Robotic manipulators as advanced manufacturing agents for laser-cut construction systems

Robotic manipulators are transforming advanced manufacturing by allowing for the precise manufacture of intricate geometries and the direct transfer of digital data to physical materials. Recent work in the Architecture and Structures Lab (ASLab) of Politecnico di Milano has explored how these technologies can be integrated into laser-cut construction systems, particularly into workflows that connect digital design with robotic assembly. A series of methods are described to optimise designs for handling by manipulator arms, employing reachability analyses and assembly sequencing to ensure that construction is feasible. The stability of structures during scaffold-free assembly has been verified using R-funicularity and Coupled Rigid-Block analysis, with the goal to minimize reliance on temporary scaffolding during robotic assembly. Online control systems have been explored to improve on more widespread offline planners, utilizing fiducial markers and point cloud data to improve accuracy and robustness of automation. These workflows significantly enhance the fabrication and assembly of interlocking panelised structures, allowing for precise placement and a reduction in errors as well as providing early-stage design feedback. A case study with laser-cut timber sheets demonstrates cost-effective manufacture of contour crafted panels and their robotic assembly. This research pushes forward the integration of online planning for robotics in manufacture, providing a scalable workflow for automated assembly. With this, it is shown that through incorporating sensor feedback it is possible to improve manufacturing process precision and lessen the need for manual calibration.