through built experimental case studies at different scales. It is finally argued how Robotic production in architecture is significantly shifting the approach in design towards a model including material and fabrication constraints. © IFIP International Federation for Information Processing 2013.
