Skeletal composites: robotic fabrication processes for lightweight multi-nodal structural components

The research presented in this chapter describes the novel robotic fabrication strategies for multi-nodal structural components made from lightweight fiber composite materials. The paper contextualizes the research within a larger area of composite manufacturing in architecture and focuses on the developed methodologies for adaptive, material-efficient production. This research builds on coreless filament winding processes that eliminate the need for large surface molds and wasted materials for composite production. This process allows for large geometrically differentiated structural building components to be easily produced adaptively for architectural applications. The research tests the production of complex components for a vertical lattice structural system. The multi-nodal structural components enable continuous material and fiber orientations across the intersections of the lattice while simplifying connections. Key improvements presented in this paper included the robotic assembly process for the reconfigurable winding frames that reduce assembly times and increase accuracy, computational techniques for developing winding syntax, and physical simulation of material orientations for robotic path planning. This is followed by a conclusion and outlook to discuss the tested results on a full-scale demonstrator and the future design potentials.