Cyber-Physical Fabrication Platform: Harnessing Wood’s Variability

Research Project 4-3 (RP 4-3)

CYBER-PHYSICAL FABRICATION PLATFORM FOR TIMBER: INLINE ASSESSMENT, TESTING AND FEATURE-RESPONSIVE FABRICATION FOR HARNESSING WOOD’S BIOLOGICAL VARIABILITY AND PRE-USE FEATURES OF RECLAIMED TIMBER BASED ON MATERIAL-MACHINE CO-AGENCY

RP 4-3 develops a cyber-physical timber fabrication platform for adaptive prefabrication with Building on the robotic prefabrication system and multi-actor fabrication methods established in during the first funding phase, the project extends the platform from project-specific flexibility toward adaptability led by material-availability. Rather than treating biological variability, irregular geometry, defects, or uncertain mechanical properties as obstacles, RP 4-3 investigates how these material features can become drivers of design, planning, and fabrication.

The project integrates inline material assessment through machine-learning methods, non-destructive testing, 3D geometry acquisition, feature extraction, adaptive fabrication planning, and feature-responsive robotic processing and joining. In close collaboration with RP 3-3, the assessed material properties and fabrication constraints will inform the design process from early planning stages onward. This enables timber elements to be assigned to suitable structural roles, joining strategies, and assembly configurations according to their estimated characteristics.

By linking material characterization, design, planning, and execution through material–machine co-agency, RP 4-3 aims to support circular, resource-efficient timber construction and increase the use of low-grade and reclaimed wood. The project will validate its methods through a demonstrator workflow and transferable data models, fabrication methods, and implementation guidelines for variability-aware timber prefabrication.

 

PRINCIPAL INVESTIGATORS

Prof. Achim Menges
Spokesperson
Institute of Computational Design and Construction (ICD)
Cluster of Excellence IntCDC

Jun.-Prof. Dr. Philippe Grönquist
Principal Investigator
Materials Testing Institute (MPA)
Institute of Construction Materials (IWB)
Cluster of Excellence IntCDC

Univ.-Prof. Dr.-Ing. Alexander Verl
Principal Investigator
Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW)
Cluster of Excellence IntCDC

RESEARCHERS

M.Sc. Tim Stark
Doctoral Researcher
Institute of Computational Design and Construction (ICD)
Cluster of Excellence IntCDC

M.Sc. Zhenxiang Huang
Doctoral Researcher
Institute of Computational Design and Construction (ICD)
Cluster of Excellence IntCDC

Dr.-Ing. Cristobal Tapia Camu
Postdoctoral Researcher
Materials Testing Institute (MPA)
Cluster of Excellence IntCDC

M.Sc. Sabrina Machanek
Doctoral Researcher
Materials Testing Institute (MPA)
Cluster of Excellence IntCDC

M.Sc. Sanoop Siby
Doctoral Researcher
Materials Testing Institute (MPA)
Cluster of Excellence IntCDC

M.Sc. Siddieq Mansour
Doctoral Researcher
Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW)
Cluster of Excellence IntCDC

M.Sc. Matthias Marquart
Doctoral Researcher
Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW)
Cluster of Excellence IntCDC

PEER-REVIEWED PUBLICATIONS

  1. 2025

    1. Aygün, D., Calepso, A. S., Yang, X., Menges, A., & Sedlmair, M. (2025). Mixing and Matching: Instruction Conveyance for Collaborative Tasks Using Asymmetric Augmented Reality Setups. 2025 IEEE Conference on Virtual Reality and 3D User Interfaces Abstracts and Workshops (VRW), 1072–1078. https://doi.org/10.1109/VRW66409.2025.00215
    2. Bechert, S., Schlopschnat, C., Göbel, M., Aicher, S., Menges, A., & Knippers, J. (2025). livMatS biomimetic shell: Structural advancements of segmented timber shells towards permanent building constructions. Structures, 79, 109524. https://doi.org/10.1016/j.istruc.2025.109524
    3. Krieglstein, J., Kolberg, J., Calepso, A. S., Kraus, W., & Sedlmair, M. (2025). A Hybrid User Interface Combining AR, Desktop, and Mobile Interfaces for Enhanced Industrial Robot Programming. 2025 IEEE International Conference on Robotics and Automation (ICRA), 4738–4745. https://doi.org/10.1109/icra55743.2025.11128291
    4. Pittiglio, A., Yang, X., Kladeftira, M., Amstberg, F., Menges, A., & Parascho, S. (2025). Augmented Human-Robot Collaborative Bending: Human-robot collaboration for biogenic material bending-active assemblies. Proceedings of the 30th International Conference of the Association for Computer-Aided Architectural Design Research in Asia (CAADRIA) 2025, 2, 315–324.
    5. Sousa Calepso, A., Kolberg, J., Bances, E., Garcia, B., Ngo, Q. Q., Siegert, J., Schneider, U., Bauernhansl, T., & Sedlmair, M. (2025). Exoskeletons and Augmented Reality: Opening Pathways to Improved Coordination in Collaborative Tasks. Human-Computer Interaction – INTERACT 2025, Article 16108. https://doi.org/10.1007/978-3-032-04999-5_29
    6. Yang, X., Amtsberg, F., Kaiser, B., Skoury, L., Stark, T., Treml, S., Opgenorth, N., Sousa Calepso, A., Sedlmair, M., Wortmann, T., Verl, A., & Menges, A. (2025). An implementation and evaluation of large-scale multi-user human–robot collaboration with head-mounted augmented reality. Advanced Engineering Informatics, 67, 103475. https://doi.org/10.1016/j.aei.2025.103475
    7. Yang, X., Pathmanathan, N., Zabel, S., Amtsberg, F., Otto, S., Kurzhals, K., Sedlmair, M., & Menges, A. (2025). Exploring the Use of Augmented Reality for Multi-human-robot Collaboration with Industry Users in Timber Construction. Proceedings of the Extended Abstracts of the CHI Conference on Human Factors in Computing Systems. https://doi.org/10.1145/3706599.3720104
    8. Yang, X., Sasikumar, P., Amtsberg, F., Menges, A., Sedlmair, M., & Nanayakkara, S. (2025). Who is in Control? Understanding User Agency in AR-assisted Construction Assembly. Proceedings of the 2025 CHI Conference on Human Factors in Computing Systems. https://doi.org/10.1145/3706598.3713765
  2. 2024

    1. Kannenberg, F., Zechmeister, C., Gil Pérez, M., Guo, Y., Yang, X., Forster, D., Hügle, S., Mindermann, P., Abdelaal, M., Balangé, L., Schwieger, V., Weiskopf, D., Gresser, G. T., Middendorf, P., Bischoff, M., Knippers, J., & Menges, A. (2024). Toward reciprocal feedback between computational design, engineering, and fabrication to co-design coreless filament-wound structures. Journal of Computational Design and Engineering, 11, Article 3. https://doi.org/10.1093/jcde/qwae048
    2. Opgenorth, N., Cheng, T., Lauer, P. R. A., Stark, T., Tahouni, Y., Treml, S., Göbel, M., Kiesewetter, L., Schlopschnat, C., Zorn, M. B., Yang, X., Amtsberg, F., Wagner, H. J., Wood, D., Sawodny, O., Wortmann, T., & Menges, A. (2024). Multi-scalar computational fabrication and construction of bio-based building envelopes – the livMatS biomimetic shell. Fabricate 2024: Creating Resourceful Futures, 22–31. https://doi.org/10.2307/jj.11374766.7
    3. Pathmanathan, N., Rau, T., Yang, X., Calepso, A. S., Amtsberg, F., Menges, A., Sedlmair, M., & Kurzhals, K. (2024). Eyes on the Task: Gaze Analysis of Situated Visualization for Collaborative Tasks. 2024 IEEE Conference Virtual Reality and 3D User Interfaces (VR), 785–795. https://doi.org/10.1109/VR58804.2024.00098
    4. Skoury, L., Treml, S., Opgenorth, N., Amtsberg, F., Wagner, H. J., Menges, A., & Wortmann, T. (2024). Towards data-informed co-design in digital fabrication. Automation in Construction, 158, 105229. https://doi.org/10.1016/j.autcon.2023.105229
    5. Wortmeier, A.-K., Calepso, A. S., Kropp, C., Sedlmair, M., & Weiskopf, D. (2024). Configuring augmented reality users: analysing YouTube commercials to understand industry expectations. Behaviour & Information Technology, 43, Article 2. https://doi.org/10.1080/0144929X.2022.2163693
    6. Yang, X., Amtsberg, F., Sedlmair, M., & Menges, A. (2024). Challenges and potential for human–robot collaboration in timber prefabrication. Automation in Construction, 160, 105333. https://doi.org/10.1016/j.autcon.2024.105333
  3. 2023

    1. Amtsberg, F., Yang, X., Skoury, L., Sousa Calepso, A., Sedlmair, M., Wortmann, T., & Menges, A. (2023). Multi-Actor Fabrication for Digital Timber Construction. eCAADe Proceedings. https://doi.org/10.52842/conf.ecaade.2023.1.417
    2. Bossecker, E., Calepso, A. S., Kaiser, B., Verl, A., & Sedlmair, M. (2023). A Virtual Reality Simulator for Timber Fabrication Tasks Using Industrial Robotic Arms. Proceedings of Mensch Und Computer 2023, 568–570. https://doi.org/10.1145/3603555.3609316
    3. Calepso, A. S., Fleck, P., Schmalstieg, D., & Sedlmair, M. (2023). Exploring Augmented Reality for Situated Analytics with Many Movable Physical Referents. https://doi.org/10.1145/3611659.3615700
    4. Kaiser, B., & Verl, A. (2023). Co-Design of Structural Timber Components Through Automated Model Generation for Manufacturing Simulation of Reconfigurable Manufacturing Systems. 2023 29th International Conference on Mechatronics and Machine Vision in Practice (M2VIP), 1–6. https://doi.org/10.1109/M2VIP58386.2023.10413396
    5. Pathmanathan, N., Öney, S., Becher, M., Sedlmair, M., Weiskopf, D., & Kurzhals, K. (2023). Been There, Seen That: Visualization of Movement and 3D Eye Tracking Data from Real-World Environments. Computer Graphics Forum, 42, Article 3. https://doi.org/10.1111/cgf.14838
    6. Sherkat, S., Skoury, L., Wortmann, A., & Wortmann, T. (2023). Artificial Intelligence Automated Task Planning for Fabrication. In K. Dörfler, J. Knippers, A. Menges, S. Parascho, H. Pottmann, & T. Wortmann (Eds.), Advances in Architectural Geometry 2023 (pp. 249–260). De Gruyter. https://doi.org/doi:10.1515/9783111162683-019
    7. Yang, X., Sousa Calepso, A., Amtsberg, F., Menges, A., & Sedlmair, M. (2023). Usability Evaluation of an Augmented Reality System for Collaborative Fabrication between Multiple Humans and Industrial Robots. Proceedings of the 2023 ACM Symposium on Spatial User Interaction, 1–10. https://doi.org/10.1145/3607822.3614528
    8. Öney, S., Pathmanathan, N., Becher, M., Sedlmair, M., Weiskopf, D., & Kurzhals, K. (2023). Visual Gaze Labeling for Augmented Reality Studies. Computer Graphics Forum, 42, Article 3. https://doi.org/10.1111/cgf.14837
  4. 2022

    1. Abdelaal, M., Amtsberg, F., Becher, M., Estrada, R. D., Kannenberg, F., Calepso, A. S., Wagner, H. J., Reina, G., Sedlmair, M., Menges, A., & Weiskopf, D. (2022). Visualization for Architecture, Engineering, and Construction: Shaping the Future of Our Built World. IEEE Computer Graphics and Applications, 42, Article 2. https://doi.org/10.1109/MCG.2022.3149837
    2. Achberger, A., Arulrajah, P., Sedlmair, M., & Vidackovic, K. (2022). STROE: An Ungrounded String-Based Weight Simulation Device. IEEE Conference on Virtual Reality and 3D User Interfaces (VR), 112–120. https://doi.org/10.1109/VR51125.2022.00029
    3. Achberger, A., Heyen, F., Vidackovic, K., & Sedlmair, M. (2022). Touching data with PropellerHand. Journal of Visualization. https://doi.org/10.1007/s12650-022-00859-2
    4. Chai, H., Guo, Z., Wagner, H. J., Stark, T., Menges, A., & Yuan, P. F. (2022). In-Situ Robotic Fabrication of Spatial Glulam Structures. Proceedings of the 27th CAADRIA Conference, Sydney, 9-15 April 2022, 2, 41–50. https://doi.org/10.52842/conf.caadria.2022.2.041
    5. Chai, H., Wagner, H. J., Guo, Z., Qi, Y., Menges, A., & Yuan, P. F. (2022). Computational design and on-site mobile robotic construction of an adaptive reinforcement beam network for cross-laminated timber slab panels. Automation in Construction, 142, Article August. https://doi.org/10.1016/j.autcon.2022.104536
    6. Fleck, P., Sousa Calepso, A., Hubenschmid, S., Sedlmair, M., & Schmalstieg, D. (2022). RagRug: A Toolkit for Situated Analytics. IEEE Transactions on Visualization and Computer Graphics. https://doi.org/10.1109/TVCG.2022.3157058
    7. Kaiser, B., Wolf, M., & Verl, A. (2022). Modular Control Architecture for Reconfigurable Fabrication Systems for Prefabrication in Construction. ISR Europe 2022; 54th International Symposium on Robotics, 1–7.
    8. Skoury, L., Amtsberg, F., Yang, X., Wagner, H. J., Menges, A., & Wortmann, T. (2022). A Framework for Managing Data in Multi-actor Fabrication Processes. In C. Gengnagel, O. Baverel, G. Betti, M. Popescu, M. R. Thomsen, & J. Wurm (Eds.), Towards Radical Regeneration (pp. 601–615). Springer International Publishing. https://doi.org/10.1007/978-3-031-13249-0_47
    9. Sousa Calepso, A., Hube, N., Berenguel Senn, N., Brandt, V., & Sedlmair, M. (2022). cARdLearner: Using expressive Virtual Agents when learning vocabulary in Augmented Reality. ACM.
    10. 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
    11. Yang, X., Amtsberg, F., Skoury, L., Wagner, H. J., & Menges, A. (2022). Vizor, Facilitating Cyber-physical Workflows in Prefabrication through Augmented Reality. CAADRIA Proceedings. https://doi.org/10.52842/conf.caadria.2022.2.141
  5. 2021

    1. Achberger, A., Aust, F., Pohlandt, D., Vidackovic, K., & Sedlmair, M. (2021). STRIVE: String-Based Force Feedback for Automotive Engineering. ACM Symposium on User Interface Software and Technology (UIST), 841–853. https://doi.org/10.1145/3472749.3474790
    2. Achberger, A., Heyen, F., Vidackovic, K., & Sedlmair, M. (2021). PropellerHand: A Hand-Mounted, Propeller-Based Force Feedback Device. International Symposium on Visual Information Communication and Interaction (VINCI), 4:1–4:8. https://doi.org/10.1145/3481549.3481563
    3. Amtsberg, F., Yang, X., Skoury, L., Wagner, H.-J., & Menges, A. (2021). iHRC: An AR-based interface for intuitive, interactive and coordinated task sharing between humans and robots in building construction. In C. Feng, T. Linner, I. Brilakis, D. Castro, P.-H. Chen, Y. Cho, J. Du, S. Ergan, B. Garcia de Soto, J. Gašparík, F. Habbal, A. Hammad, K. Iturralde, T. Bock, S. Kwon, Z. Lafhaj, N. Li, C.-J. Liang, B. Mantha, et al. (eds.), Proceedings of the 38th International Symposium on Automation and Robotics in Construction (ISARC) (pp. 25–32). International Association for Automation and Robotics in Construction (IAARC). https://doi.org/10.22260/ISARC2021/0006
    4. 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
    5. Orozco, L., Krtschil, A., Wagner, H. J., Bechert, S., Amtsberg, F., Skoury, L., Knippers, J., & Menges, A. (2021). Design Methods for Variable Density, Multi-Directional Composite Timber Slab Systems for Multi-Storey. In V. Stojakovic & B. Tepavcevic (Eds.), Proceedings of the 39th eCAADe Conference (Vol. 1, pp. 303–312). Cumincad. http://papers.cumincad.org/cgi-bin/works/paper/ecaade2021_284
    6. Qi, Y., Zhong, R., Kaiser, B., Tahouni, Y., Wagner, H. J., Verl, A., & Menges, A. (2021). Augmented Accuracy: A Human-Machine Integrated Adaptive Fabrication Workflow for Bamboo. In V. Stojakovic & B. Tepavcevic (Eds.), Proceedings of the 39th eCAADe Conference (Vol. 1, pp. 345–354). Cumincad. http://papers.cumincad.org/cgi-bin/works/paper/ecaade2021_169
  6. 2020

    1. Merino, L., Schwarzl, M., Kraus, M., Sedlmair, M., Schmalstieg, D., & Weiskopf, D. (2020). Evaluating Mixed and Augmented Reality: A Systematic Literature Review (2009 -- 2019). IEEE International Symposium on Mixed and Augmented Reality (ISMAR), 438–451. https://doi.org/10.1109/ISMAR50242.2020.00069
    2. Qi, Y., Zhong, R., Kaiser, B., Nguyen, L., Wagner, H. J., Verl, A., & Menges, A. (2020). Working with Uncertainties: An Adaptive Fabrication Workflow for Bamboo Structures. In P. F. Yuan, J. Yao, C. Yan, X. Wang, & N. Leach (Eds.), Proceedings of the 2020 DigitalFUTURES. Springer Nature Switzerland AG.
    3. Wagner, H. J., Alvarez, M., Groenewolt, A., & Menges, A. (2020). Towards digital automation flexibility in large-scale timber construction: integrative robotic prefabrication and co-design of the BUGA Wood Pavilion. Construction Robotics. https://doi.org/10.1007/s41693-020-00038-5
    4. Wagner, H. J., Alvarez, M., Kyjanek, O., Bhiri, Z., Buck, M., & Menges, A. (2020). Flexible and transportable robotic timber construction platform – TIM. Automation in Construction, Article 120. https://doi.org/10.1016/j.autcon.2020.103400
    5. Wagner, H. J., Chai, H., Guo, Z., Menges, A., & Yuan, P. F. (2020). Towards an On-site Fabrication System for Bespoke , Unlimited and Monolithic Timber Slabs. IEEE/RSJ International Conference on Intelligent Robots and Systems (IROS) Las Vegas, NV, USA (Virtual) - Workshop on Construction and Architecture Robotics, 2020. https://doi.org/10.13140/RG.2.2.14098.68802
    6. Weiß, M., Angerbauer, K., Voit, A., Schwarzl, M., Sedlmair, M., & Mayer, S. (2020). Revisited: Comparison of Empirical Methods to Evaluate Visualizations Supporting Crafting and Assembly Purposes. IEEE Trans. Visualization and Computer Graphics (TVCG, Proc. InfoVis 2020).

OTHER PUBLICATIONS

  1. 2025

    1. Mansour, S., Lechler, A., & Verl, A. (2025). Autonome mobile Roboter: Zukunft der Bau-Fertigung/Autonomous mobile robot: Future of manufacturing in construction. Wt Werkstattstechnik Online, 115, Article 06. https://doi.org/10.37544/1436-4980-2025-06-122
  2. 2022

    1. Wagner, H. J. (2022). Digitale Fabrikation: Was bringt uns die Zukunft? In 2. Internationaler Kongress Holzbau: Technik+Wirtschaft (HTW) (pp. 91–102). FORUM HOLZBAU.

DATA SETS

  1. 2022

    1. Abdelaal, M., Schiele, N. D., Angerbauer, K., Kurzhals, K., Sedlmair, M., & Weiskopf, D. (2022). Supplemental Materials for: Comparative Evaluation of Bipartite, Node-Link, and Matrix-Based Network Representations [DaRUS]. https://doi.org/10.18419/DARUS-3100
    2. Wortmeier, A.-K., Calepso, A. S., Kropp, C., Sedlmair, M., & Weiskopf, D. (2022). Replication Data for BauHCI Video Analysis [DaRUS]. https://doi.org/10.18419/darus-2117
  2. 2021

    1. Kaiser, B. (2021). Replication data for: Planning of Curvature-Optimal Smooth Paths for Industrial Robots Using Neural Networks. https://doi.org/10.18419/darus-2126

    

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