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Integrative Computational Design and Construction for Architecture (T3.0)
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Research Projects
RP 14-2 – Extention of the Cyber-Physical Prefabrication Platform

Extension of the Cyber-Physical Prefabrication Platform

Research Project 14-2 (RP 14-2)

EXTENSION OF THE CYBER-PHYSICAL PREFABRICATION PLATFORM FOR RELIABLE PRODUCTION OF LARGE-SCALE FIBER COMPOSITE BUILDING ELEMENTS USING CONVENTIONAL AND ALTERNATIVE MATERIAL SYSTEMS

In the first funding phase of IntCDC, a fabrication system for core-less filament winding (CFW) was developed and implemented, which enables the manufacturing of fiber components of varying shape with only minimal formwork. The system features two container platforms, each being equipped with a robot on a linear axis to allow manufacturing of large-scale building components and a filament placement head that allows passing between robots, on-head impregnation and tension control. While previous approaches were stationary [1] the developed platform is portable and reconfigurable. Although it already enables manufacturing of large components, the current platform has several limitations in regards to size of workpiece, speed of production, possible fiber net configurations/syntaxes, process predictability (and related safety factors), use of more sustainable materials and ease of programming. Addressing these limitations poses scientific challenges which will be addressed in the second phase by investigating the extension of the fabrication platform and related fabrication space, as well as production speed, through robot teams and Autonomous Mobile Robots. This will be complemented by methods for path planning automation, by advancing monitoring and compensation methods to reduce safety factors, and by researching possibilities of fabricating with alternative fiber/matrix systems. The developments will be tested and evaluated in two demonstrators.

PRINCIPAL INVESTIGATORS

Prof. Dr.-Ing. Alexander Verl
Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW), University of Stuttgart
Prof. Achim Menges
Institute for Computational Design and Construction (ICD), University of Stuttgart
Prof. Dr.-Ing. Peter Middendorf
Institute of Aircraft Design (IFB), University of Stuttgart

TEAM

Dr.-Ing. Stefan Carosella (IFB)
Dr.-Ing. Armin Lechler (ISW)
Marko Szcesny (IBB)
Sebastian Hügle (IFB)
Timo König (ISW)
Christoph Zechmeister (ICD)

PEER-REVIEWED PUBLICATIONS

2022
1. Gil Pérez, M., Zechmeister, C., Kannenberg, F., Mindermann, P., Balangé, L., Guo, Y., Hügle, S., Gienger, A., Forster, D., Bischoff, M., Tarín, C., Middendorf, P., Schwieger, V., Gresser, G. T., Menges, A., & Knippers, J. (2022). Computational co-design framework for coreless wound fibre-polymer composite structures. Journal of Computational Design and Engineering, 9(2), Article 2. https://doi.org/10.1093/jcde/qwab081
  - BibTeX
  BibTeX
  @article{Gil_Perez_2022, abstract = {In coreless filament winding, resin-impregnated fibre filaments are wound around anchor points without an additional mould. The final geometry of the produced part results from the interaction of fibres in space and is initially undetermined. Therefore, the success of large-scale coreless wound fibre composite structures for architectural applications relies on the reciprocal collaboration of simulation, fabrication, quality evaluation, and data integration domains. The correlation of data from those domains enables the optimization of the design towards ideal performance and material efficiency. This paper elaborates on a computational co-design framework to enable new modes of collaboration for coreless wound fibre–polymer composite structures. It introduces the use of a shared object model acting as a central data repository that facilitates interdisciplinary data exchange and the investigation of correlations between domains. The application of the developed computational co-design framework is demonstrated in a case study in which the data are successfully mapped, linked, and analysed across the different fields of expertise. The results showcase the framework’s potential to gain a deeper understanding of large-scale coreless wound filament structures and their fabrication and geometrical implications for design optimization.}, author = {Gil Pérez, M and Zechmeister, C and Kannenberg, F and Mindermann, P and Balangé, L and Guo, Y and Hügle, S and Gienger, A and Forster, D and Bischoff, M and Tarín, C and Middendorf, P and Schwieger, V and Gresser, G T and Menges, A and Knippers, J}, doi = {10.1093/jcde/qwab081}, journal = {Journal of Computational Design and Engineering}, month = {04}, note = {M. Gil Perez and C. Zechmeister: first authors equal contribution. F. Kannenberg and P. Mindermann: second authors equal contribution.}, number = 2, pages = {310--329}, publisher = {Oxford University Press ({OUP})}, title = {Computational co-design framework for coreless wound fibre-polymer composite structures}, url = {https://doi.org/10.1093%2Fjcde%2Fqwab081}, volume = 9, year = 2022 }
2. Gil Pérez, M., Zechmeister, C., Menges, A., & Knippers, J. (2022). Coreless filament-wound structures: toward performative long-span and sustainable building systems. In S. Xue, J. Wu, & G. Sun (Eds.), Proceedings of IASS Annual Symposia 2022: Innovation, Sustainability and Legacy (Vol. 2022, pp. 3366–3376). International Association for Shell and Spatial Structures (IASS).
  - BibTeX
  BibTeX
  @inproceedings{IASS2022gilperez, abstract = {Coreless filament winding (CFW) was developed in 2012 at the University of Stuttgart to reduce material waste during the fabrication of composite parts. This was achieved by diminishing the required formwork of state-of-the-art filament winding to discrete boundary frames. Then, impregnated fibers are wound between them, forming lightweight lattice structures. A series of pavilions at the University demonstrated the system's potential and enabled the transfer of CFW into practice, bringing along other engineering challenges, such as the requirement to prove structural integrity and safety. The BUGA Fibre Pavilion was the first long-span application using CFW. In this project, a series of full-scale structural tests successfully proved the structural capacity of the composite components. Maison Fibre expanded the research toward multi-story building systems and explored the combination of CFW components with timber plates as hybrid slabs. To improve the sustainability aspects of the system, the LivMatS Pavilion replaced the previously used carbon and glass fibers with natural fibers. This pavilion achieved different materiality, showing the potential of bio-composite filament wound structures. This paper describes and compares the design and engineering process in each system: long-span, hybrid slab, and natural fiber components, and reveals the potential and future research goals to achieve more sustainable building systems using CFW structures.}, author = {Gil Pérez, Marta and Zechmeister, Christoph and Menges, Achim and Knippers, Jan}, booktitle = {Proceedings of IASS Annual Symposia 2022: Innovation, Sustainability and Legacy}, editor = {Xue, Su-duo and Wu, Jin-zhi and Sun, Guo-jun}, eventdate = {September 19-22 2022}, eventtitle = {IASS/APCS 2022 Innovation, Sustainability and Legacy}, month = {09}, pages = {3366-3376}, publisher = {International Association for Shell and Spatial Structures (IASS)}, title = {Coreless filament-wound structures: toward performative long-span and sustainable building systems}, venue = {Beijing, China}, volume = 2022, year = 2022 }
3. Hügle, S., Genc, E., Dittmann, J., & Middendorf, P. (2022). Offline Robot-Path-Planning and Process Simulation for the Structural Analysis of Coreless Wound Fibre-Polymer Composite Structures. Key Engineering Materials, 926, 1445--1453. https://doi.org/10.4028/p-970esd
  - BibTeX
  BibTeX
  @article{hugle2022, abstract = {In the coreless filament winding process (CFW) anchor points are wrapped with pre-impregnated fibre bundles (Towpregs) in a defined chronological order. With this process, fibre-polymer composite structures with a very high lightweight potential and very little material consumption can be created for different applications in the automotive, aeronautical, sports and architectural sector. The winding sequence and the fibre interaction thereby does have an influence on the final fibre architecture and thus on its structural behaviour. To take this into account a process chain for path planning and process simulation out of a design model is presented. To achieve flexible considerations of different design concepts a parameter-based method for the necessary path planning of the final three-dimensional fibre architecture is introduced. The approach is evaluated on different kinds of specimen.}, author = {H{\"{u}}gle, Sebastian and Genc, Enis and Dittmann, J{\"{o}}rg and Middendorf, Peter}, doi = {10.4028/p-970esd}, journal = {Key Engineering Materials}, month = {08}, pages = {1445--1453}, title = {Offline Robot-Path-Planning and Process Simulation for the Structural Analysis of Coreless Wound Fibre-Polymer Composite Structures}, volume = 926, year = 2022 }
4. Menges, A., Kannenberg, F., & Zechmeister, C. (2022). Computational co-design of fibrous architecture. Architectural Intelligence, 1(1), Article 1. https://doi.org/10.1007/s44223-022-00004-x
  - BibTeX
  BibTeX
  @article{Menges2022CoDesignFiber, abstract = {Fibrous architecture constitutes an alternative approach to conventional building systems and established construction methods. It shows the potential to converge architectural concerns such as spatial expression and structural elegance, with urgently required resource effectiveness and material efficiency, in a genuinely computational approach. Fundamental characteristics of fibre composite are shared with fibre structures in the natural world, enabling the transfer of design principles and providing a vast repertoire of inspiration. Robotic fabrication based on coreless filament winding, a technique to deposit resin impregnated fibre filaments with only minimal formwork, as well as integrative computational design methods are imperative to the development of complex fibrous building systems. Two projects, the BUGA Fibre Pavilion as an example for long-span structures, and Maison Fibre as an example of multi-storey architecture, showcase the application of those techniques in an architectural context and highlight areas of further research opportunities. The highly interrelated aesthetic, structural and fabrication characteristics of fibre nets are difficult to understand and go beyond a designer’s comprehension and intuition. An AI powered, self-learning agent system aims to extend and thoroughly explore the design space of fibre structures to unlock the full design potential coreless filament winding offers. In order to ensure feedback between all relevant design and performance criteria and enable interdisciplinary convergence, these novel design methods are embedded in a larger co-design framework. It formalizes the interaction of involved interdisciplinary domains and allows for interactive collaboration based on a central data model, serving as a base for design optimisation and exploration. To further advance research on fibre composites in architecture, bio-based materials are considered, continuing the journey of discovery of fibrous architecture to fundamentally rethinking design and construction towards a novel, computational material culture in architecture.}, author = {Menges, Achim and Kannenberg, Fabian and Zechmeister, Christoph}, doi = {10.1007/s44223-022-00004-x}, issn = {27316726}, journal = {Architectural Intelligence}, number = 1, pages = {6--}, refid = {Menges2022}, title = {Computational co-design of fibrous architecture}, url = {https://doi.org/10.1007/s44223-022-00004-x}, volume = 1, year = 2022 }
5. Wolf, M., Kaiser, B., Hügle, S., Verl, A., & Middendorf, P. (2022). Data Model for Adaptive Robotic Construction in Architecture. Procedia CIRP, 107, 1035–1040. https://doi.org/10.1016/j.procir.2022.05.104
  - BibTeX
  BibTeX
  @inproceedings{wolf2022model, author = {Wolf, Martin and Kaiser, Benjamin and Hügle, Sebastian and Verl, Alexander and Middendorf, Peter}, doi = {10.1016/j.procir.2022.05.104}, journal = {Procedia CIRP}, pages = {1035-1040}, publisher = {Elsevier BV}, title = {Data Model for Adaptive Robotic Construction in Architecture}, url = {https://doi.org/10.1016%2Fj.procir.2022.05.104}, volume = 107, year = 2022 }
2021
1. Bodea, S., Mindermann, P., Gresser, G. T., & Menges, A. (2021). Additive Manufacturing of Large Coreless Filament Wound Composite Elements for Building Construction. 3D Printing and Additive Manufacturing. https://doi.org/10.1089/3dp.2020.0346
  - BibTeX
  BibTeX
  @article{Bodea_2021, abstract = {Digitization and automation are essential tools to increase productivity and close significant added-value deficits in the building industry. Additive manufacturing (AM) is a process that promises to impact all aspects of building construction profoundly. Of special interest in AM is an in-depth understanding of material systems based on their isotropic or anisotropic properties. The presented research focuses on fiber-reinforced polymers, with anisotropic mechanical properties ideally suited for AM applications that include tailored structural reinforcement. This article presents a cyber-physical manufacturing process that enhances existing robotic coreless Filament Winding (FW) methods for glass and carbon fiber-reinforced polymers. Our main contribution is the complete characterization of a feedback-based, sensor-informed application for process monitoring and fabrication data acquisition and analysis. The proposed AM method is verified through the fabrication of a large-scale demonstrator. The main finding is that implementing AM in construction through cyber-physical robotic coreless FW leads to more autonomous prefabrication processes and unlocks upscaling potential. Overall, we conclude that material-system-aware communication and control are essential for the efficient automation and design of fiber-reinforced polymers in future construction.}, author = {Bodea, Serban and Mindermann, Pascal and Gresser, Götz T. and Menges, Achim}, doi = {10.1089/3dp.2020.0346}, journal = {3D Printing and Additive Manufacturing}, month = {08}, publisher = {Mary Ann Liebert Inc}, title = {Additive Manufacturing of Large Coreless Filament Wound Composite Elements for Building Construction}, url = {https://doi.org/10.1089%2F3dp.2020.0346}, year = 2021 }
2. Bodea, S., Zechmeister, C., Dambrosio, N., Dörstelmann, M., & Menges, A. (2021). Robotic coreless filament winding for hyperboloid tubular composite components in construction. Automation in Construction, 126, 103649. https://doi.org/10.1016/j.autcon.2021.103649
  - BibTeX
  BibTeX
  @article{Bodea_2021, abstract = {Novel fabrication methods are necessary to capitalize on the high strength-to-weight ratio of composites engineered for construction applications. This paper presents prefabrication strategies for geometrically-complex building elements wound out of Glass and Carbon Fiber Reinforced Polymers (G/CFRP). The research focuses on Robotic Coreless Filament Winding (RCFW), a technology that eliminates formwork, proposing upscaling and industrialization strategies combined with updated robot programming and control methods. Our application addresses the prefabrication of hyperboloid, tubular components with differentiated geometry and fiber layout. We examine how the proposed methods enabled the industrial prefabrication of a building-scale G/CFRP dome structure and discuss the industrial process relative to key fabrication parameters. Highlighting the interdisciplinary nature of the research, we envisage future directions and applications for RCFW in construction. Overall, we find that synergy between academia and industry is essential to meeting research, productivity, and certification goals in the rather conservative building industry.}, author = {Bodea, Serban and Zechmeister, Christoph and Dambrosio, Niccolo and Dörstelmann, Moritz and Menges, Achim}, doi = {10.1016/j.autcon.2021.103649}, editor = {Skibniewski, Miroslaw J.}, issn = {0926-5805}, journal = {Automation in Construction}, month = {06}, pages = 103649, publisher = {Elsevier {BV}}, title = {Robotic coreless filament winding for hyperboloid tubular composite components in construction}, url = {https://doi.org/10.1016%2Fj.autcon.2021.103649}, volume = 126, year = 2021 }
3. Ellwein, C., Reichle, A., Herschel, M., & Verl, A. (2021). Integrative data processing for cyber-physical off-site and on-site construction promoting co-design. Procedia CIRP, 100, 451–456. https://doi.org/10.1016/j.procir.2021.05.103
  - BibTeX
  BibTeX
  @article{Ellwein_2021, abstract = {The term co-design describes a collaborative design process, usually across the boundaries of individual areas. A major aspect, and often an obstacle in the implementation of the co-design approach, is the establishment of a centralized data management system. In the past, the data management concept has been approached from different perspectives. Current approaches usually are oriented along the process chain and thus reflect a unidirectional flow of information. Neither the information feedback nor the reaction to adjustments in upstream model steps is supported, which makes continuous collaboration more difficult and at best reduces the co-design approach for continuous data usage. This paper addresses these weaknesses while outlining an integrative data processing concept enabling co-design between the domains of construction and industrial prefabrication. Geometrical information generated during architectural design and construction planning is reused for the production of components, manufacturing-related design adjustments are transferred back into the domain of construction. Changes throughout the entire process are centrally recorded. To ensure independence from the software tools used and to consider their great diversity, data exchange is largely based on standards, namely industry foundation classes and the standard for the exchange of product model data. In order to counteract the sequential processing according to a waterfall model and to support the co-design approach, the industrial prefabrication toolchain, consisting of computer-aided manufacturing software and downstream postprocessors, is largely automated, so that reprocessing of a workpiece for minor geometric adjustments no longer requires any interaction of the production planner.}, author = {Ellwein, Carsten and Reichle, Alexander and Herschel, Melanie and Verl, Alexander}, doi = {10.1016/j.procir.2021.05.103}, journal = {Procedia CIRP}, note = {31st CIRP Design Conference 2021 (CIRP Design 2021)}, pages = {451-456}, publisher = {Elsevier {BV}}, title = {Integrative data processing for cyber-physical off-site and on-site construction promoting co-design}, url = {https://www.sciencedirect.com/science/article/pii/S2212827121005746}, volume = 100, year = 2021 }
2020
1. Wolf, M., Elser, A., Riedel, O., & Verl, A. (2020). A software architecture for a multi-axis additive manufacturing path-planning tool. Procedia CIRP, 88. https://doi.org/10.1016/j.procir.2020.05.075
  - BibTeX
  BibTeX
  @inproceedings{wolf2019software, author = {Wolf, Martin and Elser, Anja and Riedel, Oliver and Verl, Alexander}, doi = {10.1016/j.procir.2020.05.075}, journal = {Procedia CIRP}, language = {en}, title = {A software architecture for a multi-axis additive manufacturing path-planning tool}, url = {http://www.sciencedirect.com/science/article/pii/S2212827120303966}, volume = 88, year = 2020 }
2019
1. Dambrosio, N., Zechmeister, C., Bodea, S., Koslowski, V., Gil Pérez, M., Rongen, B., Knippers, J., & Menges, A. (2019). Buga Fibre Pavilion: Towards an architectural application of novel fiber composite building systems. In K. Bieg, D. Briscoe, & C. Odom (Eds.), Acadia 2019: Ubiquity and Autonomy, proceedings of the 39th Annual Conference of the Association for Computer Aided Design in Architecture, Texas (pp. 140--149). Acadia Publishing Company.
  - BibTeX
  BibTeX
  @inproceedings{dambrosiobuga, author = {Dambrosio, Niccolo and Zechmeister, Christoph and Bodea, Serban and Koslowski, Valentin and Gil Pérez, Marta and Rongen, Bas and Knippers, Jan and Menges, Achim}, booktitle = {Acadia 2019: Ubiquity and Autonomy, proceedings of the 39th Annual Conference of the Association for Computer Aided Design in Architecture, Texas}, editor = {Bieg, Kory and Briscoe, Danelle and Odom, Clay}, isbn = {978-0-578-59179-7}, pages = {140--149}, publisher = {Acadia Publishing Company}, title = {Buga Fibre Pavilion: Towards an architectural application of novel fiber composite building systems}, year = 2019 }
2. Zechmeister, C., Bodea, S., Dambrosio, N., & Menges, A. (2019). Design for Long-Span Core-Less Wound, Structural Composite Building Elements. Impact: Design With All Senses Proceedings of the Design Modelling Symposium 2019, 401--415. https://doi.org/10.1007/978-3-030-29829-6 32
  - BibTeX
  BibTeX
  @article{zechmeister_design_2019, author = {Zechmeister, Christoph and Bodea, Serban and Dambrosio, Niccolo and Menges, Achim}, doi = {10.1007/978-3-030-29829-6 32}, journal = {Impact: Design With All Senses [Proceedings of the Design Modelling Symposium 2019]}, pages = {401--415}, title = {Design for {Long}-{Span} {Core}-{Less} {Wound}, {Structural} {Composite} {Building} {Elements}}, year = 2019 }

OTHER PUBLICATIONS

DATA SETS

2023
1. Gil Pérez, M., Mindermann, P., Zechmeister, C., Forster, D., Guo, Y., Hügle, S., Kannenberg, F., Balangé, L., Schwieger, V., Middendorf, P., Bischoff, M., Menges, A., Gresser, G. T., & Knippers, J. (2023). Post-processed and normalized data sets for the data processing, analysis, and evaluation methods for co-design of coreless filament-wound structures. DaRUS. https://doi.org/10.18419/darus-3449
  - BibTeX
  BibTeX
  @dataset{darus-3449_2023, author = {Gil Pérez, Marta and Mindermann, Pascal and Zechmeister, Christoph and Forster, David and Guo, Yanan and Hügle, Sebastian and Kannenberg, Fabian and Balangé, Laura and Schwieger, Volker and Middendorf, Peter and Bischoff, Manfred and Menges, Achim and Gresser, Götz Theodor and Knippers, Jan}, doi = {10.18419/darus-3449}, publisher = {DaRUS}, title = {Post-processed and normalized data sets for the data processing, analysis, and evaluation methods for co-design of coreless filament-wound structures}, unf = {UNF:6:3jBvTQjaf+dWmcUwcF1GkA==}, url = {https://doi.org/10.18419/darus-3449}, version = {V1}, year = 2023 }
2. Gil Pérez, M., Zechmeister, C., Kannenberg, F., Mindermann, P., Balangé, L., Guo, Y., Hügle, S., Gienger, A., Forster, D., Bischoff, M., Tarín, C., Middendorf, P., Schwieger, V., Gresser, G. T., Menges, A., & Knippers, J. (2023). Object model data sets of the case study specimens for the computational co-design framework for coreless wound fibre-polymer composite structures. DaRUS. https://doi.org/10.18419/darus-3375
  - BibTeX
  BibTeX
  @dataset{darus-3375_2023, author = {Gil Pérez, Marta and Zechmeister, Christoph and Kannenberg, Fabian and Mindermann, Pascal and Balangé, Laura and Guo, Yanan and Hügle, Sebastian and Gienger, Andreas and Forster, David and Bischoff, Manfred and Tarín, Cristina and Middendorf, Peter and Schwieger, Volker and Gresser, Götz Theodor and Menges, Achim and Knippers, Jan}, doi = {10.18419/darus-3375}, publisher = {DaRUS}, title = {Object model data sets of the case study specimens for the computational co-design framework for coreless wound fibre-polymer composite structures}, url = {https://doi.org/10.18419/darus-3375}, version = {V1}, year = 2023 }

Prof. Achim Menges

Director

Phone: +49 711 685 82786

E-Mail

Prof. Dr.-Ing. Peter Middendorf

Principal Investigator

Phone: +49 711 685 62411

E-Mail

Prof. Dr.-Ing. Alexander Verl

Principal Investigator

Phone: +49 711 685 82422

E-Mail