Extension of the Cyber-Physical Prefabrication Platform for Reliable Production of Large-Scale Fibre Composite Building Elements Using Conventional and Alternative Material Systems

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

 

PEER-REVIEWED PUBLICATIONS

  1. 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), 310--329. https://doi.org/10.1093/jcde/qwab081
    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).
    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
    4. Menges, A., Kannenberg, F., & Zechmeister, C. (2022). Computational co-design of fibrous architecture. Architectural Intelligence, 1(1), 6--. https://doi.org/10.1007/s44223-022-00004-x
    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
  2. 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
    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
    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
  3. 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
  4. 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.
    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

OTHER PUBLICATIONS

    DATA SETS

        

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