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Additive manufacturing (AM) using cyber-physical robotic coreless filament winding (FW) enhances construction automation. This advanced process for fiber-reinforced polymers enables more autonomous prefabrication and upscaling potential in the building industry.

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Area of Science:

  • Engineering
  • Materials Science
  • Construction Technology

Background:

  • The construction industry faces productivity challenges, necessitating advanced automation and digitization.
  • Additive Manufacturing (AM) offers transformative potential for construction processes.
  • Understanding material properties, such as anisotropy in fiber-reinforced polymers, is crucial for AM applications.

Purpose of the Study:

  • To present a cyber-physical manufacturing process enhancing robotic coreless Filament Winding (FW) for fiber-reinforced polymers.
  • To characterize a feedback-based, sensor-informed system for process monitoring and data acquisition in AM.
  • To demonstrate the feasibility of this AM method through a large-scale construction demonstrator.

Main Methods:

  • Enhancement of existing robotic coreless Filament Winding (FW) techniques.
  • Integration of cyber-physical systems for real-time process monitoring.
  • Development of sensor-informed data acquisition and analysis for material characterization.
  • Fabrication of a large-scale demonstrator using glass and carbon fiber-reinforced polymers.

Main Results:

  • The cyber-physical robotic coreless FW method enables more autonomous prefabrication.
  • The developed system facilitates comprehensive process monitoring and data analysis.
  • Upscaling potential for additive manufacturing in construction is significantly unlocked.
  • Anisotropic properties of fiber-reinforced polymers are effectively utilized for tailored structural reinforcement.

Conclusions:

  • Implementing additive manufacturing via cyber-physical robotic coreless FW enhances construction autonomy.
  • Material-system-aware communication and control are vital for efficient automation in fiber-reinforced polymer construction.
  • This approach paves the way for advanced material design and fabrication in the future building industry.