Journals
Emerging from research in computational design and digital fabrication, the use of robot arms in architecture is now making its way in the practice of construction. However, their increasing diffusion has not yet corresponded to the development of shared approaches covering both digital (programming and simulation) and physical (end-effector design, system integration, IO communication) elements of robotic prototyping suited to the unique needs of architectural research. While parallel research streams defined various approaches to robotic programming and simulation, they all either (A) rely on custom combinations of software packages, or (B) are built on top of advanced robotic programming environments requiring a higher skill level in robotics than conventionally available in an architectural context. This paper proposes an alternative open-source toolkit enabling an intuitive approach to the orchestration of various hardware and software components required for robotic fabrication, including robot programming and simulation, end-effector design and actuation, and communication interfaces. The pipeline relies on three components: Robot Components, a plug-in for intuitive robot programming; Funken, a serial protocol toolkit for interactive prototyping with Arduino; and a flexible approach to end-effector design. The paper describes these components and demonstrates their use in a series of case studies, showing how they can be adapted to a variety of project typologies and user skills, while keeping highly complex and specific functionality available as an option, yielding good practices for a more intuitive translation from design to production.
Rossi, A.; Deetman, A.; Stefas, A.; Göbert, A.; Eppinger, C.; Ochs, J.; Tessmann, O.; Eversmann, P.
ISBN: 978-3-031-13249-0
Available building materials are scarcer than ever before. The shortage of materials influences also timber construction, which has been experiencing a revival in the last decades, due to the material's excellent reputation as a sustainable resource. The rising motivation to build more sustainably demands large material quantities that the market can hardly supply. Hence, strategies to increase the efficiency of material usage are needed. Conventionally, material efficiency is equated exclusively with the reduction of the total amount of material used. However, a more holistic approach that considers not only the total quantities but also the dimensions and material grading could offer novel strategies to improve material usage and reduce waste. A fundamental shift in the design and construction of timber building elements is required with a particular focus on strategies enabling the reuse and recycling of small-scale timber components and on joining methods that enable the elimination of adhesives and thus allow for disassembly. This research, therefore, proposes a novel system of hollow timber slabs comprised of multiple layers consisting of an internal layer of small-scale beams in optimized locations connected to two outer plates through wood dowels. To design and fabricate these pure timber slabs the application of computational design and optimization methods to identify ideal material layouts and the use of automated robotic assembly processes to simplify production are required.
Schramm, K.; Eppinger, C.; Rossi, A.; Braun, M.; Brieden, M.; Seim, W
ISBN: 978-3-031-13249-0
Winding processes are known from fiber composite technology for highly resistance lightweight components for aviation. These fiber-based processes work predominantly with synthetic composites made of carbon or glass fibers. For the construction industry, these additive processes are very promising and resource-efficient building processes, but they are still hardly used in timber construction despite the very high level of digitalization and technical development. The 3DWoodWind research project uses a continuous strip of thin veneer as a sustainable alternative as its application material. Its natural fibers are intact, continuous, and tensile. In the project, three-dimensional winding processes were developed for material-efficient hollow profile lightweight components made of wood. We describe the material system, composed of suitable combinations of veneers and adhesives, and develop computational design methods for filament layout and robotic fabrication methods. We also show an open-source prototype development method, necessary for efficient prototyping. Through several fabrication case studies, we demonstrate the capabilities of the production process, and investigate suitable architectural applications. These hollow lightweight components could save large amounts of material in timber construction and serve as a substitute for concrete or steel components in the future. We conclude by discussing possible applications in the construction industry and future research possibilities.
Authors: Göbert, A.; Deetman, A.; Rossi, A.; Weyhe, O.; Eversmann, P.
DOI: http://dx.doi.org/10.1007/s41693-022-00067-2
Additive manufacturing (AM), as resource-efficient fabrication processes, could also be used in the dimensions of the construction industry, as a variety of experimental projects using concrete and steel demonstrate. In timber construction, currently few additive technologies have been developed having the potential to be used in large scale. Currently known AM processes use wood in pulverized form, losing its inherent structural and mechanical properties. This research proposes a new material that maintains a complete wood structure with continuous and strong fibers, and that can be fabricated from fast-growing locally harvested plants. We describe the material technology to create a solid and continuous filament made of willow twigs and investigate binding and robotic AM methods for flat, curved, lamination, and hollow layering geometric typologies. The resulting willow filament and composite material are characterized for structural capacity and fabrication constraints. We discuss our technology in comparison with veneer-based lamination, existing wood filament printing, and fiber-based AM in terms of fabrication, material capacity, and sustainability. We conclude by showing possible applications in the construction industry and future research possibilities.
Authors: Eversmann, P.; Ochs, J.; Heise, J.; Akbar, Z.; Böhm, S.
Journal: 3D Printing and Additive Manufacturing
Architectures of Weaving bridges architecture and textile by exploring fiber architectures from the micro scale of biological systems to the macro scale of textile and built structures. Selected case studies, essays, and interviews reflect on cultural practices and materials research through the lens of textile thinking. In the quest for sustainable and resilient approaches that meet the challenges of our time, the book presents fascinating approaches heralding a paradigm shift by working with fibrous materiality: structures become flexible and adaptive, they interact with their environment. As a source of inspiration, the book assembles exceptional contributions from the fields of architecture, art, material science, cultural history, design, engineering, mathematics, microbiology, and textile technology.
ISBN: 978-3-86859-739-4
Authors: Eversmann, P.
Editor: Sauer, Christiane; Stoll, Mareike; Fransén Waldhör, Ebba ; Schneider, Maxie
Office and retail interior fittings have a relatively short service life of 5-7 years. In this context, composite materials are often used, hindering possibilities of reuse or recycling. This research explores novel bio-composite materials and subsequently a construction method for CO2-neutral, circular interior fittings for office spaces. Based on the potential of fungal mycelium as a rapidly renewable, regenerative, affordable, low-carbon building material, bio-composite construction methods are explored in conjunction with timber-based additive manufacturing using continuous fibres. As mycelium has potentially excellent sound-absorbing properties but low load-bearing capacity, composite construction of timber veneer and mycelium allows to increase the structural capabilities of resulting components, while relying entirely on bio-based value chains. We describe the production process as well as the material development, including robotically aided processes for additive manufacturing of veneer reinforcement grids and compatibility studies of different mycelial species and substrates, and their bonding capabilities with veneer. We further present initial results on the mechanical characterization of the composite material, and its comparison to conventional mycelium composites. Minimal structural, acoustic, and functional requirements for different interior fitting elements are studied and compared to the characteristics of the proposed composite, highlighting the range of applications of the presented wood-mycelium composites.
Rossi, A.; Özdemir, E.; Eversmann, P.; Nolte, N.
Robot Components is a plugin for intuitive robot programming for ABB robots inside of Rhinoceros Grasshopper. Robot Components offers a wide set of tools to create toolpaths, simulate robotic motion and generate RAPID code within Grasshopper.
Authors: Eversmann, P.; Deetman, A.; Akbar, Z.; Rossi, A.; Rumpf, G.; Wannemacher, B.; Dawod, M.
URN / URL: https://robotcomponents.github.io/RobotComponents-Documentation/
Winding processes are known from the fiber composite industry for strength and weight optimized lightweight components. To achieve high resistance and low weight, mainly synthetic materials are used such as carbon or glass fibers, bonded with petrochemical matrices. For the construction industry, these additive processes present a very promising and resource-efficient building technology, yet they are still hardly used with sustainable materials such as natural fibers or timber.
The 3DWoodWind research prototype has developed a new generation of additive technologies to wood construction. The modular building system is built with a three-dimensional robotic winding process for material-efficient hollow lightweight components. An AI-controlled design logic enables the intelligent combination and design of modular components into multi-story structures, which may be used in the future to substitute solid wood panels and beams as well as concrete slabs and steel sections.
Our current research uses a continuous strip of thin timber veneer, which is a waste product from the plywood industry and therefore, presents a highly sustainable alternative to synthetic fibers usually used in winding, as well as solid timber products known in construction. The veneer’s natural fibers are intact and continuous, and offer high tensile strength. In the presented project, three-dimensional winding processes were developed for material-efficient lightweight components made of wood. The demonstrator presents a modular column and ceiling system, which aims at large scale applications in multi-level structures. Having won an open national design competition for Germany’s ‘ZukunftBau’ Pavilion, a first demonstrator is currently being built to be presented in May 2022, as part of the DigitalBau exhibition. The paper discusses all planning engineering and production processes in detail with particular emphasis on the machine-learning algorithm, which was trained during the design process to facilitate design iterations and future planning with this component-based building system.
ISBN: 978-3-031-13249-0
Authors: Margariti, G.; Göbert, A.; Ochs, J.; Eversmann, P.; Lienhard, J.
Editor: Gengnagel, C., Baverel, O., Betti, G., Popescu, M., Thomsen, M.R., Wurm, J.
Today's challenges in Architecture and Engineering arise from ever more complex networks of boundary conditions, which often address contradicting environmental, social and economic aspects. Within this context, finding a single best solution for a construction type or planning method to solve these challenges, is often not possible. In pursuit of efficient solutions for both digital modelling and actual construction, we are discovering new hybrids as forerunners of our creative profession. In this context, we are also discovering new fields of application for textile architecture for both products and planning techniques beyond their classic application for membrane structures. The current paper on 'new hybrids' will address this potential and show new fields of application, where knowledge from textile architecture is the starting point for developing new design and construction methods, using traditional building materials. The current paper reviews some recent developments of design and construction principals in textile architecture and gives an outlook, towards how these can be transferred, onto the development of a new filament-based timber material.
Lienhard, J.; Eversmann, P.
ISSN: 1745-2007
Authors: Ochs, J.; Akbar, Z.; Eversmann, P.
Editor: Maciel, Abel;
Book title: Design Computation Input/Output 2020
ISBN: 9781838129408
The ease of access to sophisticated computational technologies normally used for engineering purposes have thoroughly transformed the way architects can design and generate structures. In a first step of digitalization, traditional timber joining methods have been adapted for CNC-fabrication and manual assembly, enabling intricate joinery methods. The next step integrates the digital workflow to the extent of a fully automated assembly using robotic building processes. The potential of these processes calls for a rethinking of traditional connection geometry and requires the creation of specifically adapted joints to accommodate the constraints and precision of kinematic movement. This article gives an overview of recent developments in joining techniques for robotic assembly and investigates two prototypical timber structures, which were constructed in the framework of the NCCR Digital Fabrication at the ETH Zurich. The first structure consists of connections of multiple members with complex intersection geometries, which were joined through an ultrafast-curing resin. The second prototype consists of a double-story timber structure of more than 4,000 individual members with singular face to face connections with a maximum of two members, connected by carbon steel screws. The results are compared in terms of the relationship between computational form finding, joint geometry, connection system, robotic fabrication process, and structural stability. We discuss applications in the building industry, spatial potentials, structural challenges, and fabrication developments and conclude by showing the potential development in future research.
Authors: Eversmann, P.
Editor: Hudert, Markus; Pfeiffer, Sven
Book title: Rethinking Wood: Future Dimensions of Timber Assembly
ISBN: 9783035616897
Advances in Additive Manufacturing (AM) techniques have expanded the possibilities to fabricate unique shapes, offering various advantages over traditional manufacturing techniques concerning material efficiency, product customisation and process control. AM using organic materials such as wood has been introduced by the combination with polymers to produce 3D printing filaments. These filaments use groundwood and therefore eliminate long fibres of naturally grown timber, losing its inherent material qualities such as anisotropy and structural performance. This research investigates strategies for a novel AM process using continuous solid wood to fabricate high-resolution material-efficient timber structures based on topology optimization. We examined this novel AM process in three work packages: material production, robotic fibre placement process and a design method through topology optimisation. The developed robotic fabrication process enables the deployment and extrusion of a novel material: a continuous solid wood filament made of willow withies. This process allows for a high degree of geometric freedom to assemble timber to create homogeneous structures at high resolution, providing the aesthetics and structural advantages of wood on a micro-scale and therefore giving entirely new possibilities for timber construction.
Dawod, M.; Deetman, A.; Akbar, Z.; Heise, J.; Böhm, S.; Klussmann, H.; Eversmann, P.
ISBN: 978-3-030-29828-9
Our project is an investigation of the design, shaping, simulation, manufacture, and construction of lightweight load-bearing structural components made of wood-based continuous-fiber textiles. Our aim is to innovatively adapt established concepts in wood construction, such as panelized construction and wood framing, to textile construction. We are developing a continuous filament out of solid wood that can be made into wood-textile structures. Textiles have many advantages: excellent suitability for light construction, versatility of form and function, refined and tested manufacturing and processing technologies, and a characteristic, ever-changing, deeply familiar aesthetic of parallel and crossing threads. Our ultimate goal is to develop a material-efficient, functional, and aesthetically appealing architecture based on solid-wood textiles.
Authors: Silbermann, S.; Böhm, S.; Eversmann, P.; Klussmann, H.
Editor: Hudert, Markus; Pfeiffer, Sven
Book title: Rethinking Wood. Future Dimensions of Timber Assembly
ISBN: 978-3-0356-1706-1
Our project is an investigation of the design, shaping, simulation, manufacture, and construction of lightweight load-bearing structural components made of wood-based continuous-fiber textiles. Our aim is to innovatively adapt established concepts in wood construction, such as panelized construction and wood framing, to textile construction. We are developing a continuous filament out of solid wood that can be made into wood-textile structures. Textiles have many advantages: excellent suitability for light construction, versatility of form and function, refined and tested manufacturing and processing technologies, and a characteristic, ever-changing, deeply familiar aesthetic of parallel and crossing threads. Our ultimate goal is to develop a materialefficient, functional, and aesthetically appealing architecture based on solid-wood textiles.
Silbermann, S.; Heise, J.; Kohl, D.; Böhm, S.; Akbar, Z.; Eversmann, P.; Klussmann, H.
ISBN: 978-3-0356-2023-8
The demand for transparent but robust designs in architecture is still enormous. One of the most complex points of the application of glass is the use of efficient and appropriate connection details. The article examines a modular glass system about its architectural possibilities with a special focus on the connection methodology. We constructed a 2 x 2 x 1m prototype of specially laminated glass sheets with integrated connection details in the framework of a Master of Science programme on digital fabrication with support from Seele and Bischoff Glastechnik, which was also featured in two public exhibitions at TU Munich and the House of Architecture in Munich. The design potential is investigated using parametric geometrical modelling as well as FEM sensitivity analysis. At the interface between the architect and the engineer, the consequences of the FEM analysis are discussed reflecting the influence of the chosen connection to the peak stresses within the structure and expected deflections. A typical part of the examined structure is prepared as an FEA-model. The abstraction of the connection details within the model allows a more in-depth analysis of the load transmissions between the glass panes using non-linear contact effects as well as the rheological behaviour of the interlayer material. The examined structure was designed for application in small-scale architectural design. Beside the design, and analysis of the structure fabrication and installation aspects and their consequences to the design is explained in detail. Unique aspects of this article are new possibility to build transparent and efficient façade systems that can be flexibly adapted to possible areas of application due to the parametrically supported design processes. In addition to the design process, the direct interaction between the architect and the engineer was also able to consider the aspects of the data exchange regarding detail development. The article concludes with a description of further development for full-scale architectural applications and the necessary research.
Eversmann, P.
Both natural materials such as timber and low-grade or recycled materials are extremely variable in quality and geometry in unprocessed state. Additive digital fabrication processes in robotics in combination with sensor feedback techniques offer large design freedom, high precision and material efficiency and enable a highly customized fabrication and calculation process. Separate studies have been made on scanning, efficient algorithmic arrangement and automated assembly of structures of variable timber elements. In this paper we explore a robotic fabrication process, in which we combine the techniques of scanning, digitally arranging and robotically assembling in one continuous real-time workflow. This means that the final design and appearance only emerge after a unique fabrication process, corresponding to the material used and the assembly sequence. We describe techniques for the simulation modelling and performance analysis using particle simulation, and demonstrate the feasibility through the realisation of the envelope of a robotically assembled double-story timber structure with hand-split wood plates of varying dimensions. We discuss a future use of natural, low-grade or waste material in the building industry through robotic processes. We conclude by analysing the integration of qualitative analysis, physical simulation and the degree of variability of input material and resulting complexity in the computation and fabrication process.
Eversmann, P.
Many studies have been conducted on the geometric definition and simulation of curved-folded elements using a wide range of computational techniques. Robotic fabrication technologies have already been applied to single-panel folding processes. However, few large-scale applications have been realized. Structural joining techniques remain a challenging subject, since the geometry and assembly trajectories between multiple curved-folded panels are extremely complex. This study employs computational design and digital fabrication technology in order to structurally connect single and double-layer curved-folded aluminium panels. It shows experimentation on joining techniques, engraving and cut precision using milling and waterjet cutting. We demonstrate two largescale prototypes which were realized at the EPF Lausanne and TU Munich, and analyse their structural capabilities using a custom meshing algorithm and FE-Modelling. With the proposed digitally fabricated joining types, curved-folded structural shells can be realized using extremely thin aluminium plates without the need for additional mechanical fasteners. Double-layer panels can improve stability within one panel, but generate geometric challenges when connecting multiple panels. The efficiency of joining typology, such as traditional mechanical fasteners, folded joints and integral mechanical attachments are compared. We conclude by showing possible future developments and discuss applications in the building industry for structural metal facades and wall systems.
Eversmann, P.
eISBN: 2518-6582
The consequences of automation technology on industry are currently widely discussed in terms of future tasks, work organisation and working environments. Even though various novel education programmes specialise in digital fabrication, relatively little has been written on concepts for a deeper integration of digital technologies in the architectural curriculum. This paper gives an overview of interdisciplinary educational approaches and digital project development techniques and describes a teaching method featuring intensive collaboration with research and industry, an iterative teaching method employing digital production of large-scale prototypes and a moderated self-learning process. We describe two examples of teaching initiatives in particular that were undertaken at TU Munich and ETH Zurich and analyse their results in terms of physical outcomes, teaching accomplishments, resource efficiency and connection to research. We discuss the relationship between necessary teaching intensity, project size and complexity of digital fabrication equipment and conclude by giving an outlook for future initiatives.
Eversmann, P.
Despite modern timber construction being on the forefront of digital technology in construction, subtractive CNC—fabrication technologies are still predominantly used in the industry. An important break in the digital chain occurs when prefabricated small building parts have to be assembled manually into functional modules. This can result in a loss of digital information in the process. Therefore, a robotic setup for timber construction was specifically developed by the authors enabling large-scale spatial fabrication possibilities using a combination of subtractive external tools for cutting and drilling and additive robotic operations. Through automatization techniques and innovative feedback processes, the system can minimize material waste by reacting to different material sizes even during the construction process. In a case study, which was undertaken in the course of the Master of Advanced Studies program in Digital Fabrication at ETH Zurich, a complete digital workflow using additive robotic fabrication processes in timber construction was realized. We demonstrate the conception of the worldwide first double-story robotically assembled timber structure, explain its fabrication processes including an integrated envelope, and conclude by analyzing the robotic fabrication technologies in terms of their efficiency and structural and functional capabilities and limits.
Eversmann, P.
The fabrication of projects with complex geometries often implies a significant waste of material, since custom molds need to be created and irregular shapes need to be cut out of larger sized elements. For low curvatures, cold elastic bending processes can be applied. However, elastic bending techniques have mainly been utilized to create simple curvature panels for architectural projects. This paper explores computational simulation in relation to a digitally controlled fabrication method of bending rectangular glass sheets elastically into irregular double curvature. This is done through exploratory prototyping within the framework of a Master of Science course on digital production, and additional computational modeling and FE-analysis. We used algorithmic real-time simulation to approximate the bending process of cold-bent glass and elaborated on details of the simulation process and possible surface types and curvatures. Our empirical tests on simply curved, ruled and doubly curved surface types used float glass as well as heat-treated glass. A detailing system was developed to clamp the glass panels into position. We evaluated the results of the computational simulation (Rhino with plug-ins) as well as FE-Analysis (Strand 7) and compared the resulting geometries to the measurements of the physical prototypes. In order to demonstrate the system’s capacities on a larger multi-panel geometry, we constructed a 5m x 4m prototype of a doubly-curved glass surface.
Eversmann, P.
ISBN: 978-90-825-2680-6
The realization of doubly curved façades often requires large investments in fabrication equipment and produces additional waste through subtractive fabrication processes and non-reusable molds. In glass construction, elastic bending techniques can be used for small curvatures. This paper continues previous research of the authors on bending rectangular glass elements into irregularly curved panels. First, we analyze the stresses occurring in cold bent glass during assembly, thus defining a particlespring model which is able to compute approximate stresses in real-time during the bending procedure. In a second step, we compare the structural performance of the bent glass with that of flat panels using FE-analysis. Finally, we illustrate the implementations on multi-panel façade layouts. We analyze the dependencies between curvature, gap-tolerance and panelization. We present a method to minimize gap-tolerances by optimizing the distribution of surface curvature. Our results highlight the structural and geometrical potentials and possible applications for curved glass construction.
Eversmann, P.
eISBN: 2518-6582
This paper presents a novel method for integrated topology optimization and fabrication of advanced timber space-frame structures. The method, developed in research collaboration between ETH Zürich, Aarhus School of Architecture and Israel Institute of Technology, entails the coupling of truss-based topology optimization with digital procedures for rationalization and robotic assembly of bespoke timber members, through a procedural, cross-application workflow. Through this, a direct chaining of optimization and robotic fabrication is established, in which optimization data is driving subsequent processes solving timber joint intersections, robotically controlling member prefabrication, and spatial robotic assembly of the optimized timber structures. The implication of this concept is studied through pilot fabrication and load-testing of a full scale prototype structure.
Authors: Eversmann, P.
Editor: Reinhardt, Dagmar, Saunders, Rob, Burry, Jane
The following paper explores the application of hybrid timber-glass elements on semi-continuous architectural structures. The use of glass as a structural material opens multiple fields of investigations. Beyond structural matters and safety issues, architectural questions as functionality and spatiality are briefly addressed, since they are paired with the structural layout. Furthermore, the potential of a glass plate system of overlaying, but yet discontinuous glass elements is addressed in more depth. Geometrical specifications on the structural glass application are elaborated on and generalized into a ‘card house’ algorithmic discretization model. Through the design and fabrication of a ‘case study’, the parallel use and digital simulation and empirical physical testing are discussed. A further potential use in the construction industry of the system is debated.
Authors: Eversmann, P.
Editor: Philippe Block; Jan Knippers; Niloy J. Mitra; Wenping Wang
ISBN: 978-3-319-11418-7
DOI: http://dx.doi.org/10.1007/978-3-319-11418-7_4
Magazines
With the magazine enclosed in the respective issues of the Deutsches Architektenblatt and Deutsches Ingenieurblatt at the beginning of the year, the BMI and BBSR are addressing some 190.000 chamber members of architects, planners and engineers. The magazine serves to publicise the funding programme and the new funding guideline 2021, which will start on 15 February 2021.
The magazine presents exemplary, interesting future construction research projects. Interviews with experts, statements and a preview of various Zukunft Bau events in 2021 complete the look at current research in the Zukunft Bau funding programme.
Eversmann, P.; Liebringshausen, A.; Göbert, A.
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DER ENTWURF, a special issue of DBZ Deutsche Bauzeitschrift for students, graduates and young professionals.
The special issue of the DBZ contains many useful tips and advice, especially for students, graduates and young professionals.
Eversmann, P.; Liebringshausen, A.; Göbert, A.
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Research reports
The subject of the research was the examination of industrial waste such as used sand and wood for their suitability as formwork materials, and their processing using digital manufacturing methods. At each stage of the process, testing methods were used to check and optimise the moulding materials. Demonstrators were produced in different scales with the help of industrial partners to check and optimise the results.
Eversmann, P.; Liebringshausen, A.; Göbert, A.
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