RobTech - Robotic Technologies for a Non-Standard Design and Construction in Architecture

Investigating Robotic Technologies for a Non-Standard Design and Construction in Architecture

An FCT Research Project —

ISBN 9789898527066

9 789898 527066

90000 >

Technologies

for Non-Standard

Design

in

Robotic

and

Architecture

Construction

An FCT Research Project — Robotic Technologies for Non-Standard Design and Construction in Architecture — Edited by José Pedro Sousa Foreword by Branko Kolarevic

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Foreword Introduction Laboratory Research Discussions Publications Events Outputs Lab Life Credits

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Foreword

by Branko Kolarevic

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The Craft of Robot Making

Architecture as a material practice implies that making, the close engagement of the material, is intrinsic to a design process. Making, however, is increasingly being mediated: today it is the robotic machines and not the hands of the maker that mostly shape the material parts and place them in the right locations in the assemblies. New techniques based on parametric design, digital fabrication and robotic assembly are redefining the relationships between design and production, enabling a closer interrogation of materials from the earliest stages of design.

Like some resurrected craftsmen of the past, designers today are increasingly using new digital techniques and robotic technologies to explore material effects, such as pattern, texture, relief, or varying properties, as a means through which building surfaces could manifest the design intent, often at different scales. As surfaces become more complex in their form, shape, composition, and appearance, the generation and manufacturing of material effects becomes a locus of design and production efforts. And in the process, architecture could be seen as an art and craft of digital, robotic making.

The various processes of digital fabrication have provided designers with an unprecedented capacity to control the parameters of material production, and to precisely craft the desired material effects.

Knowing the production capabilities and availability of particular digitally-driven fabrication and robotic assembly equipment enables designers to design specifically for the capabilities of those machines.

The consequence is that designers are becoming much more directly involved in the fabrication processes, as they create the control data that drives the machines.

The remarkable research project on “Robotic Technologies for a Non-Standard Design and Construction in Architecture” featured in the book have utilized parametric design techniques and the digital production technologies in an innovative fashion. Both the parametric description of the geometry and the resulting control code for robotic fabrication and assembly were crafted through a series of iterative

steps, in which small quantitative changes in the values of certain parameters would produce qualitatively different results.

Just as craftsmen of the past, the craftsmen of the digital age – the designers working with virtual representation of the material artifacts – would seek out unpredictable outcomes by experimenting with what the medium and the tools have to offer. These digital craftsmen were in continuous control of design and production and relied on iterative, cyclical development based on feedback loops between the parametric definition of the geometry and the robotic production of material artifacts. The designers were constantly looking for particular affordances that a chosen production method could offer or unexpected resistances encountered as they engaged a particular tool and a piece of material.

It is this constant, cyclical interaction between the “work of the mind” and the “work of the robot” that provides a particularly rich and rewarding context for design, in which designers go from a parametric model of the geometry to a simulation of the actual material production and then back to the parametric representation for another iterative refinement of the geometric representation and its material manifestation. It is pure craft – the craft of robotic making.

Branko Kolarevic Faculty of Environmental Design, University of Calgary

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Introduction

by José Pedro Sousa

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Robotic Technologies for a Non-Standard Design and Construction in Architecture.

A Research Experience.

On July 2013, the Faculty of Architecture at the University of Porto (FAUP) and the Institute for Systems and Computer Engineering, Technology and Science (INESC TEC) started a 2-year research project on the use of robotic fabrication technologies in architecture and building construction. Funded by the national Foundation of Science and Technology (FCT), this was a unique and vibrant experience on a new field for the two institutions, which spread out beyond the scope of the research group to gather the interest of many other agents. Being one of the outputs of the research project, the present book provides a brief and illustrated introduction to this experience.

The Context After Crafts and Mass Production paradigms, architecture is facing today new production possibilities that support geometric freedom and mass customization. A close look into contemporary architecture reveals that many of the most innovative built works around the globe are resulting from an increasing interest in exploring unique forms and constructive solutions, which could hardly be conceived and materialized a few years ago. Over his seminal work, Branko Kolarevic [1] has shown how the combined use of computer-aided design and manufacturing technologies (CAD/CAM) has enabled such creative endeavors.

Non-standardization, as announced before by Bernard Cache [2] and Freferic Migayrou [3], is a true design and construction opportunity in architecture today. With this new technological advent, architects can explore an expanded world of design and material solutions at all scales to face the critical challenges of our age. At the same time, the building material and construction companies that seek to stay innovative and competitive are embracing this new production paradigm.

This global tendency naturally affects the national context. Recent Portuguese architecture has revealed an interest in exploring more intricate geometric solutions (e.g. Siza and S. Moura’s Serpentine Gallery Pavilion 2005, or Luis Pedro Silva’s Passenger Terminal) while, at the

same time, a growing number of foreign architects, with different ideas, have started to build in the country (e.g. Rem Koolhaas’ Casa da Música or Amanda Levete’s EDP Cultural Center in Lisbon). When facing such complex design challenges, the Portuguese building industry reveals strong limitations because it is still rooted in mass-production processes based on standardization. This situation becomes more critical when the current economical crisis in the country has forced their internationalization, placing them in direct competition with advanced global companies. Thus, the competitiveness of the Portuguese building industry is more than ever tied with its capacity to innovate at the global scale, responding to contemporary non-standard design challenges. Refactoring their products and services to embrace flexibility, sustainability and customization seems the true key to strength the economy of this sector.

The Foundations Facing this challenge, the Research Project featured in this book was planned by focusing in the most flexible digital manufacturing technology available today – the Industrial Robot – to investigate its potential to support non-standard modes of design and construction in architecture. Developed and widely implemented in other industries (e.g. the automotive), robots are advanced computer-driven machines, which, unlike other CNC equipment, can perform multiple fabrication actions (e.g. handling, milling, welding, folding…) with different materials sizes and shapes. Since Gramazio and Kohler introduced them at the ETH Zurich in 2005 [4], a growing number of researchers and schools started to explore the use of robots in architecture. At the time this research project proposal was submitted for funding, there were 18 established robotic architecture labs in the world [5]. So, by looking for uncovering the potential of robotics in architecture and building construction, the research project would establish the first robotic architectural laboratory in Portugal and thus join the few similar initiatives in the world by then.

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Introduction

by José Pedro Sousa

Together with colleagues A. Paulo Moreira and Germano Veiga, the research project was structured for a 2 years length time, comprising a set of tasks related with: “Survey”, “Research”, “Management and Monitoring”, and “Diffusion”. The following table summarizes the entire research plan.

R E S E A RC H P ROJ ECT ST RU CT U R E I Survey

1.1 Computational design 1.2 Robotic Technologies 1.3 Architecture

II Research

2.1 Material 2.2 Design 2.3 Technology

Additive Fabrication Subtractive Fabrication Revising Tradition Innovative Installation Alternative Robotic System

III Management and Monitoring

3.1 Creation of the Laboratory 3.2 Discussion

IV Diffusion

4.1 Website 4.2 Catalogue 4.3 Conferences, Workshops and Final Exhibition

Being the central activity of the project, the “Research” task was subdivided in three parts to investigate Material, Design and Technology goals. The following table summarizes the tasks planned and developed in the research project.

R E S E A RC H E X P E R I M E N TS Material

Pixel Wall Striated Wall Brick Tower CG Column Face Bricks Clover Wall Diamond Screen Wooden Connections Serpentine Structure Nasoni Keystone Ruled Concrete

Cork Wood Bricks (EPS) Bricks (EPS) Bricks (EPS) Cork Wood Wood Wood Stone (EPS) Concrete + EPS

Additive Additive Additive Additive Additive Subractive Subractive Subractive Subractive Subractive Subractive / Formative

Assembly Assembly Assembly Assembly Assembly Water-Jet Cut / Milling Milling Milling Milling Milling / Hotwire Cut Milling / Hotwire Cut

Design

Hestnes Column CorkCrete Arch

Bricks (EPS) Cork + Concrete + EPS

Additive Subractive / Formative

Assembly Milling / Hotwire Cut

Technology

SPIDERobot

…

Additive

Assembly

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As an underlying principle, the work had to focus its attention in the national context (e.g. materials and building construction traditions) as well as in the state-of-the-art at the international level. The research project thus sought to promote innovation at both the local and global levels. To assure its success, a multidisciplinary team was assembled, bringing together the FAUP, its CEAU research center, and the INESC TEC institutions.

The Experience The research project officially started in July 2013. The first concerns were related with finding the space to set up the new laboratory, and purchasing the industrial robot. After some difficulties, the University of Porto (UP) lent an old building in the center of the city of Porto to FAUP, which required some crucial renovation works. Regarding the robot, after an early review of the options, the selection fell on the KUKA KR120 R2700 HA. Since both the space renovation and the robot delivery took a few months, the team started with the three Survey tasks. The selection, analyses and discussion of references on Computation, Robotics and Architecture, helped in specifying the following Research tasks and in realizing other equipment needed for the robot and the laboratory.

On December 2013, the team from FAUP was officially accepted by the CEAU as the new research group called Digital Fabrication Laboratory (DFL). On the Summer of 2014, the DFL could finally move to the renovated space. To provide the industrial background for the development and assessment of the research tasks, it was important to seek and established partnerships with Portuguese material companies. With their support, cork, wood, concrete, bricks and expanded polystyrene (EPS) were selected for the non-standard design and construction challenges using robotic technologies. This was a very enriching period, which resulted in the production of a series of digital and physical models, prototypes and installations. Overtime new, the laboratory noticeably grew booth from the know-how (i.e. team’s expertise) and the resources levels (e.g. laboratory’s tools and capabilities).

After 10 months, the Material tests were almost concluded and gave place to the Design Research, with the Hestnes Column and the CorkCrete Arch works. While the first one attempted to revise brick architecture tradition based on the works of Portuguese architect

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Introduction

by José Pedro Sousa

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Raúl Hestnes Ferreira, the second one conceived and fabricated a new building construction system based on cork and glass-fiber reinforced concrete (GRC). Running in parallel with this material and design-based tasks conducted at the DFL, an alternative concept for a robotic technology based on cable system –the SPIDERobot- was developed at the INESC TEC. A fully functional prototype of the technology was programed and built to prove that concept.

Overtime, the development of the Research Project was widely reported through a series of diffusing actions and events, like: publications, conferences, exhibitions, videos, website, social media platforms, workshops, class assignments, visits, etc. For its conclusion on the 30th November 2015, it was organized a final public event at FAUP including: A comprehensive communication of the research project work; A discussion with external guests on the relevance of the achievements and the impact of such technologies in architectural education, practice and industry; The public display of the CorkCrete Arch installation in the garden of FAUP; The opening of an exhibition in gallery at the DFL.

modes of design and construction in architecture. It is important to highlight that this fact has a double importance. Besides being the technical solution for complex design aspirations, their knowledge can also act as a trigger for design imagination and efficiency. Among the practical works, the CorkCrete arch and the SPIDERobot can be considered the most original and relevant contributions in the field.

By considering the very short length of the project (i.e. 2 years), the number and quality of the outputs achieved is significant. They comprise the production of several publications, communications, physical models, prototypes, installations, digital media contents, technologies and custom-made tools. Besides this quantitative list of practical results, the creation of the new laboratory and the consolidation of a new and skilled research team are, from a personal point of view, the most precious outcomes of this project. Besides being the reason supporting the previous outputs achievement, they assure the future extension of the work, thus justifying even more the investment that FCT has made on this project over the last 2 years. Thanks to this funding institution, the differences between the start and the end of this project are immense, both at the scientific and the resources levels. It would be great if this publication could convey a bit of this exciting and productive adventure in the field of robotic technologies in architecture.

Conclusion This research project made possible to start a new research field in Portuguese architecture scene. The DFL was set at FAUP and CEAU, and is now actively participating in the worldwide discussion on the use of robotic technologies in architecture. Simultaneously, the INESC TEC extended its expertise on robotics into the field of building construction.

With the conclusion of the research project, it is possible to affirm the accomplishment of the proposed goals. For instance, the interest of major national companies of the building industry (e.g. Amorim Isolamentos, Mota Engil, Cerâmica Vale da Gândara or Valchromat) in developing formal initiatives for collaboration, illustrate the importance the work has reached at the local level. At the same time, the acceptance to publish and communicate the work in the most important international conferences in the field, can testify its relevance at the global level. At the practical level, the diverse Research tasks confirmed the potential of robotic technologies to address non-standard

Jose Pedro Sousa Faculty of Architecture, University of Porto + DFL / CEAU Principal Investigator of the research project

[01]

Kolarevic, B. (Ed.)(2003): Architecture in the Digital Age. Design and Manufacturing. New York: Spon Press. Kolarevic, B. & Klinger, K. (Eds.)(2008): Manufacturing Material Effects. Rethinking Design and Making in Architecture. New York: Routledge

[02]

Cache, B. (1995): Earth Moves. Cambridge MA: MIT Press

[03]

Migayrou, F. (Ed.)(2005): Architectures Non-Standard. Paris: Center Georges Pompidou.

[04]

Gramazio, F.; Kohler, M. (2007): Digital Materiality in Architecture. Baden: Lars Müller

[05]

Brell-Cokcan, S.; Braumann, J.: World map of Robots in Architecture, Association for Robots in Architecture, TU Vienna, in http://www.robotsinarchitecture.org (consulted in April 30, 2012):

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Laboratory

Existing Space

Finding the space to setup the Digital Fabrication Laboratory (DFL) was the first and one of the most difficult tasks of the project. The installation of the industrial robot and the fabrication nature of the work required a generous working area and volume. Due to space limitations, it was not possible to host the research project at the FAUP facilities. So, the University of Porto approved the use of an old 3-storey building in the city center of Porto to install the future Laboratory. The poor condition of the building demanded some important renovation works.

Laboratory

Existing Space

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Laboratory

Renovation Project

Laboratory

Renovation Project

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The project for the Laboratory was structured over the 3 building floors. The fabrication and robot rooms (1) (2) were organized in the ground floor. The design studio (3) and the meeting room (4), with the 3D printer and paper cut machine, were placed in the 1st floor. A gallery space (5) to exhibit the physical productions made by the Laboratory was planned for the 2nd floor.

The remaining free rooms (6) can be used for materials storage and, in future, to expand the activities of the Laboratory.

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Laboratory

Renovation Works

Laboratory

Renovation Works

The renovation works were essentially in the ground floor. Besides changing the entrance door, the existing corridor disappeared to increase the space of the fabrication area. In the robot room, the ceiling slab was demolished to create a double height space, and the concrete foundation for the robot was built in. The wall between these spaces saw the opening of two doors and a wide window for surveying the robotic works. In the first floor, the design studio received the addition of new windows and, together with the ground floor areas, got a fresh painting. The electrical installation and computer network were also revised.

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Laboratory

Robot Installation

The arrival of the robot, a Kuka KR120 R2700 HA, was an epic day. Manufactured in Germany, it was shipped and stored in the South of Portugal. By the end of the renovation works, he travelled to Porto on a big truck. Moving the robot to the building with a forklift faced some unexpected setbacks. For instance, 2cm of the beam’s stucco in the entrance tunnel had to be removed, and a door inside of the building was demolished to allow the robot reach its room. When finally arrived to the platform, it was officially named (Coronel) Pacheco, like the name of the square in front of the Laboratory.

Laboratory

Robot Installation

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Laboratory

Final Space

Finally, the Laboratory was furnished and, by the Summer 2014, the research works started to take place in the new facilities. Overtime, the materials for the fabrication tests (e.g. cork, bricks, wood, EPS...) and the new tools and technological equipment (e.g. robotic and fabrication tools, computers, printer...) started to arrive to the Laboratory, which became known as the DFL, Digital Fabrication Laboratory. With the DFL, the FAUP became the first architecture school in Portugal equipped with an industrial robot.

Laboratory

Final Space

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Material Research

Process:

Material:

Additive Fabrication

Cork

Robotic Assembly

Pixel Wall The Pixel Wall was developed as part of the “Now & Next” installation developed for the 5th International Insulation Cork Conference in Lisbon. Commissioned by Amorim Isolamentos, it wanted to unveil different possibilities to use cork in architecture by means of digital fabrication technologies.

The Pixel Wall is a 2x2 meters wall part built as an assembly of standard cork blocks. Instead of customizing the geometry of each element, the Pixel Wall explored the use of the industrial robot to place identical blocks in different specific positions in space to materialize irregular customized wall parts. The fabrication of this structure was the first experiment with the robot at the DFL. By then, there was no gripper available. So, the team engineered the use of double side tape in the robot to grab the cork bricks. After the precise layering of each level, the glue was manually deposited on the brick’s top surface before the next one.

Although the automation was not fully achieved in the assembly process, this experiment allowed testing the computational design of irregular brick structures and the digital programming of their robotic fabrication. Besides this technological side, the Pixel Wall demonstrated the possibility to produce acoustic and thermal insulation walls in cork with variable and customized material effects. Without changing their production processes based on standardization, the cork industry can expand the application of their product using robotic assembly methods.

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Material Research

Pixel Wall

Material Research

Pixel Wall

Digital design generation A computational algorithm transformed a gray scale image into a 3D surface, which was then converted into a variable assembly of standard bricks. The final solution had 2x2 meters and was divided in four parts, in order to match the range of the robot and also the transportation requirements.

The robotic assembly process The robot was programmed to pick the bricks from a table placed next to it. The simulation of the robotic movements in space allowed detecting and preventing collisions.

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Material Research

Pixel Wall

At this moment, there was no end-effector for the robot. So, a double-side tape was used to pick the cork bricks from the table. The four assembled parts were then prepared to be shipped to Lisbon in a truck.

Material Research

Pixel Wall

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Material Research

Pixel Wall

The Installation This Pixel Wall was installed at the Sana Metropolitan Hotel in Lisbon to be shown during the Amorim Isolamento’s 5th International Insulation Cork Conference.

The four parts were fixed to an aluminum structure. The final undulating pixel effect can perform as an effective surface for acoustic insulation.

Material Research

Pixel Wall

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Material Research

Process:

Material:

Additive Fabrication

Wood

Robotic Assembly

Striated Wall The construction of wooden structures was the second step to continue testing the robotic assembly processes. This experiment was inspired by the “Sequential Wall” work by Gramazio & Kohler, and started by developing computational design methods to generate different solutions for a partition wall structure. This process was paired with the production of 3D printed models, which allowed the physical visualization and evaluation of the different striated structures.

The Striated Wall version selected for fabrication was made out of 525 wooden bars. By considering the action range of the robot, the solution was divided in four parts, which were then fabricated in the horizontal position. This time, a vacuum gripper was mounted in the robot to pick and place the wooden bars in the right position. Bein one of the first robotic experiments in the project, the speed of the robot was limited for safety reasons.

The whole process went very well, but some minor deviations in the position of some bars could be detected. This is explained by the occurrence of some material slippage in some points because the glue did not dry fast. Despite this fact, the experience and the global result clearly revealed the potential of robotic technology to handle with non-standard material assemblies. The fact that the structure was displayed in a different position from the one it was fabricated was intriguing. It made everyone thinking about how it had been produced with the robot.

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Material Research

Striated Wall

Material Research

Striated Wall

Computational design exploration Different strategies for wooden assemblies were conceived and modeled using computational design methods. Each of the solutions was made out of different systems of bars arrangements. The Striated Wall version selected for fabrication emerged from this research. The continuous variation of its wooden bars positioning challenged the use of robotic fabrication processes.

The design exploration involved the production of several 3D printed models. Due to the geometric intricacy of the structural designs, it was difficult to create physical models for visualization by other means. The final Striated Wall corresponds to the white 3D printed model.

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Material Research

Striated Wall

The robotic fabrication and final assembly The Striated Wall was made out of 263 bars with 43x44x380mm, and 262 bars with 43x44x195mm. Those 525 wooden bars were conveniently prepared to facilitate feeding then the robot. The overall geometry of the structure was divided in four parts to be manufactured in the horizontal position, two at the same time. Thus, after two fabrication rounds, the Striated Wall parts were ready to be manually assembled in the vertical position, and installed in the entrance of the DFL.

Material Research

Striated Wall

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Material Research

Striated Wall

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Material Research

Process:

Material:

Additive Fabrication

Bricks (EPS)

Robotic Assembly

Brick Tower Brick construction counts with a long and rich aesthetic and structural tradition in architecture, which can be traced back to the origins of our civilization. However, despite the remarkable works of F. L. Wright, L. Kahn, E. Dieste or A. Aalto in the 20th century, the brickwork of more irregular geometries is difficult to be achieved by manual means. In this context, the Brick Tower project wanted to compare two different fabrications processes a robotic and a manual one aided by a video projection technique.

The geometry for the Brick Tower was conceived with central symmetry to generate two identical parts. Using each of them, the two different fabrication processes could be tested under the same design condition. The robotic assembly process was based on the know-how acquired in the previous tests, but included now a wooden ramp to serve as a brick dispenser. Initially, a basin with glue was used to dip the bricks before placing them in the structure, but this automated process was abandoned because it wasted too much glue. The manual assembly implied fixing a video projector over the table. Using parametric design, the sections of the different bricklayers were generated and then conveniently deformed in perspective, to assure the right proportion of each unique projected drawing. In both experiments, the glue was manually placed over the bricks.

The development of this test proved the highest level of precision and speed of the robotic fabrication process. However, in those circumstances where these technologies are not available, the manual system proposed can be an interesting option to overcome human limitations when interpreting and assembling irregular brick structures.

Both experiences contribute to keep alive the art and traditions of brick construction today.

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Material Research

Brick Tower

Material Research

Brick Tower

The 3D printed model of the Brick Tower proved the geometric concept of its design.

The overlap and rotation of the two identical parts created the model of the complete and formally continuous Brick Tower.

The computational design generation The geometric concept for the Brick Tower was based on a central symmetry to create two identical parts for running the two fabrication experiments under the same design condition. This concept also allowed the development of the project by modeling parametrically just one half of the Tower. Thus, its surface was algorithmically subdivided into a progressive set of sections, points and boxes (i.e. bricks). The introduction of two openings in the design of the Tower increased the complexity at the computational level. The bricks had to rotate in variable angles to adapt to the different, and sometimes split sections.

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Material Research

Brick Tower

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The robotic assembly process of a Brick Tower half The robot movements were simulated to prevent collisions along the process.

It also allowed checking the right sequence for the assembly of bricks.

In a first trial, a basin filled with glue was used to automatically dip the bricks before placing them in the structure. However, this process was abandoned because it wasted a considerable amount of glue. For this experiment, the robot picked the bricks on a custom-made ramp. After layering each level of bricks, the glue was manually depositioned on their upper surface.

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Material Research

Brick Tower

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The placement of the bricks was guided by the projection of two overlapping figures. The dark one corresponded to the position of the bottom face of the brick. If it was placed right, the red cross had to correspond exactly to the upper face of the brick. By projecting the next level of bricks on the top of the last layered ones, this technique also helped in identifying the area to put the glue.

The manual assembly process aided by video-projection of a Brick Tower half The environment was setup by carefully checking the perspective deformation over the table, both in depth and in height. This iterative adjustment was run interactively with the help of a parametric design model.

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Material Research

Brick Tower

Material Research

Brick Tower

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The assembly of the complete Brick Tower The comparison between the two fabricated halves show some minor deviations between them. Nonetheless, their final assembly together confirms the geometric continuity between them. The Brick Tower was installed and exhibited in the DFL gallery.

Material Research

Brick Tower

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Material Research

Process:

Material:

Additive Fabrication

Bricks (EPS)

Robotic Assembly

CG Column The integration of robotic technologies in architectural education was tested in one assignment of the 3rd year Constructive Geometry (CG) course at the FAUP. During 5 classes, the students had to design a non-standard and self-supporting brick structure, by considering 500 bricks (25x25x5cm) at their disposal. One of the designs would then be selected by the class to be fabricated by the robot at the DFL. The techniques for the design exploration were purposely unrestricted. Organized in groups of two, the students started with manual experimentations with small EPS bricks while used the computer to develop some explicit and parametric models. To help framing their design imagination, an introduction to the robotic fabrication process was given at an early stage, during a visit to the DFL. On a mid-term review in the 4th class, the students had to present their solutions with the help of posters and 3D printed models and vote for the best project. This process elected a beautiful curvilinear column to be fabricated at 1:1 scale. The students gathered at the DFL and experimented programming and controlling the robot. The CG Column was fabricated and assembled in two parts. The result presented interesting material effects created by the differentiated brickwork.

This was an innovative and successful pedagogic experience in the school. In a short assignment, the students were able to develop a design project from its conception to its fabrication, which, furthermore, dealt with some geometric complexity. They also realize that the use of EPS bricks instead of ceramic ones resulted only from limitations of the Lab in moving heavyweight constructions. The learning experience could thus be directly applied to the use of real building bricks. The nature of this experience also recalled the influence that material and building methods can have at early stages of the design conception in architecture.

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Material Research

CG Column

Material Research

CG Column

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The production of 3D printed models helped in the evaluation of the assembly details and the structural integrity of the design proposals.

Due to their intricate geometry, it would have been very difficult to physically visualize them without the use of 3D printing technology.

The design exploration in the class Organized in groups of 2, the students started imagining design solutions for non-standard brick structures by playing with computer models and EPS bricks. A visit to the DFL informed about the limitations and potentials of robotic fabrication technologies in the automated assembly of irregular structures. In the mid-term review the students presented their solutions and voted for their preference.

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Material Research

CG Column

Material Research

CG Column

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The robotic fabrication At the DFL, the students tried by themselves to run the robot. During the process, some extra bricks had to be manually placed to support the structure. In a future scenario, the placement of those bricks can be anticipated and included in automated assembly routine. The built structure was installed in the gallery space of the DFL and demonstrated the successful accomplishment of the two assignment goals: the non-standard design and the self-supporting condition.

The elected solution for fabrication The most voted design for robotic fabrication was the CG Column conceived by the students Saule Grybenaite and Jorge Juan Pérez. By featuring central symmetry, it could be fabricated in two identical parts.

Material Research

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CG Column

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Material Research

Process:

Material:

Additive Fabrication

Bricks (EPS)

Robotic Assembly

Brick Faces The computational design and robotic fabrication of brick structures was mastered with the previous practical experiments. Thus, the challenge to participate in two artistic events was accepted by the DFL as an opportunity to present, in the public realm, two installations produced in such a way. The idea of conceiving brick structures based on the shape of a face emerged as the common design concept for both interventions.

The first Brick Face installation took place during the 2015 Creative Camp in the city of Abrantes. As one of the entities selected to participate in this international urban art festival, the DFL conceived the Lucky Face installation. Starting by scanning the face of a local citizen through a photogrammetry process, the resulting point cloud was converted into a surface, which was then transformed into a brick assembly. In this digital process, different brickwork strategies were explored using 3D printed models to examine them. The Lucky Face was fabricated following the video projection technique tested in the BrickTower installation. It was then assembled and installed in the Isabéis Decorações store. The visitors were then invited to deposit a written note inside the face with a personal wish for the city of Abrantes.

The second Brick Face installation was created for the OFFF Festival in Porto in the Batalha Cinema. Designed by architect Artur Andrade and built in 1947, this is iconic building of the city has been abandoned over the last years. Since this kind of unused spaces are usually sealed with brick walls to prevent their clandestine occupation, it seemed thought provoking to use the face of the architect to generate a brick wall that could call the attention to this problem. Besides this analogy, it was possible to see through the architect’s eyes a couple of pictures of the Batalha Cinema full of people, which were taken when it was a popular venue. Named as FaceOFFF, this wall was robotically fabricated in 8 parts at the DFL and then moved to the cinema where it was installed for the show.

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Material Research

Brick Faces

The design concept of the Lucky Face The face of an inhabitant from the city of Abrantes was converted into a brick wall representation. Once installed in the storefront, the visitors could write a wish on a ticket and throw it inside of the brick face. The wish tickets could be seen from the outside of the building. The brickwork strategy was refined with the help of several 3D printed models. It was decided to assemble the bricks in vertically aligned columns.

Material Research

Brick Faces

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Material Research

Brick Faces

The fabrication and installation The Lucky Face structure was manually assembled with the help of a video projection technique. Given that there was no robot available in the Abrantes, this technique permitted the exploration in-situ of a robotically inspired design strategy.

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Material Research

Brick Faces

The design concept of the FaceOFFF The place of the OFFF festival was the Batalha cinema in Porto, which was designed by architect Artur Andrade. The showcase room in the upper floor was chosen for the DFL’s intervention – the Face OFFF.. Conceptually, this work started by abstracting the face of Artur Andrade into an assembly of bricks. Computational design techniques were employed in this formal and geometric translation. The resulting brick wall was divided in eight parts to optimize the range of the robot and the transportation. A facial expression was introduced in the FaceOFFF wall to intensify the engagement with the visitors.

Material Research

Brick Faces

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Material Research

Brick Faces

The fabrication and installation The robotic assembly process happened at the DFL using the vacuum gripper tool. The dimensions of the parts challenged the range limits of the robot. The eight parts were fabricated in 2 afternoons and then shipped to the Batalha cinema, where they were assembled in one morning. During the OFFF Festival, a set of lights added a colorful dimension to the installation, which served as the background for recording a serious of interviews with the guest artists of the event.

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Material Research

Process:

Material:

Substractive Fabrication

Bricks (EPS)

Robotic Assembly

Clover Wall The Clover wall was the first material experiment with subtractive fabrication. Together with the Pixel Wall, it was part of the “Now & Next” installation developed for the 5th International Insulation Cork Conference in Lisbon. Commissioned by Amorim Isolamentos, it sought to unveil different possibilities to use cork in architecture by means of digital fabrication technologies.

The Clover Wall is a 2x2 meters wall part, which explored the possibility of perforating cork, a 100% natural and recyclable material produced in Portugal. To challenge the potential of robotic production, the design of the openings was defined by the ruled surface geometry resulting from lofting a circle with a clover-shape contour. Since regular 3-axis CNC machines could not fabricate such perforations, this experiment used a water-jet cutting system mounted in a robot at CEIIA company in Porto. Unlike many building construction materials, cork is suited for this kind of wet fabrication process, which produces a smooth finishing surface with just a single cutting pass. However, due to the slanting geometry of the openings depth and the near-zero thickness of the water jet, each hole had to be cut following two different contours in order to be possible to remove the inner part. A later experience with robotic milling surpassed that limitation. The thickness of the milling tool allowed the extraction of the resulting interior piece with just a single cutting pass. Thus, this last fabrication process proved to be more flexible than water-jet to embrace the production of a wider range of geometric solutions.

The Clover Wall installation ended up demonstrating the possibility to produce interior wall partitions in cork. This application can be an interesting opportunity for this traditional Portuguese material since the design exploration of variable visual permeability can be coupled with the acoustic properties of this natural material.

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Material Research

Clover Wall

The design and fabrication processes The geometry of the openings was based on a loft between a circle and a clover contour.

Its design was also studied to assure the geometric continuity between panels. As a result, the Clover Wall presented a different material effect on each side. The robotic fabrication employed a water-jet system mounted in an industrial robot. Given that cork is a soft material, this process could cut through the panels in a single pass while leaving a precise and smooth finishing.

Material Research

Clover Wall

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Clover Wall

The installation The Clover Wall was installed at the Sana Metropolitan Hotel in Lisbon to be shown during the Amorim Isolamento’s 5th International Insulation Cork Conference. The eight panels were fixed to an aluminum frame structure. The future developments of this work should explore connection systems that could avoid or hide the use of such supporting structure.

Nonetheless, the Clover Wall proved to be an interesting solution for dividing spaces and filtering light, while acting as an acoustic surface.

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Material Research

Diamond Screen The industrial research partner Valchromat challenged the DFL to design a structure to be shown in an architectural conference event.

Being placed next to the company’s stand, the structure had to show some of the unique features of this material. This invitation was accepted as an opportunity to test the use of a robotic subtractive process with wood, and show the result in the public realm.

Valchromat is a wood-based material, which is produced by a Portuguese company and available in multiple colors. Thus, it was decided to produce 3 sandwich panels, using the grey color on one side and a warm color (i.e. yellow, orange, red) on the other side. A parametric design strategy was then employed to design the perforations of the screen wall, which were based on a diamond-shape. While standard repetitive openings were applied in the exterior grey panels, a set of differentiated ones was assigned to the internal colored panels. This system of sandwich panels allowed for modulating light effects and organizing space. The robotic cut of these non-standard panels only employed 3-axis movements to create a more abrupt transition between the two layers of Valchromat. This process produced more intense light and shadow effects.

The structure was exhibited in the Silo Auto, which is an iconic parking building in Porto. By folding its panels, the screen can assume different configurations in space, from a flat wall to a triangular prismatic column. The user can also play with the contrast between the continuous monotonous gray color on one side and the vivid warm colors on the other. Besides showing the aesthetic potential of this material, this project also demonstrated the possibility for its design customization using robotic fabrication technologies.

Process:

Material:

Substractive Fabrication

Wood

CNC Cutting

Valchromat (EPS)

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Material Research

Diamond Screen

The computational design Using parametric design, a series of diamond-shape based perforations was conceived to create a customized screen in Valchromat. The exterior panels are grey and their repetitive openings reveal the warm colors of the interior panels - yellow, orange and red. These color panels have differentiated perforations to modulate the light. The Diamond Screen is a folding structure that can range from a flat wall position to a triangular column.

Material Research

Diamond Screen

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Diamond Screen

The robotic production and installation The panels were fabricated in three stages. The first one consisted in the vertical cut of the openings in all panels. Then, after arranging and gluing them in sandwich panels, they were placed on the robot’s table to cut their inclined edges at once. The final operation was the engraving of the letterings, which required changing the tool. The panels were fixed against each other with hinges, to allow folding into different configurations. During the event at the Silo Auto building, the Diamond Screen was installed in an open position to show both sides of the structure.

Material Research

Diamond Screen

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Material Research

Diamond Screen

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Material Research

Wooden Connections The exploration of robotic subtractive fabrication processes with wood led to the research of three different types of material connections.

The first one was based on the wooden joint in Kengo Kuma’s Chidori Furniture. The development of a parametric model of its detail made possible its geometric adaption to non-orthogonal situations. This condition required cutting the wooden bars following different orientations. Developed at the computational design level, this research was demonstrated with 3D printed models. The routines for the robotic cutting were investigated in the third test.

The second experiment aimed at investigating the connection between panels meeting in non-orthogonal directions. In the ICD’s 2011 Summer Pavilion, Achim Menges explored the production of finger connections to address this challenge. By taking this example, a series of computational models were developed to expand the tectonic possibilities of finger joints. The production of 3D printed models verified the geometry of the panels and their interlocking feature. One of the designs was used to test the robotic fabrication of the finger joint in a Valchromat panel.

The third test looked for designing and materializing a reciprocal structure made out of wooden bars. Designed in a non-planar condition, their connections became differentiated and distorted. The use of the robot was thus essential to solve this material connection. A series of eight bars were thus cut in a single robotic milling operation.

This was a very opened research on wooden connections. Given that cutting repetitive and orthogonal connections is as easy as cutting differentiated and slanted ones, the use of robotic technologies can make affordable the design exploration and construction of more complex wooden structures.

Process:

Material:

Substractive Fabrication

Wood

CNC Cutting

Vlachromat (EPS)

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Material Research

Wooden Connections

Non-orthogonal wooden joints Based in Kengo Kuma’s joints, the diagram shows the geometry of non-orthogonal connections between wooden bars. Solving those situations imply the production of differentiated cuts on each of the 3 wooden bars. The geometry and the interlocking feature of the bars were tested with the help of several 3D printed models.

Non-orthogonal connections between wooden panels The exploration of the connection between panels that meet in different angles, led to the development of a series of different design solutions. Besides solving the connection problem, they tried to explore the aesthetic potential emerging from that condition. The designs were demonstrated with 3D printed models.

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Material Research

Wooden Connections

One of the finger joint panels was used to test the robotic programming and fabrication in Valchromat. Unlike the Diamond Screen experiment, the robot had to perform 6-axis movements to manufacture the desired cuts. The size of the fingers was adjusted to fit the tool diameter (i.e. 20mm). The robotic fabrication started by trimming the slanted boundary of the panel and ended by cutting the joints.

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Material Research

Wooden Connections

Reciprocal wooden frame The digital model of a reciprocal wooden frame was the basis to generate differentiated connections between four wooden bars. With the robot, it was possible to implement a serial, but customized, production of variable wooden bars. This operation involved the program of 6-axis robotic movements.

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Material Research

Process:

Material:

Subtractive Fabrication

Wood

Robotic Milling

Serpentine Structure Built in London, the Serpentine Gallery Pavilion 2005 was designed by Álvaro Siza and Eduardo Souto de Moura, and count with the collaboration of Cecil Balmond. After the previous tests on wooden connections, this work emerged as an interesting case study for two main reasons. From the material point of view, it was a non-standard wooden structure that defied conventional representation and construction means. From the methodological perspective, its development required the articulation of geographically dispersed expert teams. It was designed in Portugal, engineered in the UK, fabricated in Germany with Finish wood and then assembled in UK. The experiment started with the comprehensive study of the pavilion’s geometry assisted by the information retrieved from direct contacts with the office of Souto de Moura and Finnforest Merk, which were the German manufacturers of the structure. A small part of the complete digital model of the structure was selected to test its materialization. In order to analyze the non-orthogonal connections and slanting edges of the wooden frames, several small-scale models were produced, both manually and 3D printed. Requiring 6-axis cutting movements, the robot was programmed to cut the differentiated wooden components. Following the constructive detail of the original pavilion, a set of acrylic panels was cut with hotwire to cover the structure. This integrated process resulted in the assembly of that small part of the Serpentine Gallery Pavilion at 1/3 of its real scale.

The Serpentine Gallery Pavilion is a remarkable work where tradition was ingeniously combined with the use of advanced technologies.

Besides the success of learning the process for robotic production of variable wooden components, this experiment also demonstrated the possibility of colapsing in a single geographic location the design, engineering and fabrication phases that occurred separately 10 years ago.

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Material Research

Serpentine Structure

Material Research

Serpentine Structure

The Serpentine Gallery Pavilion 2005 Pictures of the non-standard wooden structure assembled in London. The map shows the geographic organization of the different teams involved in the project.

02 Engineering and Construction

01 Conception

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Fabrication

Material (LVL) Production

The digital design model Model of the Serpentine Gallery Pavilion. From this representation, three parts were selected and analyzed in detail to understand the geometric intricacy of the wooden connections. One part of the roof was chosen for testing its fabrication.

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Serpentine Structure

Material Research

Serpentine Structure

Physical studies To support the design studies, several physical models were produced using different technologies. A full model was 3D printed by SLS (Selective Laser Sintering), while some details were 3D printed with FDM (Fused Deposition Modelling), and others were cut by hand in balsa.

The robotic fabrication process Based on previous experiments, the fabrication of the 14 different building components was programed considering three phases - perforating the corners, cutting the internal holes and trimming the skewed contours. The definition of 6-axis movements was decisive to accomplish the materialization of such irregular geometries. In addition to the wooden frames, two acrylic panels for covering the structure were cut with the hotwire.

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The installation The assembly of the Serpentine structure involved interlocking 14 customized wooden frames. The acrylic panels were fixed according to the original construction detail. The installation reproduces at 1/3 of the scale a part of the original Serpentine Gallery Pavilion 2005.

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Material Research

Process:

Material:

Subtractive Fabrication

EPS (stone)

Robotic Milling

Nasoni Keystone The Nasoni Keystone experiment investigated the application of robotic fabrication in heritage intervention with a focus in stone architecture. Nicolau Nasoni was a 18th century Italian architect and a leading figure of the baroque architecture in Portugal. One of his works was the Episcopal Palace in Porto, whose main door has a granite arch crowned with a decorative keystone. Due to its intricate ornamental motifs, this piece was selected to test the use of a multi-axis milling process with the robot.

The work started by scanning the keystone through photogrammetry. A series of 24 photos was shot and used to create a 3D point cloud with the Agisoft Photoscan software. This data was converted into a mesh and then refined in Blender. The resulting 3D model became the base to generate a set of tool paths in Rhinoceros and Grasshopper. The program instructed the spindle to move normal to the tool path curves with a weighted smoothing to avoid collisions between the tool and the stock fabricated piece. After completing the milling process, the piece was placed on top of a pedestal to cut its vertical perimeter with a hotwire tool mounted on the robot. For practical reasons, EPS was used as the raw material instead of real stone.

However, the two fabricated processes (i.e. milling and hotwire cutting) are analogous to those that can be employed in stone fabrication (i.e. milling and diamond wire cutting).

The Nasoni Keystone experiment demonstrated the digital flow of information from the analysis of existing designs to their ultimate materialization. In heritage preservation this can be significant at many levels, for example, to allow the reproduction and replacement of old building components. In this process, the robot proved to be a flexible and precise machine for the fabrication of intricate decorative geometries that can be found in historical stone architecture.

Robotic HotWire Cutting

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Nasoni Keystone

Material Research

Nasoni Keystone

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The Nasoni Keystone The facade of the Episcopal Palace in Porto designed by Nicolau Nasoni in the 18th century.

The keystone selected for this experiment is located above the arch of the main entrance door. The diagram bellow shows in elevation and plan, the position of the camera during the series of 24 picture shots.

Digital modeling and prototyping Using photogrammetry, the point cloud obtained from the pictures was converted into a mesh and a surface. The results of this translation were very good, and could be confirmed with a 3D printed model.

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Material Research

Nasoni Keystone

Material Research

Nasoni Keystone

The fabrication process The materialization of the keystone in EPS involved a two-step robotic fabrication process: surface milling followed by the contour cutting with hotwire tool. The combination of these two processes is analogous to those used in case of stone fabrication. In that case, the wire diamond tool would replace the hotwire one. The fabrication sequence was programed and simulated with Kuka|Prc in Rhinoceros/Grasshopper environment.

The first fabrication step was milling the decorative motif of the Nasoni Keystone.

The organic surface of the piece required the 6-axis movements of the robot to be cut. The initial strategy was to mill from a position normal to the surface. However, to avoid the collision of the spindle with the stock material and the table, and to optimize the speed of the process, the average of the normals was used to set the definitive position of the robot.

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Material Research

Nasoni Keystone

The robotic milling of the keystone unfolded in two operations. An initial rough cut for the fast removal of the unnecessary material, and a final finishing cut to create a smooth surface. Cutting the perimeter with the hotwire tool was the last fabrication step. The main difference between the EPS and the stone fabrication lies at this stage. Besides the technical apparatus, using diamond wire cutting would have been much slower.

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Nasoni Keystone

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Material Research

Ruled Concrete The Ruled Concrete experiment investigated the potential of using robotic hotwire cutting (RHWC) in the production of customized concrete formwork in the prefabrication context. For this purpose, a custom-made hotwire tool was produced and mounted on the robotic arm.

The concept for the Ruled Concrete test was based on the design of precast panels for mechanically stabilized earth. By projecting a set of standard contours onto a ruled surface, their identical flat shapes became differentiated and curved. With this arrangement, three panels were used to explore specific features of RHWC process and its material possibilities: smooth surface finishing in Panel 1, undulating textures in Panel 2, and variable material composition in Panel 3. In all these works, the challenge resided in programming a sequence of RHWC operations to produce different layers of EPS surfaces and frames to build the molds for concrete casting. A series of initial tests was conducted to find the most appropriate balance between the diameter, temperature and speed of the wire, and the finished quality of the cut EPS surface. This experience revealed that RHWC is a faster process when compared to CNC milling. The EPS molds were poured with a special mix of concrete and fibers at the Faculty of Engineering of the University of Porto (FEUP). For the variable composition panel, different colored concrete mixes were poured in the mold in two separate phases with a 24-hour curing period between them.

The finished precast panels not only achieved the proposed design goals but also revealed the speed and precision of the RHWC process.

The possibility to fabricate customized expressive textures and controlled variable material composition in concrete components, without increasing production costs and time, opens the door for the creative and industrial exploration of concrete using RHWC.

Process:

Materials:

Subtractive Fabrication

EPS

Robotic HotWire Cutting

Concrete

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Ruled Concrete

Material Research

Ruled Concrete

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Design concept Projecting standard shapes onto a ruled surface generated the geometry of the concrete panels. The resulting panels were formally differentiated. Their geometry was confirmed with the production of 3D printed models.

The production of the concrete molds in EPS The molds for the concrete panels were conceived as a sequential process of robotic hotwire cutting of EPS blocks. The resulting EPS slices were then assembled to obtain the mold.

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Material Research

Ruled Concrete

Material Research

Ruled Concrete

The production of the concrete panels The EPS molds were poured with a special mixture of concrete with polypropylene fibers at FEUP. They rested curing for 24 hours before removing the panel. In the end, the molds could not be reused again just because the appropriate demolding oil was not employed.

The final concrete panels proved the efficiency of robotic hotwire cutting processes to generate ruled surface geometries with variable geometries, textures and compositions.

The robotic hotwire cutting of the EPS blocks was fast and precise. It started by cutting the surfaces of the panel followed by its contour in the end. In one of the panels, a textured effect was explored by defining an undulating tool path.

Although the final material effect is more exuberant, this option did not represented an increase in the production time regarding the smother finishes.

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Material Research

Ruled Concrete

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Design Research

Process:

Maaterial:

Additive Fabrication

EPS bricks

Robotic Assembly

Hestnes Column This design research task studied the brick architecture of Raúl Hestnes Ferreira. Showing influences of Louis Kahn, with whom he collaborated, this Portuguese architect uses bricks in all its tectonic dimensions. The corners and columns in the Municipal Library in Moita, and the vaults in the House of Culture in Beja, are two built examples where the expressive and structural potential of bricks were explored side by side. In this experiment, the challenge consisted in investigating the possibility of using robotic technologies to expand those tectonic interests, which were discussed with the architect himslef.

The work started by identifying three themes in brick construction - “corner”, “column” and “vault” – to develop a computational design exploration. The original situations found in Hestnes Ferreira’s architecture were parameterized to automatically generate differentiated and non-regular versions. The regular production of 3D printed models was important for a better evaluation of the tectonic potential of those explorations. Once these topics were reviewed from the design point of view, Hestnes Ferreira was invited to select one solution to be robotically fabricated, and his choice fell on a twisted column. An initial manual experimentation with ceramic bricks made clear the difficulty in interpreting and reproducing the variable brickwork by hand.

Thus, the use of the robot became justified to accomplish the twisted Hestnes Column.

The robotic assembly of this 2100 mm height column with 246 bricks took only 50 minutes to be completed. By imagining the number of columns that could be built in a single day, independently of their geometric complexity or variability, the potential of robotic technologies to innovate in the brick construction, both from the creatve and the industrial points of view, is evident.

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Material Research

Hestnes Column

Material Research

Hestnes Column

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Building references designed by Hesntes Ferreira In the Municipal Library (1989-1997) in Moita, Hestnes Ferreira used bricks in both the exterior and the interior of the building. Walls, corners and columns were subject to an intensive tectonic exploration of this ceramic material. In the House of Culture in Beja (1975-85), the architect extended the use of bricks in the construction of the vaults. At that time, he faced some difficulties in finding specialized workers for this traditional type of brick construction. These buildings provided the background to develop a series of computational design studies on corner wall, column and vault situations

Computational design research - Corner Wall Digital parametric design studies of different corner wall situations, exploring different degrees of geometric complexity. This research was verified with the production of 3D printed models.

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Material Research

Hestnes Column

Computational design research - Column Digital parametric design studies of different column situations, exploring different degrees of geometric complexity. This research was verified with the production of 3D printed models.

Material Research

Hestnes Column

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Computational design research - Vault Digital parametric design studies of different vault situations, exploring different degrees of geometric complexity. This research was verified with the production of 3D printed models.

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Material Research

Hestnes Column

The robotic fabrication of the Hestnes Column With the help of the 3D printed models, Hestnes Ferreira found interesting the dynamic geometry of one column design. For this reason, it was named “Hestnes Column” and was selected to test its robotic fabrication at 1:1 scale at the DFL. By manually trying to assembly that geometry using ceramic bricks, the human limitations became evident.

With the robot, it took just 50 minutes to assemble the complete column, involving the manual deposition of glue after each layering each level of bricks. This experiment lead to the further development of a customized system for automatic glue spraying.

Material Research

Hestnes Column

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Material Research

Hestnes Column

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Design Research

CorkCrete Arch The CorkCrete Arch was developed as a design-based research activity towards the production of a novel building system. By exploring the combination of two materials – cork and concrete (GRC) - the goal was to merge the sustainable and insulation properties of the first with the structural efficiency of the second. The result is a lightweight and performative material system suited for customized prefabrication and easy on-site installation. From the production side, this project represented a complex challenge. Since it is not a single material work, the process had to coordinate the different physical tolerances resulting from employing diverse materials and fabrication processes.

The design and material deployment of the arch were envisioned from the beginning in an algorithmic fashion. This allowed its full development in a single parametric design environment, from conception to materialization. Based in the catenary curve, the geometry of the arch was conceived to challenge the different fabrication processes. Pursuing a milling process, the outer face of the cork panels was designed as a double curved surface with a customized engraved texture. Envisioning the hotwire cutting, the inner surface of the GRC panels was designed as a ruled surface with a subtle crease effect. This work conunted with the collaboration of Amorim Isolamentos (cork) and Mota Engil companies (GRC).

Once completed, the CorkCrete Arch was manually assembled three consecutive times in different places, which proved the ease of construction due to the lightness of this building construction system.

From the structural side, it was stable enough to be installed on the FAUP garden without any fixation. From the aesthetic point of view, the contrasts between the cork and the concrete materials (e.g. dark/ bright, textured/smooth, soft/hard...) triggered the curiosity of the people who felt compelled to visit and touch it. From the technological point of view, robotic fabrication proved to be a flexible and precise process to manufacture building components. The CorkCrete arch experiment thus opened possibilities for real industrial implementations.

Process:

Materials:

Subtractive Fabrication

Cork

Robotic milling

Glassfiber Reinforced Concrete

Robotic Hotwire Cutting

(GRC) EPS molds

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Design Research

CorkCrete Arch

Design Research

CorkCrete Arch

The digital design The geometry of the CorkCrete arch was driven by two factors: the catenary curve and the robotic fabrication technologies. While the first one introduces a structural principle in the arch, the later shapes the surfaces of the material layers. Intended for milling, the cork panels were designed as a doubly curved surface with a customized texture. Thought for hotwire cutting, the GRC panels were conceived as a ruled surface with an emergent longitudinal creasing effect. In total, the arch is made out of 18 cork panels and 3 GRC elements.

Cork Cork Surface

GRC Surface

Concatenated Surface EPS

GRC

EPS

The structure of the arch was evaluated using a Finite Element Analysis (FEA) software. A 3D printed model was produced to evaluate the formal decisions. The whole fabrication and assembly process of the cork and GRC components is explained in the diagram.

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CorkCrete Arch

The production of the GRC panels Due to geometric constrains, each mold in EPS for the GRC panels had to be divided in two halves for fabrication, which involved two operations: the robotic hotwire cutting of surfaces and the robotic milling of contours. This process produced a series of EPS layers, which were then assembled and glued to create the molds.

Design Research

CorkCrete Arch

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CorkCrete Arch

Design Research

CorkCrete Arch

The production of the cork panels While the GRC panels were being produced in Rio Maior, the cork panels were robotically fabricated at the DFL in Porto. This manufacturing process involved three operation steps: the surface milling, the texture engraving and the contour cutting of the panels. All routines required the 6-axis movements of the robot to be accomplished.

The production of the GRC panels took place at the precast facilities of Mota Engil in Rio Maior. A set of anchor elements was introduced in the molds before spraying the GRC with an average thickness of 15mm. After curing for 24 hours, the final panels were ready to be shipped back to Porto.

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Design Research

CorkCrete Arch

The installation(s) of the CorkCrete Arch The CorkCrete arch was assembled three consecutive times in different places. The first one happened at the DFL to test the whole assembly process and check that everything was fitting together. Then, a second installation took place in the gardens at the FAUP to record additional footage for a short movie on the project. Finally, for the final presentation event, the CorkCrete arch was assembled again at FAUP and stayed there for 3 weeks exposed to several weather conditions.

These installations were done manually with the help of five people, which demonstrated the ease of the prefabricated building system. The contrast between the outside cork and the inside GRC elements created interesting material effects while triggered the curiosity of those passing by.

Design Research

CorkCrete Arch

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Design Research

CorkCrete Arch

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Technology Research

Robotic Technology

On-Site Construction Cable-Robot

Spiderobot The SPIDERobot resulted from the research task oriented towards the investigation of an alternative robotic technology for on-site construction. The use of robots in such scenarios has been a research field since the 1980’s, which has comprised the exploration of large-scale robotic structures, mobile robotic units and, more recently, flying robotic vehicles. By analyzing those approaches and discussing their advantages and limitations, an alternative strategy to automate the building construction processes in on-site scenarios was devised.

The SPIDERobot is a cable-driven robot system developed at the INESC TEC to perform assembly operations. It consists in a moving platform linked to structural supports by 4 cables. A specific Feedback Dynamic Control System (FDCS) based on a vision system programs the movements of the cables that displace the platform, where different fabrication tools can be mounted. When compared to other robotic technologies thought for on-site construction, the main advantages of the cable-robot rely on its portability, low cost, reduced energy consumption and ability to build large structures on-site.

To prove the concept, it was developed a functional prototype with a gripper installed in the platform to perform assembly operations.

Unlike the previous assembly experiments with the industrial robot, the SPIDERobot with its FDCS has the ability to visually detect and recognize the position of the blocks and adjust the orientation of the gripper to pick them correctly. A series of small-scale walls and columns were fabricated using the current version of the SPIDERobot.

Future developments of this research avenue will include the scale-up of the system.

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Technology Research

Spiderobot

The technology concept The approaches to introduce robotics in the construction site have ranged from the exploration of large-scale robotic structures to mobile robotic units and, more recently, to flying robotic vehicles. The proposed alternative robotic technology was based on four cable-driven system. Controlled by a Feedback Dynamic Control System (FDCS) based on vision system placed above the construction area, the SPIDERobot could move freely in the space. A fully functional prototype was developed and tested at INESC TEC.

Technology Research

Spiderobot

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The FDCS allowed the introduction of a more efficient behavior in the robot. Unlike the previous experiences with the industrial robot, the SPIDERobot can detect the bricks in space and adjust its orientation to pick them in the right position. There is no need to place the bricks in a specific and precise position.

Fabrication tests The SPIDERobot prototype was tested to assembly different kinds of brick structures, like walls and columns. The fabrication process was manually programed with data extracted from digital model.

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Technology Research

Spiderobot

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Future applications Due to its lightness and energy efficiency, the SPIDERobot has a strong potential to automate the on-site construction processes. By using cranes or the existing buildings, it is possible to quickly set up a cable-driven robotic system to perform automated building operations. Its application in practice can also foster the vision of different and complementary robotic construction technologies cooperating together in the on-site construction of architectural buildings.

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Discussions

Material Innovation with Robotics

Material Innovation with Robotics

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A Robotic Production of GRC Panels Paulo Eduardo Fonseca de Campos Faculty of Architecture and Urbanism at University of São Paulo (FAUUSP) DIGI-FAB Research Group

The CorkCrete arch research work involved the use of two different materials – concrete (GRC) and cork – in the design of a novel building system. By providing an introduction to the nature of both materials, the following short-essays discuss the potential of robotic technologies to innovate in the production of building components in GRC and cork for architectural construction.

The currently available knowledge about the strength and durability properties of high-performance concrete brought the opportunity to retain and upgrade the premises for the development of lightweight prefabrication based on thin wall elements[01]. Furthermore, such improvement of the concrete quality is an effective possibility for replacing quantity by quality.

In the recent article[02] written in the scope of the research project featured in this publication, the proposed title refers to the use of high-performance microconcrete in the production of thin wall precast elements, which were casted in EPS molds manufactured through robotic hotwire cutting. The innovation in architectural technology that this research is intended to consolidate is supported on what might be called the combination of product technology and process technology. Particularly, the spread of digital means of production, not only opens up the opportunity to explore new productive and constructive solutions, as well as to resume promising alternatives set aside in the past, due to both technological and material limitations by then. In this regard, one of the most significant examples of resumption of a promising technological alternative in the field of structural concrete is perhaps the automated manufacture of GRC or Glassfibre Reinforced Concrete.

As a compound or composite material, GRC is a latest generation and high technology product constituted of a high-performance cement matrix with the latest admixtures, reinforced with high-performance alkali resistant glass fibers. Specifically, in the manufacturing process known as “spray-up”, concrete matrix and glass fibers are simultaneously sprayed onto the mold surface in a single operation.

This process enables the creation of slender architectonic panels, with large and absolutely free forms, if compared with the conventional precast concrete ones.

The word “resumption” should be used here in its strict sense, since a research on GRC robotic production today rekindles the old aspirations of the study conducted in Spain in 1993 by the Division of Systems and Automation Engineering (DISAM) of the Polytechnic University of Madrid, together with the company Dragados y Construcciones, led by

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Discussions

professors Carlos Balaguer and José Manuel Pastor Garcia[03]. Between 1993 and 1995, these researchers developed the design and implementation of an automated plant for the production of GRC facade panels, using a robotic arm to replace the manual labor of spraying concrete onto the mold. The process was designed to be, in fact, automated, since it started from three-dimensional digital models of facade panels, which obeyed to certain limitations predetermined by the manufacturing conditions, such as dimensions, thickness and size of the opening spans.

As reported by Lopes [04], this development and implementation of an automated manufacturing plant was successful, culminating in the publication of one last paper in 1998, which summarized all the research, including a comparative study between the GRC panels fabricated with robotic automation versus conventional manufacturing, revealing a wide advantage of the first one. Although the published study has been successful and practical experiences have been carried out, we cannot conclude why there was no continuity in academic studies, particularly with regard to new research that might couple the digital robotic manufacturing techniques to the production of GRC facade panels.

On the midway towards the robotic automation of the manufacturing of GRC elements, the development of the CorkCrete Arch project addressed the use of the robotic hotwire cutting in the creation of curved shaped molds without laborious manpower. By integrating the knowledge from previous works, it was possible to fabricate complex molds ready for conventional GRC spray-up, within a very fast and cost-effective way.

[01]

FONSECA DE CAMPOS, Paulo E. Da argamassa armada ao microconcreto de alto desempenho: perspectivas de desenvolvimento para a pré-fabricação leve (From the reinforced mortar to the high-performance microconcrete: new trends of development for the lightweight prefabrication). São Paulo, Faculdade de Arquitetura e Urbanismo da Universidade de São Paulo, FAUUSP, 2002.

[02]

MARTINS, P. F.; FONSECA DE CAMPOS, P.; NUNES, S. e SOUSA, J. P. “Expanding the possibilities of lightweight prefabrication in concrete through the use of robotic hotwire cutting”, in: Real Time Proceedings of the 33rd eCAADe Conference - Volume 2, Vienna University of Technology, Vienna, Austria, 16-18 September 2015, pp. 341-351.

[03]

BALAGUER, C., RODRÍGUEZ, F.J., PASTOR, J.M. et al. Robotized System of GRC Panels for Construction Industry. In: 10th ISARC, Houston (USA), 1993.

[04]

BALAGUER et al. 1993, 1994, 1995; PENIN et al. 1998, cited in LOPES, E. Doctoral research project entitled “Digital Concrete: New materialization possibilities in contemporary architecture”, currently under development at FAUUSP, under the guidance of Prof. Paulo Fonseca de Campos and co-supervision of Prof. José Pedro Sousa (FAUP - Portugal). São Paulo: FAUUSP, 2015

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Due to the current development stage of robotic digital manufacturing technologies and the spread of low cost software solutions (CAD, CAM and CNC), there is a firm belief that it is possible to continue with such work, pointing to new fields for possible applications of GRC technology in lightweight prefabrication. Finally, decreasing the thickness of prefabricated components, making them lightweight and slim, also presents an opportunity to enter into the field of laminar structures and break up with the past of the historic prefabrication model of post-war Europe, whether in structural engineering or in architecture.

Cork, Architecture and (Robotic) Fabrication José Pedro Sousa Faculty of Architecture of the University of Porto Coordinator of the DFL

Germano Veiga INESC TEC

A. Paulo Moreira Faculty of Engineering, University of Porto + INESC TEC

Cork is a natural and recyclable material, which is extracted from the Cork Oak tree (i.e. Quercus Suber), present in the West borders of the Mediterranean Sea. Unlike wood harvesting, the extraction of cork from the bark every 9 years does not imply the death of the tree. Its singular capacity of growth and regeneration opens “the possibility of using the cork oak tree as a sustainable producer of cork throughout its lifetime” [01]. The unique convergence of different properties in a single element makes cork a unique natural material. Its cellular structure and chemical composition of cork is at the basis of its lightness, buoyancy, viscoelasticity, compressive resilience, and low conductivity of heat and sound properties [02] [03] [04]. From the aesthetic and sensorial point of view, its texture, colour and temperature convey the idea of a warm and comfort material.

Although its main focus has been in the production of cork stoppers, the industry of cork has been connected with the building construction industry through the production of cork agglomerates.

Among them, the expanded cork agglomerate (i.e., internationally known as ICB - Insulation Cork Board) is perhaps the most interesting product for architecture, due to its production process. Although it is processed, it remains a 100% natural material. Indeed, its agglomeration process consists in injecting superheated water vapour through

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an autoclave filled with cork granules. Under such conditions, the cork granules expand against each other and release a chemical substance -the suberine-, which bonds them all together without requiring the addition of any other adhesive. The resulting expanded cork agglomerate blocks are thus still 100% made of cork, which sets its performative and recycling possibilities.

The traditional application of the expanded cork agglomerate, henceforth simply referred as cork, has been as a hidden insulation material inside the walls. However, by perceiving its unique properties, the Portuguese architect Álvaro Siza proposed, for the first time, to use it in the facade of the Portuguese Pavilion for the Expo 2000 in Hannover. Since then, the Portuguese company Amorim Isolamentos started to promote the exterior application of cork in building construction. A growing number of architects began to employ it as a natural and recyclable material to solve different building requirements at the same time (e.g. acoustic, thermal, aesthetic...).

Despite this innovative application, this cork product remained available in just standard -flat and rectangular- formats, available within a set of predefined thickness and densities. To investigate the possibility to overcome this condition, a PhD research was developed from 2004 to test and evaluate different CNC fabrication technologies in the production of customized shapes, textures and forms in cork[05].

The results led to propose the integration of a specific set of CAM technologies in the end of the production chain. As a consequence, the company decided to implement CNC fabrication technologies in the factory (i.e., 3-axis milling machine) to embrace the challenges of non-standard architectures. Since then, these possibilities have been explored in many situations. Among them, the Amorim Isolamentos’ stand for the Concreta fair in 2013 was a clear example of such innovative design and material opportunities[06].

Aside with the investigation on CNC fabrication, the exploration of robotic fabrication with the expanded cork agglomerate emerged as the next logical research step. Thus, the authors initiated this avenue of inquiry in 2012, by joining the efforts of their research institutions.

Since then, this interdisciplinary collaboration developed the IJUP research project where they explored the robotic assembly of smallscale constructions with cork. Within the research project featured in this book, these explorations could be expanded to the real scale and also to other research topics like cutting and milling. The current

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book features some of those works, like the Pixel and Clover walls, and the CorkCrete arch. In this last project, the cork panels with inclined cut edges and a variable texture engraved show the flexibility of robotic fabrication to go beyond the possibilities allowed by conventional CNC machinery. This research work thus contribute to demonstrate how advanced manufacturing technologies, like the industrial robot, can be used also to rethink and update the application of traditional materials in architecture, like cork.

[01]

Pereira, H. (2007). Cork: Biology, Production and Uses. Amsterdam: Elsevier.

[02]

Stecher, G.E. (1914): Cork: Its Origin and Industrial Uses. New York: Nostrand Reinhold.

[03]

Gil, L. (1998). Cortiça, Produção, Tecnologia e Aplicação. Lisboa: INETI.

[04]

Gibson, L. (1999): Cellular Solids: Structure and Properties. Cambridge University Press.

[05]

Sousa, J.P. (2010): From Digital to Material. Rethinking Cork in Architecture through the use of CAD/ CAM Technologies. PhD thesis in Architecture. IST, Technical University of Lisbon.

[06]

Varela P, Paio A, Sousa JP (2014): “The Cork Vault Pavilion. A Design Research through Practice”, in Proceedings of the Architectural Research through Practice: 48th International Conference of the Architectural Science Association 2014 (pp. 395-404), Genoa, Italy.

NOTE This text is a short version and adaptation of the paper published in the Proceedings of the ACADIA 2015 conference, which is featured on page 182.

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The Relevance in Architectural Education, Practice and Industry

The public presentation of the research project brought together three external guests: José Pinto Duarte, Professor at the Faculty of Architecture of the University of Lisbon, Guilherme Machado Vaz, Architect with a recognized practice in Portugal, and Luis de Sousa, Innovation Consultant at Mota Engil building construction company.

Together with the members of the research team - A. Paulo Moreira and Germano Veiga from INESC TEC, José Pedro Sousa, João Pedro Xavier and Clara Vale from FAUP- they shared their view on the research project work and the relevance of new digital technologies in the architectural education, practice and industry realms. Here is a selection of their contributions.

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José Pinto Duarte Faculty of Architecture, University of Lisbon

Before anything else, what one needs to do here is a critical remark about the job and, in my opinion, it is extremely positive. Who has a debt and the ability to pay, but fails to do so, has an unspeakable attitude. The debt here is to praise the work and therefore having such an opportunity, I will not miss it. Congratulations for the excellent work.

Excellent, excellent, excellent! Very good, indeed. Congratulations to Prof. José Pedro and the whole team, to Professor João Pedro Xavier and all the other collaborators. Congratulations also to the School of Porto for supporting work of this nature. Without such a support, it would not be, in fact, possible. Fortunately, I am in a position to compare the results of this work with what is done all over the world in the same area and I can say that they are at the level of the best I have had the chance to see. Congratulations! It is a great pleasure to be here and be able to say that so openly.

Then, I would like to make a few specific comments on the work. I think there are several interesting things to say, but I will just mention two that seem more relevant.

The first thing to highlight is the opportunity of this investment in new technologies. Without giving up anything that is essential to architecture, new technologies allow new approaches, which is well demonstrated in that piece that’s out there, produced under this project. It does not make any compromise between what is the essence of architecture and the exploration of technological possibilities. Indeed, this characteristic is present in all other essays developed in the context of the project. Although they investigate the possibilities bring about by new technologies, the common thread between the different essays is not the technology itself, but an approach to architecture, which starting from a critical interpretation of the problem seeks to reconcile the solution of functional issues with the satisfaction of aesthetic requirements. This is the thread of the project and the reason for the huge impact that one feels when looking at the results produced. This is closely related to what I consider to be the essence of the Port School. As recently I said to Prof. Carlos Guimarães, the work out there has the “genes” of the School of Porto. I think it’s very important to recognize this fact, as this commitment to new technologies does not affect the school, but can give it new dimensions.

The important thing to note is that today, as yesterday, the architecture

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should reflect the technology of its time and this is what justifies the investment in new technologies, as it allows the school to stay in tune with the times, without turn the back to its traditions.

Then there is something else that is necessary to highlight, namely, the connection to industry that I consider fundamental. The Portuguese industry has not realized yet the contribution that architecture can make to the development of the economy through the investment in technology. Innovation at this level can give Portuguese companies new opportunities, not only in the construction of remarkable and unique buildings, but also of current ones. It’s a bit like in Formula 1, where experimental solutions are tested first to be put into effect on common cars. Thus, although the results of technological essays, such as those developed in the present project, can be regarded as unique and exceptional on a first glance, they actually can be applied in current buildings. Innovation can be aesthetic or functional, but it also may rest on the rationalization of construction, which can be translated into cost savings, a key aspect in a context of limited resources such as the one we live in today. The use of new technologies helps make affordable design solutions that would otherwise be restricted to buildings with a very high budget.

Guilherme Machado Vaz Architect

I am very interested in this subject but I am not a specialist at all. The first time I made contact with this type of expression was with the work

by Gramazio and Kohler in the Swiss Pavilion at the Venice Biennale [2008]. By then, I never heard about that mode of construction and I was surprised with that big brick wall. I tried then to understand how it was built and I realized a robot did it. (...)

I think the possibilities allowed by robotic technologies are almost endless and one of the main factors constraining its regular use may be, today, the economic one. Thus, prefabrication may be the logic that should be followed at the moment, by promoting objects and aesthetic features in materials such as concrete or other innovative ones.

Architects can then take advantage of such possibilities to develop new plasticity features and forms. The production of more exclusive objects seems another possibility for the application of this technology, although its costs can not be afforded by everyone. (...)

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Another interesting thing I would like to bring into the discussion is the example of the robot at the ETH Zurich, which is mounted in a rail. I think the possibility for the movement of the robot of can be very useful to take it out of that space and bring it into the construction site. This would allow building things in a different scale and with more flexibility. If we want to tackle the construction at this level, we have to find a way to put the robot in the construction site, and let it move to where it is necessary.

Since it has an arm, maybe it needs some legs now! (...)

I think there must be developed also a charming operation in relation to the city and the society. This is a fascinating machine to be seen at work by anyone who is, or not, connected to the field of architecture and construction, and it could be used by the city itself in public scenarios and facilities. Today, the city of Porto has a vibrant cultural and artistic life, which, at some point, could incorporate the robot to promote them through the objects that can be made by this machine. (...)

Luís de Sousa MOTA ENGIL

From the industry point of view, I would like to thank for the opportunity of contributing for this this research work [the CorkCrete Arch] with our expertise in a process that is conventional for Mota Engil. We fabricate this kind of GRC [Glass-fiber Reinforced Concrete] panels in a regular basis for the building construction industry. However, the processes we use in the production of the molds have never been done in such a way.

These were the first GRC panels where the molds were robotically fabricated, thus avoiding the need for an experienced carpenter or specialized factory to produce such intricate geometry. (...)

Today, the industry in Portugal is more developed than 10 years ago, and our company (Mota Engil) has built widely since then. We are used to accept new challenges, which are often presented by architects. Then, our engineers try to solve them and our construction team finally builds them. That is our mission and, as an educated architect, I feel very happy to see these new technologies becoming more and more integrated in architecture schools. I usually say that while contractors and engineers are focused in building and solving technical problems, the building creativity and complexity usually results from the architects’ imaginative spirit. So, we have to get the means to respond to their design challenges. (...)

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I am also very pleased to have established this protocol with the DFL/FAUP today. Together with the university we want to strength the promotion of research and innovation in the construction field. From the industry point of view, and this is the particular vision of Mota Engil, we believe that Portugal has the capacity to become a cluster in terms of knowledge in the engineering and architecture areas, due to the internationally recognized value of its Schools. So, rather than assisting to the exportation our architects and engineers to foreign countries, we would like, instead, to embrace the opportunities emerging from new technologies by concentrating and keeping that know-how in the country. From this position, we aim at strengthen our presence and action in a world dominated by an open and highly competitive economy.

This is the path to propose the achievement the difficult goals that can make a difference in our current times. (...)

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Reports 01, 02, 03

Research Tasks

Surveys

Survey

Material Research

Design Research

Technology Research

Computational Design

Report 01

Robotic Technologies

Report 02

Architecture

Report 03

Pixel Wall

Article 01

Striated Wall

Article 02

Brick Tower

Article 03

CG Column

Article 04

Face Bricks

Article 05

Clover Wall

Article 06

Diamond Screen

Article 07

Wooden Connections

Article 08

Serpentine Structure

Article 09

Nasoni Keystone

Article 10

Ruled Concrete

Article 11

Hestnes Column

Article 12

CorkCrete Arch

Master Thesis 01

SPIDERobot

Master Thesis 02 Master Thesis 03 Master Thesis 04

Published: University of Porto Repository

171

T1.1 Computational Design In the scope of the introductory activities of the project (T1.1, T.1.2 and T1.3), the present task surveys the current state-of-the art in computational design technologies. (...)

Chapters: Advanced modeling, Computational design (software), Computational design (programming languages), Performative analysis, Digital fabrication, Robotics Link: http://bit.ly/1pCOILI T1.2 Robotic Technologies In the scope of the introductory activities of the project (T1.1, T.1.2 and T1.3), the present task surveys the current state-of-the art in robotic technologies, and their application in the field of architecture. (...)

Chapters: Robots, Tools and Accesories, Applications in Architecture, Applications in other Fields Link: http://bit.ly/1n0k1yo T1.3 Architecture In the scope of the introductory activities of the project (T1.1, T.1.2 and T1.3), the present task surveys architectural projects showing pertinent issues regarding material, formal (geometry) or constructive aspects. These projects should thus raise interesting challenges to be tackled by means of robotic technologies. (...)

Chapters: Concrete, Ceramics, Wood, Stone, Cork, Metal Link: http://bit.ly/1lX84tN

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Article 01

published: 32nd eCAADe Conference Newcastle upon Tyne, 2014

Article 02

Published: ENHSA: What’s the Matter Barcelona, 2014

173

Digital Fabrication Technology in Concrete Architecture

Cork as a Digital Material

Technological innovation has been an important driving force in architecture, enabling and inspiring architects and engineers by giving them new tools for solving existing problems. In the last two decades, the exploration of digital design and fabrication technologies has stimulated the development of a variety of interests and strategies to materialize increasingly complex and customized solutions in architecture, with traditional building materials. Reinforced concrete is the most widely used material in the building industry today and throughout its history has been the subject of vast research into its performance as a construction material and its tectonic potential in architecture.

As such, the introduction of digital fabrication processes in concrete construction represents the biggest prospect for renovation of our built environment and at the same time, presents particular difficulties and opportunities, which are now being addressed. In an effort to investigate the alternative design and material possibilities in concrete emerging from the use of digital fabrication technologies in architecture, this paper proposes a focused view of digital fabrication applied to concrete construction with two areas of research. By framing the research in the context of reference works in concrete architecture of the 20th century, this paper describes and illustrates taxonomy of existing and possible types of integration of digital fabrication technologies in concrete architecture in the realms of Practice and Research.

This characterization allows the authors to frame the relation between material, technology and architecture in different environments regarding the same material, extracting a clear image of existing processes, their potential and shortcomings, as well as expectations for future developments.

In the recent years, the use of computational design and digital fabrication tools has opened new material opportunities in architecture.

The possibility to design specific physical qualities (e.g., contour, form, textures or composition) and to materialize them through flexible manufacturing processes has reinvigorated the role of materials in architectural design. Instead of becoming passive receptors of form, materials can be increasingly active in stimulating the form generation processes, as described by Manuel DeLanda (1998).

As Antoni Gaudí or Frei Otto showed, that possibility and interest is not new. (...) However, the introduction of digital technologies can expand such design explorations into a wider range of geometric possibilities. (...) That creative landscape of material opportunities in architectural design was surveyed by Kolarevic and Klinger (2008), who verified that the digital impact in the physical realm can occur at two levels: by inventing new materials, artificially engineered to fulfill customized goals (eg. composite materials); by reevaluating existing traditional materials to find new application possibilities.

It is in the scope of the second hypothesis that this paper is inscribed. With the advent of digital fabrication technologies, traditional materials like concrete, metal, wood or ceramics, have known alternative “non-standard” applications in architecture by means of digital processes. (...) As a result of this technological influence, architects have kept their interest in using them, despite the complexity and uniqueness of their design intentions. Realizing this fact, the author started with his PhD research in 2004 a long research interest in investigating the possibility of using digital design and fabrication technologies to open new applications for cork in architecture (Sousa, 2010).

The present paper thus summarizes some of the main achievements since them, obtained in close collaboration with Amorim Isolamentos.

Pedro Martins [01], José Pedro Sousa [01]

José Pedro Sousa [01] [01] Faculty of Architecture, University of Porto + CEAU-DFL, Portugal [02] Faculty of Engineering, University of Porto

[01] Faculty of Architecture, University of Porto + CEAU-DFL, Portugal

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Article 03

Published: 5as Jornadas Portuguesas de Engenharia de Estruturas, Lisboa, 2014

Article 04

Published: Automation in Construction Vol.51 March 2015 (pp. 113-123) Elsevier

175

Elementos Compósitos em Betão com Geometria Complexa por Processos de Fabrico Automatizado

Symmetry-based generative design and fabrication: A teaching experiment

A integração emergente de tecnologias de fabricação automatizada na industria da construção revela, no contexto atual, grandes potencialidades para a revisão dos processos construtivos tradicionais em betão, procurando suplantar de forma sustentada a normalização e repetição características da construção corrente em betão. Fazendo parte de uma investigação alargada sobre processos de fabricação automatizada em betão, este artigo considera o estado de integração das tecnologias de fabrico aditivas e subtrativas em betão em obras contemporâneas, para focar dois problemas fundamentais: a produção de elementos em betão com geometrias complexas e a criação de variabilidade material funcional em elementos de betão. Para o efeito é apresentada uma experiência prática que, convergindo estes dois interesses, investiga a viabilidade da criação de elementos com dupla curvatura e betonagens estratificadas com moldes em EPS, por processos de fabricação digital subtrativa. Com o presente trabalho pretende-se demonstrar as possibilidades emergentes ao nível da produção de variabilidade formal e material em betão e apontar o interesse estético e funcional resultante, antevendo as possibilidades futuras para a sua aplicação na construção.

Throughout history, symmetry has beenwidely explored as a geometric strategy to conceive architectural forms and spaces. Nonetheless, its concept has changed and expanded overtime. Nowadays, it is understood as an ordering principle resulting from the application of isometric transformations that keep the original object invariant.

Departing from this notion, scientists, philosophers and designers have extended it to embrace other geometric scenarios. Following this idea, exploring symmetry does not mean the generation of simple and predictable design solutions. On the contrary, it is a creative window to achieve geometric complexity based on very simple rules. In this context, this paper aims at discussing the relevance of exploring symmetry in architectural design today by means of digital technologies. It argues that the coupled use of computational design and digital fabrication processes allows designers to explore and materialize a higher level of design complexity in a structured and controlled way, especially when non-isometric transformations are involved. As the background for testing and illustrating its arguments, this paper describes a teaching experiment conducted in the Constructive Geometry course at the FAUP, following design-to-fabrication methodologies.

Pedro Martins [01], Sandra Nunes [02], José Pedro Sousa [01]

José Pedro Sousa [01], João Pedro Xavier [02]

[01] Faculty of Architecture, University of Porto + CEAU-DFL, Portugal

[01] Faculty of Architecture, University of Porto + CEAU-DFL, Portugal

[02] Faculty of Engineering, University of Porto

[02] Faculty of Engineering, University of Porto

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Article 05

Published: 2015 IEEE International Conference on Industrial Technology (ICIT) , Seville 2014

Article 06

Published: 33rd eCAADe Conference Viena, 2015

177

Cable Robot for Non-Standard Architecture and Construction: A Dynamic Positioning System

Digital Flow in Stone Heritage Buildings: The Nasoin Keystone

In the past few years, cable-driven robots have received some attention by the scientific community and the industry. They have special characteristics that made them very reliable to operate with the level of safeness that is required by different environments, such as, handling of hazardous materials in construction sites. This paper presents a cable-driven robot called SPIDERobot, that was developed for automated construction of architectural projects. This robot has a rotating claw and it is controlled by a set of 4 cables that allow 4 degrees of freedom. In addition to the robot, this paper introduces a Dynamic Control System (DCS) that controls the positioning of the robot and assures that the length of cables is always within a safe value. Results show that traditional force-feasible approaches are more influenced by the pulling forces or the geometric arrangement of all cables and their positioning is significantly less accurate than the DCS. Therefore, the architecture of the SPIDERobot is designed to enable an easily scaling up of the solution to higher dimensions for operating in realistic environments.

In a moment when digital technologies can interfere in every moment and task in the architectural production, architects are using them in many different ways. In architectural heritage, stone is a prevalent material and one can find some examples of architects exploring particular uses of computers when facing this kind of challenges. However, it seems that there is a lack of references trying to develop a transversal reading of the context, by offering a systematisation of those approaches. With this concern, this paper wants to describe and illustrate the way digital technologies can support architectural intervention in stone heritage buildings, bearing the specificity of this material, its constraints and opportunities. For each moment, specific computer-based technologies can be employed not only to perform those tasks, but also, to assure the flux of information through a digital continuum. This paper overviews those moments by discussing the technologies available and presenting some examples from existing reference practices. To test those concepts and arguments, this paper includes the description and illustration of an experiment carried out in the Laboratory by the authors, of a digital continuum process from surveying a stone building, to design and fabrication.

Eduardo Moreira [04], Andry Maykol Pinto [01], Paulo Costa [01], A. Paulo Moreira [01], Germano Veiga [04], José Lima [02], José Pedro Sousa [03], Pedro Costa [01]

Pedro de Azambuja Varela [01], José Pedro Sousa [01]

[01] INESC TEC + Faculty of Engineering, University of Porto [02] INESC TEC + Polytechnic Institute of Bragança [03] Faculty of Architecture, University of Porto [04] INESC TEC

[01] Faculty of Architecture, University of Porto + CEAU/DFL

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Article 07

Published: 33rd eCAADe Conference Viena, 2015

Article 08

Published: 33rd eCAADe Conference

179

Viena, 2015

Expanding the Material Possibilities of Lightweight Prefabrication in Concrete Through Robotic Hot-wire Cutting. Form, Texture, Composition.

Between Manual and Robotic Approaches to Brick Construction in Architecture. Expanding the Craft of Manual Bricklaying with the Help of Video Projection Techniques.

In recent years, digital fabrication technologies have enabled renewed explorations into traditional materials, with innovative results. This paper focuses on concrete and on the potentials of a specific technology: robotic hot-wire cutting for the production of expanded polystyrene (EPS) formwork. Academia and industry have explored this process recently but the number of works built with this technology is reduced and the general concrete prefabrication industry has been slow to adopt it. In this context, this paper analyzes the use of EPS in the production of concrete formwork by reviewing its application in contemporary examples. In order to develop a clear assessment of the possibilities of expanding prefabrication in concrete using robotic hotwire cutting, this paper also documents a set of practical experiments developed in the laboratory, addressing three material challenges: form; texture and composition. This research involved the design, formwork production and casting of concrete elements to explore the limits and characterize the process of robotic hot-wire fabrication in the context of concrete prefabrication. By recognizing the different approaches present in contemporary examples and in the explored practical experiments, we point out the advantages and limitations of using hot-wire cutting, and develop the reasons behind its limited application in practice.

Brick construction has a long and rich structural and aesthetic traditions in architecture, which can be traced back to the origins of our civilization. However, despite the remarkable works of Frank Lloyd Wright, Louis Kahn, Eladio Dieste or Alvar Aalto in the 20th century, the application of this construction process to address more irregular geometries is very difficult to be achieved by conventional manual means.

In this context, the last decade assisted to emergence of robotic applications in architecture. While Gramazio & Kohler looked for solving non-standard brick structures, others, like the S.A.M. robot initiative, are interested in improving the productivity in the fabrication of regular brick structures. By surveying the recent advances on bricklaying automation, this paper is interested in reflecting on the actual role of manual brickwork. In doing so, the authors present the Brick Tower experiment developed at the DFL/CEAU/FAUP, where two different fabrications processes are critically compared: a robotic and a manual one, which is aided by a video projection technique. By describing and illustrating this experiment, the authors argue that it is possible to expand the traditional craft of bricklaying by devising simple strategies to increase the human capacity to understand and materialize more elaborated geometries. This research avenue can be relevant if one considers that manual work should remain the most common form of brickwork practice in the next decades.

Pedro Martins [01], Paulo Fonseca de Campos [02], Sandra Nunes [03], José Pedro Sousa [01]

José Pedro Sousa [01], Pedro de Azambuja Varela [01], Pedro Martins [01]

[01] Faculty of Architecture, University of Porto + CEAU/DFL [02] Faculty of Architecture and Urbanism, University of São Paulo [03] Faculty of Engineering, University of Porto

[01] Faculty of Architecture, University of Porto + CEAU/DFL

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Article 09

Published: 33rd eCAADe Conference Viena, 2015

Article 10

Published: SIGRADI Conference

181

Florianópolis, 2015

Robotic Fabrication with Cork.

Emerging Opportunities in Architecture and Building Construction.

A Fabricação Robótica no Ensino da Arquitetura: Uma Experiência Sobre o Projecto e Construção de Estruturas em Tijolo.

In the last two decades, CAD/CAM technologies have opened new conceptual and material opportunities in architecture. By combining computational design and digital fabrication technologies, architects have embraced a higher level of geometric complexity and variability in their design solutions. Such non-standard possibilities were expanded with the recent introduction of robotic technologies in the discipline, which have allowed moving beyond the fabrication of building components to reach the construction of building parts. As a result of this digital condition, traditional materials have known innovative applications in architecture. In this context, this paper presents cork, which is a natural and recyclable material. By describing its unique set of properties and features, it argues about its relevance for the building construction in the present times. With this underlying motivation, this paper defines the current state of the architectural research on the use of robotic fabrication with cork. It does so by describing and illustrating a set of different experiments conducted by the authors in their academic institutions. The results unveil a set of innovative applications of cork in building construction and, at the same time, contribute to show how robotic technologies can be used to rethink and update traditional and old materials in architecture.

In the last decade, architectural researchers have demonstrated the potential of using robots to design and construct in novel ways.

However, the integration of such practices in architectural education has been difficult and the examples are rare. By analyzing this context, this paper describes a teaching experience at FAUP where robotic technologies were introduced to the Master students for the first time.

The assignment consisted in the production of a brick structure and ended up with the construction of a 1:1 scale installation. With this experience, this paper wants to contribute for the dissemination of robotic technologies in architectural curriculums.

José Pedro Sousa [01], João Pedro Xavier [01]

José Pedro Sousa [01], Germano Veiga [02], A. Paulo Moreira [03]

[01] Faculty of Architecture, University of Porto + CEAU/DFL [02] INESC TEC [03] INESC TEC + Faculty of Engineering, University of Porto

[01] Faculty of Architecture, University of Porto + CEAU/DFL

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Article 11

Published: RobArch Sidney, 2016

The SPIDERobot: A Cable-Robot System for On-Site Construction in Architecture.

The use of robots in architectural construction has been a research field since the 1980’s. Driven by both productive and creative concerns, different systems have been devised based on large-scale robotic structures, mobile robotic units or flying robotic vehicles. By analyzing these approaches and discussing their advantages and limitations, this paper presents an alternative strategy to automate the building construction processes in on-site scenarios. The SPIDERobot is a cable-robot system developed to perform assembly operations, which is driven by a specific Feedback Dynamic Control System (FDCS) based on a vision system. By describing and illustrating this research work, the authors argue about the advantages of this cable robot system to deal with the complexity and the scale of building construction in architecture.

Article 12

Published: SIGRADI Conference

The CorkCrete Building System: Concept, Design and Fabrication

The CorkCrete arch is a 1:1 scale construction aiming at testing the use of robotic fabrication technologies in the production of a novel building system made out of two different materials – cork and concrete (GRC). The combination of these materials is promising since it merges the sustainable and performative properties of first with the structural efficiency of the second one. The result is a material system suited for customized prefabrication and easy on-site installation. The current paper describes the design and fabrication process of the arch, which employed a single parametric design environment to bridge design and fabrication, and an innovative sequence of different robotic processes. The success of this experience invites the team to continue this research into the future construction of larger scale applications.

José Pedro Sousa [01], Pedro de Azambuja Varela [01], Pedro Martins [01]

José Pedro Sousa [01], Cristina Gassó Palop [01], Eduardo Moreira[02], Andry Maykol Pinto [02], José Lima [03], Paulo Costa [04], Pedro Costa [04], Germano Veiga [02], A. Paulo Moreira [04]

[01] Faculty of Architecture, University of Porto + CEAU/DFL [02] INESC TEC [03] INESC TEC + Polytechnic Institute of Bragança [04] INESC TEC + Faculty of Engineering, University of Porto

183

Florianópolis, 2015

[01] Faculty of Architecture, University of Porto + CEAU/DFL

184

Master Thesis 01

Faculty of Engineering University of Porto

Robotic Architecture. Developing a “Cable-Robot” for Construction.

With the increase of the world population, grows the need to build infrastructures that respond the demands of modern society. The construction involves the handling of large loads, reason why the tools used more often are cranes. Focusing on repositioning large objects in big distances, arise the cable-robot. Contour Crafting is a relatively new layered fabrication technology that enables automated construction of whole structures. The concept is based on a robot with long legs, capable of supporting loads with large mass. The robot has the capacity of reach any point in a considerable large work space.

The system proposed consists in a robot whose moving parts are only a platform and a set of four cables. The movement of the mobile platform is caused by the forces applied to the wires. It may be installed a great amount of tools to the moving point of the robot, on this case it is used a mechanic hand capable of perform the task pick-andplace. This system is entirely automated and has the main goal of assembly structures quickly and precisely. With this kind of robots arise compelling attributes when compared to the more common systems such as: better portability, lower cost and the ability to build larger structures.

This dissertation presents the whole process of developing a robot with four cables from the analysis of the kinematics to the implementation of the control system.

Completed

Student:

Master Thesis in Electric and Computer Engineering

Mário Miguel Martins

Faculty of Engineering, University of Porto

Supervisor:

July 2014

Prof. Pedro Gomes da Costa Co-Supervisor: Prof. José Magalhães Lima

Master Thesis 02

Faculty of Architecture University of Porto

185

Architecture and Customization.

The Impact of CAD/CAM Technologies

Today, the development and integration of CAD/CAM technologies in the discipline of architecture has endowed the architects with the instruments to explore a new world of formal and constructive possibilities, until today inaccessible by craft and serial paradigms. Being imported from other industries, the tendency of architectural practice reveals a growing interest in the development of free form solutions and customized components enabled by these technologies. This condition doesn´t influence only the built reality but leads the architects to face the new challenges relatively to their position in the development of the architectural project. With the intention of investigating and examine the true impact of the inclusion of digital technologies in architectural practice, this thesis performs a survey on contemporary buildings, following specific criteria that varies from the start of the design to the production of constructive components. By exposing these data, this thesis tries to demonstrate, not only the potential and limitations of digital driven technologies in architecture, but also the new tendencies and approaches to follow with the development of specific digital tools for architectural reality.

Completed

Student:

Master Thesis in Architecture

Manuel Oliveira

Faculty of Architecture, University of Porto

Supervisor:

2014

Prof. José Pedro Sousa

186

Master Thesis 03

Faculty of Architecture University of Porto

Master Thesis 04

Faculty of Architecture University of Porto

187

Tradition and Innovation. Digital Technologies in the Design Process of the Serpentine Gallery Pavilion 2005

Digital Design and Construction possibilities with Bricks, departing from the Work of Raúl Hestnes Ferreira

(...) The Serpentine Pavillion 2005, designed by Álvaro Siza and Eduardo Souto de Moura in collaboration with Cecil Balmond, from Arup, reflects the potential of a design process that combines two different approaches. The tradition approach, with great respect for the project context and that praises the freedom of freehand drawing; and the technological innovation approach, that seeks formal exploration and constructive efficiency. Being clear that these different approaches increased the gap between the design and construction phases, this dissertation investigates the design process of the Serpentine pavilion 2005, from its conception to construction, with a focus on the understanding of the architects’ role in a work where no technical/project drawings were produced. For this, and since it is a work with not much documentation, the author contacted Álvaro Siza and Eduardo Souto de Moura’s offices, in order to collect exclusive important information for the investigation.

The brick has been present in construction since the beginning – it may be considered one of the most basic material in construction. Its fabrication has evolved alongside the big technological revolutions; however its manual way of laying persists. Over the last decades the laying methods resorting to robotics have been subject of research and development.

The dissertation aims to study how these technologies can interfere in the design and brick construction and tries to comprehend the potential of these technologies in structural and formal ways in brickwork. To accomplish this purpose, the brickwork of Arch. Raúl Hestnes Ferreira is analyzed because of its expressiveness in constructive details.

To understand the potential of these elements, the work analyzed plans and details of the most significant elements of Hestnes Ferreira s work and has the contribute of the architect himself.

In addition, this study presented experimentations that point out where brick architecture meets robotic and digital fabrication technologies. This research aims to clarify the potential of these technologies even with an ordinary material. The work does not intend to condemn manual construction; instead, it demonstrates the possibilities of building beyond some of its limitations.

In order to achieve a more comprehensive understanding of this matter, this dissertation presents a practical research, entirely related to the Serpentine pavilion 2005, aiming to analyze the possibility of a closer relationship between the architect and the materialization of the work. As a conclusion, this dissertation shows that, with digital technologies, is possible to counteract the dispersed information associated to the traditional process in the architectural practice.

Completed

Student:

Master Thesis in Architecture

Daniel Almeida

Faculty of Architecture, University of Porto

Supervisor:

2015

Prof. José Pedro Sousa

Completed

Student:

Master Thesis in Architecture

Rui Oliveira

Faculty of Architecture, University of Porto

Supervisor:

2015

Prof. José Pedro Sousa

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189

190

Events

Lab Opening

Lab Opening

Events

Exhibitions

191

Exhibitions

The official opening of the new DFL - Digital Fabrication Laboratory, happened on the 11th of March, 2015. The ceremony counted with speeches from the director of the FAUP, Carlos Guimarães, and the Coordinator of the DFL, José Pedro Sousa. The attendees could visit the spaces and resources of the new facilities, watch the demonstration of the robot and check an exhibition with digitally fabricated works in the gallery. The opening session was featured in the press and TV news.

The work produced during the research project was featured in the following public exhibitions: “1st Lisbon Mini Maker Faire”, in the Pavilion of Knowledge Ciência Viva, Lisbon (September 19-21, 2014); “DFL Opening Exhibition”, in the DFL gallery, Porto (March-April 2015); “Anuária 2014-15”, in the FAUP, Porto (September – November 2015); “Research Project Final Exhibition”, in the DFL gallery, Porto (November-December, 2015).

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Events

Conferences

Conferences

Events

Workshops

Workshops The research team organized 3 workshops on the use of digital fabrication technologies in arts and architecture: “Constructive Geometry and Wood Connections”, Faculty of Fine Arts of the Lisbon University (May 10, 2014); “Walls & Robots”, FAUP and INESC TEC, Porto (May 17-21, 2014); “Digital Tools and Robotics in Architecture” for the Beirut Arab University students, DFL and UPTEC, Porto (scheduled for January 25-29, 2016).

During the research project, the DFL organized 3 conferences with external guests: “Design democracy” by Branko Kolarevic, from the Faculty of Environmental Design, University of Calgary (May 22, 2014); “Virtual standardization: From the assembly line the digital factory” by Paulo Fonseca de Campos, from the Faculty of Architecture and Urbanism, University of Sao Paulo, (January 21, 015); “A Brazilian experience: Fostering digital integration at LAMO and FAU-UFRJ” by Gonçalo Castro Henriques, from the Federal University of Rio de Janeiro (July 29, 2015); The DFL also hosted a special Creative Morning event on “Robots”, with a lecture by José Pedro Sousa (May 22,2015).

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194

Events

Field Trips

Field Trips

Events

Visits to DFL

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Visits to DFL

To help complementing and informing the research work, the team did the following fieldtrips: Robotic lab of the Architecture and Digital Fabrication group led by Fabio Gramazio and Matthias Kohler, ETH Zurich (July 26, 2013); Robotic lab of the Institute of Computational Design (ICD) led by Achim Menges, University of Stuttgart (July 25, 2013); Fabricate 2014 - Conference on Digital Design and Robotic Construction, ETH Zurich (February 14-15, 2014) Shape Grammar event organized by José Pinto Duarte with the presence of George Stiny, at the Faculty of Architecture, University of Lisbon (April 18, 2014); Factory of Cerâmica Vale da Gândara in Mortágua (November 21, 2014); Factory of Amorim Isolamentos in Vendas Novas (November 27, 2014); Prefabrication Unit of Mota Engil in Rio Maior (August 27, 2015).

With the new facilities, the DFL got the attention of several institutions that planned a visit to the Laboratory to know more about the research work on robotic technologies. Among them: CEAAD, the Advanced Studies Program in Digital Architecture, FAUP + ISCTE, Portugal (November 6, 2014) ISTHMUS Escuela de Arquitectura y Diseño de América Latina y el Caribe, Panamá (November 11, 2014) SAC, Stadelschule Architekturklasse, Germany (May 22, 2015) UPTEC, Porto (June 17, 2015) School of Architecture, University of Minho, Portugal (October 2, 2015); DIA, Dessau International Architecture Graduate School, Germany (October 19, 2015) Master in Art and Design for the Public Space, Faculty of Fine Arts of the University of Porto (November 11, 2015)

196

Events

Final Presentation

Final Presentation To conclude the research project and present its results to the public a final event was organized at the Faculty of Ahrchitecture of the University of Porto. This initiative comprised five parts: installation and exhibition of the CorkCrete Arch in the School; presentation by FAUP Director, Carlos Guimarães; The communication of the work produced during the research project and its results by the principal investigator, José Pedro Sousa; Discussion session with external guests José Pinto Duarte (FAUL), Guilherme Machado Vaz (Architect) and Luís de Sousa (Mota Engil) and team members José Pedro Sousa, João Pedro Xavier, Maria Clara Vale, A. Paulo Moreira and Germano Veiga, on the relevance of robotic technologies in architecture education, practice and industry; Opening of an exhibition of the work in the DFL gallery space.

Events

Final Presentation

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Outputs

Publications

Outputs

Research Project Outputs Summary

Publications

201

Presentations The work developed during the research project was presented to the public in different events, including: 10 Communications in Scientific Meetings 9 Invited Lectures (selection)

Publications

Reports Articles Master Thesis PhD Thesis (in progress) Other

3 12 4 2 5

Presentations

Communications Invited Lectures

10 9

Physical Production

Models Prototypes Installations

66 11 10

Computational Applications

Parametric Definitions

12

Digital Media

Videos Websites

3 3

Technology

New Systems New Tools

1 2

Resources

Laboratory

1

Partnerships

Industrial Technology Research

4 3 3

Workshops Conferences Exhibitions

2 4 4

Events

01

Communications Sousa, J.P. (2014): “Cork as a Digital Material”, What’s the Matter. International Conference. COAC, Barcelona (September, 4)

02

Martins, P. (2014): “Digital Fabrication Technology in Concrete Architecture”, 32nd eCAADe Conference, Northumbria University, Newcastle (September 10)

03

Martins, P. (2014): “Elementos Compósitos em Betão com Geometria Complexa por Processos de Fabrico Automatizado”, 5ª JPEE, LNEC, Lisbon (November 26)

04

Moreira, E.; Veiga, G. (2015): “Cable Robot for Non-Standard Architecture and Construction: a Dynamic Positioning System”, 2015 IEEE ICIT, Seville (March 19)

05

Martins, P. (2015): “Expanding the Material Possibilities of Lightweight Prefabrication in Concrete through Robotic Hot-Wire Cutting”, 33rd eCAADe Conference, TU Vienna (September 17)

06

Sousa, J.P. (2015): “Between Manual and Robotic Approaches to Brick Construction in Architecture”, 33rd eCAADe Conference, TU VIenna (September 17)

07

Varela, J.P. (2015): “Digital Flow in Stone Heritage Buildings. The Nasoni Keystone Experiment”, 33rd eCAADe Conference, TU VIenna (September 18)

08

Sousa, J.P. (2015): Robotic Fabrication of Cork. Emerging Applications and Opportunities in the Building Construction Industry, ACADIA 2015 Conference, 21c Museum hotel, Cincinnati, OH. (October 23)

09

Xavier, J.P. (2015): Fabricação Robótica de Estruturas em Tijolo. Uma experiência no Ensino da Arquitectura, XIX SIGRADI Conference, UFSC, Florianópolis, Brazil. (November 26)

10

Sousa, J.P. (2015): “Robotic Technologies for a Non-Standard Design and Construction in Architecture – Presentation of the Research Project’s Results”, FAUP, Porto (November 30)

01

Invited Lectures Sousa, J.P. (2014): “Printing (in) Architecture”, Faculty of Engineering, University of Porto (April 9)

02

Sousa, J.P. (2014): “Digital Experiments. Material Realities”, 1º ENEA, Encontro Nacional de Estudantes de Arquitectura, Faculty of Architecture, University of Porto (July 14)

03

Sousa, J.P. (2014): “(Digital) Research on Cork”, RoadShow APCOR, FEUP, Porto (November 28)

04

Sousa, J.P. (2015): “Latência do Digital na Arquitectura”, Digital DArq, FCTUC, Coimbra (April 29)

05

Varela, P. (2015): “Repensar a estereotomia”, Digital DArq, FCTUC, Coimbra (April 29)

06

Sousa, J.P. (2015): “Digital Experiments. Material Realities”, Lusófona University, Lisbon (May 21)

07

Sousa, J.P. (2015): “Robots”, Creative Mornings Porto, Porto (May 22)

08

Sousa, J.P.; Gassó, C. (2015): “DFl. Fazedores”, Conferências GLOTE, Porto (May 26)

09

Sousa, J.P. (2015): “Fair faced cork”, FA-UL, Lisbon (July 5)

202

Outputs

Publications

Outputs

Publications

203

Publications

11

Sousa, J.P.; Gasso, C.; Moreira, E.; Pinto, A.M.; Lima, J.; Costa, P.; Costa, P.; Veiga, G.; Moreira, A.P. (2015): “The SPIDERobot: A Cable-Robot System for On-Site Construction in Architecture”. Full Paper accepted for publication in the Rob|Arch 2016 – Robotic Fabrication in Architecture, Art and Design, University of Sidney.

The research work fostered the publication of: 1 Book 12 Articles (peer-reviewed) 3 Reports 4 Master Thesis 5 Publications by Others.

12

Sousa, J.P.; Martins, P.; Varela, P. (2016): “The CorkCrete Arch Project. The Design and Fabrication of a Novel Building System”, in Proceedings of the 21st Annual Conference on Computer-Aided Architectural Design Research in Asia / CAADRIA, The University of Melbourne (to be published)

01

01

Books Sousa, J.P. (Ed.) (2015): Robotic Technologies for a Non-Standard Design and Construction in Architecture. Faculty of Architecture, University of Porto.

Articles Martins, P.; Sousa, J.P. (2014): “Digital Fabrication Technology in Concrete Architecture”, in E.M. Thompson (ed.), Fusion - Proceedings of the 32nd eCAADe Conference - Vol.1 (pp. 475-484), Department of Architecture and Built Environment, Faculty of Engineering and Environment, Newcastle.

02

Sousa J.P. (2014): “Cork as a digital material”, in M. Voyatzaki (Ed.), What’s the Matter. Materiality and Materialism in the Age of Computation (pp. 481-497), ENHSA, Barcelona.

03

Carvalho, P., Nunes, S., Sousa, J.P. (2014): “Elementos Compósitos em Betão com Geometria Complexa por Processos de Fabrico Automatizado” in 5as Jornadas Portuguesas de Engenharia de Estruturas, 26 a 28 Novembro 2014, LNEC, Lisboa, Portugal.

04

Sousa, J.P.; Xavier, J.P. (2015): “Symmetry-Based Generative Design and Fabrication: a Teaching Experiment”, in Automation in Construction Vol.51, March 2015 (pp. 113-123), Elsevier.

05

Moreira, E.; Pinto, A.M.; Costa, P.; Moreira, A.P.; Veiga, G.; Lima, J.; Sousa, J.P.; Costa, P. (2015): “Cable Robot for Non-Standard Architecture and Construction: A Dynamic Positioning System”. in Industrial Technology (ICIT), 2015 IEEE International Conference on (pp. 3184-3189), Seville.

06

Varela, P.; Sousa, J.P. (2015): “Digital Flow in Stone Heritage Buildings. The Nasoni Keystone Experiment “, in B. Martens, G. Wurzer, T. Grasl, WE Lorenz and R. Schaffranek (Eds.), Real Time – Proceedings of the 33rd eCAADe Conference (pp. 717-726), Vienna University of Technology.

07

08

Martins, P; Campos, P.F.; Nunes, S.; Varela, P.; Sousa, J.P. (2015): “Expanding the Material Possibilities of Lightweight Prefabrication in Concrete through Robotic Hot-Wire Cutting” in B. Martens, G. Wurzer, T. Grasl, WE Lorenz and R. Schaffranek (Eds.), Real Time – Proceedings of the 33rd eCAADe Conference (pp. 341-351), Vienna University of Technology.

Sousa, J.P.; Varela, P.; Martins, P (2015): “Between Manual and Robotic Approaches to Brick Construction in Architecture”, in B. Martens, G. Wurzer, T. Grasl, WE Lorenz and R. Schaffranek (Eds.), Real Time – Proceedings of the 33rd eCAADe Conference (pp. 361-370), Vienna University of Technology.

09

Sousa, J.P.; Veiga, G.; Moreira, A.P. (2015): “Robotic Fabrication of Cork. Emerging Applications and Opportunities in the Building Construction Industry”, ACADIA 2015 Conference -Computational Ecologies. Design in the Anthropocene (pp-251-258), Cincinnati, OH.

10

Sousa, J.P., Xavier, J.P. (2015): “Fabricação Robótica de Estruturas em Tijolo. Uma experiência no Ensino da Arquitectura”, in XIX Congresso da Sociedade Iberoamericana de Gráfica Digital - SIGRADI 2015, Blucher Design Proceedings (pp. 143-147), Florianópolis, Brazil.

01

Reports Sousa, J.P. (2014): RobTech – Task 1.1 – Survey in computational design. Report of the Research Project “Robotic Technologies for a Non-Standard Design and Construction in Architecture”, FAUP, INESC TEC, FCT, Porto. Link: http://bit.ly/1pCOILI

02

Sousa, J.P., Moreira, A.P., Veiga, G. (2014): RobTech – Task 1.2 – Survey in robotic technologies. Report of the Research Project “Robotic Technologies for a Non-Standard Design and Construction in Architecture”, FAUP, INESC TEC, FCT, Porto. Link: http://bit.ly/1n0k1yo

03

Sousa, J.P., Xavier, J.P., Póvoas, R. (2014): RobTech – Task 1.3 – Survey in architectural design and construction. Report of the Research Project “Robotic Technologies for a Non-Standard Design and Construction in Architecture”, , FAUP, INESC TEC, FCT, Porto. Link: http://bit.ly/1lX84tN

01

Master Thesis Martins, M.M. (2014): Robotic Architecture. Developing a “Cable-Robot” for Construction. Master Thesis in Electrical and Computer Engineering, Faculty of Engineering of the University of Porto.

02

Oliveira, M. (2014): Architecture and Customization. The Impact of CAD/CAM Technologies. Master Thesis in Architecture, Faculty of Engineering of the University of Porto.

03

Almeida, D. (2015): Tradition and Innovation. Digital Technologies in the Design Process of the Serpentine Gallery Pavilion 2005. Master Thesis in Architecture, Faculty of Engineering of the University of Porto.

04

Oliveira, R. (2015): Digital Design and Construction Possibilities with Bricks departing from the Work of Raul Hestnes Ferreira. Master Thesis in Architecture, Faculty of Engineering of the University of Porto.

01

Publications by Others Neves, C. (2015): “Projectos de Investigação na Área da Arquitectura Digital”, Porto Canal, March 10, 2015 Link: http://bit.ly/1RO3qlS

02

Novo, A.F. (2015): “Arquitectura Digital. Novo Laboratório de Fabricação Digital é único em Portugal”, RTP 1, March 11, 2015 Link: http://bit.ly/1QX2prJ

03

Larguesa, A. (2015): “Escola dos Pritzker cria laboratório para a indústria”, Jornal de Negócios, March 11, 2015. Link: http://bit.ly/1QX2qeZ

04

Faria, R. (2015): “Interview with José Pedro Sousa”. Revista Téchne n.222 (pp. 12-16), São Paulo, Brazil.

Link: http://bit.ly/22uXodB

05

Pinto, L.; Pinheiro, P. (2015): “Robótica Industrial. Um admirável Mundo Novo”. INESC TEC 30 Anos, RTP3, Noveber 14, 2015. Link: http://bit.ly/1mmmUkr

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Outputs

Models

Physical Productions The development of the research tasks on material, design and technology, resulted in the materialization of: 56 models 11 prototypes 10 installations By involving the use of different materials and digital fabrication technologies (e.g. 3d printing and robotic fabrication), this extensive production was presented in the final exhibition at the gallery space of DFL.

Outputs

Models

205

206

Outputs

Prototypes

Outputs

Installations

207

208

Outputs

Website

Outputs

Videos

Website

Videos

The research project involved the creation and mantainance of digital platforms to document and disseminate the work, including: DFL website (http://dfl.arq.up.pt) Project website (http://dfl.arq.up.pt/fct-robtech) Social network (http://www.facebook.com_/faupdfl)

The production of short movies are the best strategy to convey the dynamics of the work produced with the robotic technologies. A set of renders, diagrams, photos and videos were edited to describe the whole digital process –design / fabrication/ installation – of the following 3 works: Striated Wall (http://vimeo.com/127912769) Brick Tower (http://vimeo.com/147909162) CorkCrete Arch (http://vimeo.com/147705782)

Produced from the scratch, the websites covered two goals. One is dedicated to present the new DFL - Digital Fabrication Laboratory (DFL) and register its work and activities.

Inside of this website, it is possible to get access to another website which was specifically programmed to document and illustrate the research project featured in the book.

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Outputs

Laboratory and Partnerships

Outputs

Technology and Tools

Laboratory and Partnerships

Technology and Tools

The creation of the first Digital Fabrication Laboratory in Portugal equipped with robotic technology was one of the most significant achievements of the research project. As a result, the DFL became a member of the International Association of Robots in Architecture.

By uncovering the potentials and limitations of robotic technologies, the development of the research project originated the conception of novel technologies and tools, including: 1 robotic system – the SPIDERobot 2 custom-made fabrication tools – the large-size hotwire and the automatic glue spray system.

The new facilities and resources prompted the establishment of: 4 partnerships with major industrial companies: Amorim Isolamentos; Mota Engil; Valchromat; Cerâmica Vale da Gândara; 3 partnerships with technological companies: ESI, Engenharia, Soluções e Inovação; Kuka Robotics; Norcam.

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Lab Life

Lab Life

215

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Lab Life

Lab Life

217

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Lab Life

Lab Life

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Research Project Robotic Technologies for a Non-Standard Design and Construction in Architecure Ref: PTDC/ATP-AQI/5124/2012 Site: https://dfl.arq.up.pt ftc-robotic-technologies-for-a-non-standard-architecture/ Institutions Principal Contractor FAUP, Faculty of Architecture of the University of Porto www.arq.up.pt Participating Institution INESC TEC, Institute for Systems and Computer Engineering, Technology and Science www.inesctec.pt Hosting Institution CEAU, Center of Studies in Architecture and Urbanism ceau.arq.up.pt Research Group DFL, Digital Fabrication Lab dfl.arq.up.pt Team Principal Investigator José Pedro Sousa FAUP Researchers (PhD) A. Paulo Moreira[01], Germano Veiga[02], João Pedro Xavier [01], Rui Póvoas [01], José Lima [02], Pedro Costa [02], Andry Pinto [02], Eliana Pinho [01], Maria Clara Vale [01], António Valente, P. 2, Moura Oliveira [02], Manuel Silva [02] Researchers (Non-PhD) Pedro Martins [01], Pedro de Azambuja Varela [01], Cristina Gassó Palop [01], Eduardo Moreira [02], António Pedro Moreira [02], Nuno Maia [02], Manuel Oliveira [01], Leonhard Trummer [03], Joana Pinho da Costa [03] Student Assistants Mário Martins [02], Rudrapalsinh Solanki [01,03], Daniel Almeida1, Rui Oliveira [01], Luisa Barreira [01], Rafael Barros [01], Gabriel Correia [01], João Carvalho [01], Catarina Brites [01] Project Management Support Benilde Lopes [04] Consultants Branko Kolarevic, Faculty of Environmental Design, University of Calgari, Canada Paulo Fonseca de Campos, Faculty of Architecture and Urbanism, University of São Paulo, Brazil Mário Kruger, Faculty of Sciences and Technology, University of Coimbra, Portugal Dennis Shelden, Gehry Technologies + Massachusetts Institute of Technology, USA Lawrence Sass, Massachusetts Institute of Technology, USA José Pinto Duarte, Faculty of Architecture, University of Lisbon, Portugal

[01]

FAUP + CEAU

[02]

INESC TEC

[03]

External

[04]

University of Porto

Industrial Partners

Technology Partners

Other Collaborations Seri/Driftec, Frezite, Herco, Falex, Pronun, Epiforma, Building Pictures Technology (Selection) Industrial Robot - KUKA KR 120 R2700 extra HA 3D Printer - Makerbot Replicator 2x Software - Rhinoceros, Grasshopper, Kuka|Prc Building Facilities University of Porto FAUP, Faculty of Architecture of the University of Porto Almeidas & Magalhães – Sociedade de Construções Funding

Robotic Technologies for a Non-Standard Design and Construction in Architecture — Editor: José Pedro Sousa Contributors: Branko Kolarevic, Paulo Fonseca de Campos, A. Paulo Moreira, Germano Veiga, José Pinto Duarte, Guilherme Machado Vaz, Luís de Sousa Design: Epiforma Publisher: FAUP, Faculdade de Arquitectura da Universidade do Porto Edition: DFL, Digital Fabrication Laboratory - dfl.arq.up.pt - dfl@arq.up.pt Place: Porto, Portugal — This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, re-use of illustrations, recitation, broadcasting, reproduction on microfilms or in other ways, and storage in databases.

For any kind of use, permission of the copyright owner must be obtained. (c) 2015 FAUP / DFL (c) 2015 INESC TEC — Printing: Gráfica Maia Douro, SA, Porto, Portugal ISBN: 978-989-8527-06-6 Legal Deposit: 402364/15 — This book made in the scope of the Research Project with the reference PTDC/ ATP-AQI/5124/2012, funded by FEDER funds through the Operational Competitiveness Programme – COMPETE, and by national funds through the FCT – Foundation for the Science and Technology