{"id":3263,"date":"2020-08-11T16:05:42","date_gmt":"2020-08-11T20:05:42","guid":{"rendered":"https:\/\/robodk.com\/blog\/?p=3263"},"modified":"2024-12-02T10:37:08","modified_gmt":"2024-12-02T15:37:08","slug":"building-facades-robot-fabrication","status":"publish","type":"post","link":"https:\/\/robodk.com\/blog\/building-facades-robot-fabrication\/","title":{"rendered":"Case Study: Abstract Building Facades With Robot Fabrication"},"content":{"rendered":"\n<p><!--StartFragment--><strong>Abstract shapes are one of the big challenges for fabrication. But, they are becoming more and more common in architecture. <\/strong><\/p>\n\n\n\n<p><strong>How can architects untie themselves from the restrictions of traditional construction methods? <\/strong><\/p>\n\n\n\n<p><strong>One research team has found an ingenious way using RoboDK and Grasshopper. <\/strong><\/p>\n\n\n\n<!--more-->\n\n\n\n<p>In a world of architecture, easy-to-manufacture shapes have traditionally been made up of regular, straight lines. This is why buildings tend to feature smooth, vertical facades with very little variation from one building to the next.<\/p>\n\n\n\n<p>But, times are changing.<\/p>\n\n\n\n<p>Recently, architects have found ever more ingenious ways to break free from the restrictions of traditional building methods. We are now becoming more familiar with the sight of strangely shaped buildings with interesting, varied appearances.<\/p>\n\n\n\n<p>The facade of the building (its front-facing appearance) is key to creating these interesting shapes. But, it can be difficult to fabricate complex facades in a way that is quick and cost-effective.<\/p>\n\n\n\n<p>This is exactly the problem that one research team has tackled with RoboDK.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Introducing\u2026 the Building Envelope Research Group<\/h2>\n\n\n\n<p>The <a target=\"_blank\" name=\"https:\/\/www.hs-anhalt.de\/en\/home\/research-group.html\" rel=\"noopener noreferrer\"><\/a><a href=\"https:\/\/www.hs-anhalt.de\/en\/home\/research-group.html\" target=\"_blank\" rel=\"noopener noreferrer\">Building Envelope Research Group<\/a> (BERG) is based in the Anhalt University of Applied Sciences in K\u00f6then, Germany.<\/p>\n\n\n\n<p>BERG&#8217;s primary focus is to expand the &#8220;scope of the building envelope&#8221; with new and innovative fabrication methods, looking at materials, construction techniques, technology, and energy. Their current research projects range from methods to create self-sufficient ventilation systems through to the development of bendable acoustic panels.<\/p>\n\n\n\n<p>The group got in touch with us because they were using RoboDK for one of their research projects.<\/p>\n\n\n\n<p>This project used an interesting approach to robot manufacturing to create forms for abstract concrete facades.<\/p>\n\n\n\n<figure class=\"wp-block-video aligncenter\"><video height=\"640\" style=\"aspect-ratio: 640 \/ 640;\" width=\"640\" controls muted src=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/Berg-Research-Panel-Manufacturing-KUKA-RoboDK.mp4\"><\/video><figcaption class=\"wp-element-caption\">Video from Building Envelope Research Group (BERG)<\/figcaption><\/figure>\n\n\n\n<script src=\"\/videoplay.js\"><\/script>\n\n\n\n<h2 class=\"wp-block-heading\">Why Abstract Facades Are Tricky to Fabricate<\/h2>\n\n\n\n<p><a target=\"_blank\" name=\"https:\/\/www.homify.co.uk\/ideabooks\/4145093\/8-materials-perfect-for-exterior-facades\" rel=\"noopener noreferrer\"><\/a><a href=\"https:\/\/www.homify.co.uk\/ideabooks\/4145093\/8-materials-perfect-for-exterior-facades\" target=\"_blank\" rel=\"noopener noreferrer\">Many different materials<\/a> can be used to create a building facade. Common options include wood, metal, stone, and masonry. However, one of the most versatile options is concrete.<\/p>\n\n\n\n<p>Concrete has an advantage over other materials because it is cheap, hard-wearing, and extremely adaptable. As it begins in liquid form, you can create almost any shape that you can imagine\u2026 as long as you have a method to hold the shape of the wet concrete as it sets.<\/p>\n\n\n\n<p>The challenge, therefore, comes in the creation of forms to hold the shape of the concrete facade panels. If you want to create interesting abstract shapes out of concrete, you need to create equally interesting abstract forms that are capable of supporting the wet concrete.<\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5785-768x1024.jpg\" alt=\"\" class=\"wp-image-3265\" srcset=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5785-768x1024.jpg 768w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5785-225x300.jpg 225w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5785-1152x1536.jpg 1152w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5785-1536x2048.jpg 1536w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5785-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Image from Building Envelope Research Group (BERG)<\/figcaption><\/figure>\n\n\n\n<p>Common options for creating such forms include<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Creating a mold out of wood, rubber, or metal.<\/li>\n\n\n\n<li>Using a flexible table with actuators and membranes to alter its shape.<\/li>\n\n\n\n<li>Using a CNC machine to mill a form out of foam or plastic.<\/li>\n<\/ul>\n\n\n\n<p>These are all good options but they can be expensive and take a long time to create. For example, flexible tables are quick to reconfigure into a new shape, but the upfront machine cost is very high. CNC milled foam takes 5-10 hours to create and can only be reused 5-10 times before they need to be remade.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Why Use Abstract Facades At All?<\/h3>\n\n\n\n<p>You might wonder why we want to create abstract facades for buildings at all.<\/p>\n\n\n\n<p>Of course, the main reason is aesthetics \u2014 they look good. However, modern facades are not all about aesthetics. The design of the facade can also <a target=\"_blank\" name=\"https:\/\/wfmmedia.com\/future-facade-is-about-creating-a-sustainable-facade\/\" rel=\"noopener noreferrer\"><\/a><a href=\"https:\/\/wfmmedia.com\/future-facade-is-about-creating-a-sustainable-facade\/\" target=\"_blank\" rel=\"noopener noreferrer\">enhance the sustainability of the building<\/a>.<\/p>\n\n\n\n<p>Facades are also a great place to test out new fabrication techniques, as the team at BERG demonstrated in their project.<\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5760-1024x768.jpg\" alt=\"\" class=\"wp-image-3266\" srcset=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5760-1024x768.jpg 1024w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5760-300x225.jpg 300w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5760-768x576.jpg 768w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5760-1536x1152.jpg 1536w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5760-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Image from Building Envelope Research Group (BERG)<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">The Project: Creating Abstract Forms for Fiber-Reinforced Concrete<\/h2>\n\n\n\n<p>The team decided to use robot fabrication to create styrofoam molds for the concrete, which was reinforced with glass fibers.<\/p>\n\n\n\n<p>The robot used a hot wire to cut the styrofoam blocks and was programmed via RoboDK.<\/p>\n\n\n\n<p>To handle the abstract shapes, they chose the CAD package Rhino due to its parametric modeling capabilities. Parametric modeling allows designers to create previously unimaginable structures easily and it is often used by architects for this reason. We previously discussed the benefits of using Rhino with RoboDK in our article <a target=\"_blank\" name=\"https:\/\/robodk.com\/blog\/rhino-robodk-projects\/\" rel=\"noopener noreferrer\"><\/a><a href=\"https:\/\/robodk.com\/blog\/rhino-robodk-projects\/\" target=\"_blank\" rel=\"noopener noreferrer\">6 Amazing Things You Can Do With Rhino and RoboDK<\/a>.<\/p>\n\n\n\n<p>They first designed their CAD model within Rhino (and its algorithmic modeler Grasshopper) and then used the <a target=\"_blank\" name=\"https:\/\/robodk.com\/blog\/rhino-robot-programming\/\" rel=\"noopener noreferrer\"><\/a><a href=\"https:\/\/robodk.com\/blog\/rhino-robot-programming\/\" target=\"_blank\" rel=\"noopener noreferrer\">RoboDK Rhino plugin<\/a> to send these designs directly to their robot.<\/p>\n\n\n\n<p>As the team at BERG is largely focused on material properties, a major part of this research project involved testing the structural properties of the concrete after it was formed in this way.<\/p>\n\n\n\n<p>One important property was the surface finish. They found that they could vary the detail of the surface finish by changing how quickly they moved the robot. Slower speeds led to a smoother surface finish.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5616-768x1024.jpg\" alt=\"\" class=\"wp-image-3270\" srcset=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5616-768x1024.jpg 768w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5616-225x300.jpg 225w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5616-1152x1536.jpg 1152w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5616-1536x2048.jpg 1536w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5616-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\">The Robotic Setup<\/h3>\n\n\n\n<p>The robotic hardware that the team used was as follows:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Robot:<\/strong> A KUKA KR 16-2 6-axis industrial robot.<\/li>\n\n\n\n<li><strong>End effector: <\/strong>A metal rig on which was mounted a hot wire to cut the styrofoam.<\/li>\n\n\n\n<li><strong>Table: <\/strong>The styrofoam block was fixed to a table, ensuring that it didn&#8217;t move during the cutting operation.<\/li>\n\n\n\n<li><strong>Programming setup: <\/strong>Rhino and Grasshopper for CAD design and structural (<a name=\"https:\/\/interestingengineering.com\/what-is-finite-element-analysis-and-how-does-it-work#:~:text=Finite%20Element%20Analysis%20or%20FEA,a%20variety%20of%20other%20disciplines.\" target=\"_blank\" rel=\"noopener noreferrer\"><\/a><a href=\"https:\/\/interestingengineering.com\/science\/what-is-finite-element-analysis-and-how-does-it-work\" target=\"_blank\" rel=\"noreferrer noopener\">FEA<\/a>) analysis, attached to RoboDK via the plugin.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Benefits of Using Robot-Fabricated Styrofoam for Facades<\/h2>\n\n\n\n<p>There were several benefits that the team found with their method compared to the more standard approaches to concrete facade fabrication.<\/p>\n\n\n\n<p>These included:<\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong>It was cheaper \u2014 <\/strong>The up-front costs for this method were less than those with other methods of form production. For example, CNC milled forms cost up to \u20ac400 per square meter. With this method, the cost was only \u20ac30 per square meter.<\/li>\n\n\n\n<li><strong>It was quicker \u2014 <\/strong>The time to create the form was only 1 hour. With every other type of manufactured form, it would take between 2-10 hours to create. The only faster option would be to use the costly flexible tables.<\/li>\n\n\n\n<li><strong>It was flexible \u2014 <\/strong>Unlike other options, the only limit to this method was the reachability of the robot and the dimensions of the cutting wire. This increases the flexibility of this method.<\/li>\n<\/ol>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5776-768x1024.jpg\" alt=\"\" class=\"wp-image-3280\" srcset=\"https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5776-768x1024.jpg 768w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5776-225x300.jpg 225w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5776-1152x1536.jpg 1152w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5776-1536x2048.jpg 1536w, https:\/\/robodk.com\/blog\/wp-content\/uploads\/2020\/08\/IMG_5776-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/figure>\n\n\n\n<p>For more information about this project, <a target=\"_blank\" name=\"https:\/\/www.researchgate.net\/publication\/310470580_Robotic_fabrication_of_freeform_foam_structures_with_quadrilateral_and_puzzle_shaped_panels\" rel=\"noopener noreferrer\"><\/a><a href=\"https:\/\/www.researchgate.net\/publication\/310470580_Robotic_fabrication_of_freeform_foam_structures_with_quadrilateral_and_puzzle_shaped_panels\" target=\"_blank\" rel=\"noopener noreferrer\">check out their research paper<\/a>.<\/p>\n\n\n\n<p><em>What architectural projects can you think of for robotic fabrication? <strong>Tell us in the comments below or join the discussion on <a rel=\"noopener noreferrer\" href=\"https:\/\/www.linkedin.com\/company\/robodk\/\" target=\"_blank\">LinkedIn<\/a>, <a rel=\"noopener noreferrer\" href=\"https:\/\/twitter.com\/robodkinc\" target=\"_blank\">Twitter<\/a>, <a rel=\"noopener noreferrer\" href=\"https:\/\/www.facebook.com\/robodkinc\" target=\"_blank\">Facebook,<\/a> <a rel=\"noopener noreferrer\" href=\"https:\/\/www.instagram.com\/robodk\/\" target=\"_blank\">Instagram,<\/a> or in <a rel=\"noopener noreferrer\" href=\"https:\/\/robodk.com\/forum\/\" target=\"_blank\">the RoboDK Forum<\/a>.<\/strong><\/em><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Abstract shapes are one of the big challenges for fabrication. But, they are becoming more and more common in architecture. [&hellip;]<\/p>\n","protected":false},"author":753,"featured_media":3269,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[2210,887,29,391,6,44],"tags":[2057,1558],"class_list":["post-3263","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-art","category-cad","category-cam","category-construction","category-robot-machining","category-robot-software","tag-architecture","tag-kuka"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Case Study: Abstract Building Facades With Robot Fabrication - RoboDK blog<\/title>\n<meta name=\"description\" content=\"Abstract shapes are one of the big challenges for fabrication but are becoming more common in architecture. 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