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Integrative Computational Design and Construction for Architecture (T3.0)
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Research Projects
RP 11-2 – Hybrid FRP-Timber Elements and Material System Development

Hybrid FRP-Timber Building System and Material System Development

Research Project 11-2 (RP 11-2)

HYBRID FRP-TIMBER BUILDING SYSTEM AND MATERIAL SYSTEM DEVELOPMENT FOR LONG-SPAN STRUCTURES AND EXISTING BUILDING STOCK EXTENSIONS

Conceived as an extension of Research Project RP 11-1, this project will address the fundamental research challenges encountered in the development of novel coreless filament wound fibre reinforced polymer (FRP) building systems. Three main challenges have been identified and formalised: the weakness of such systems in creating continuous surfaces and thus properly enclosing a space, the relatively long production time of the construction elements and, ultimately, the heavy environmental footprint of the predominantly used materials.

One of the main consequences of the filigree or lattice-like configuration of coreless filament wound fibre elements is their inherent inability to create continuous surfaces and thus define hermetic architectural spaces. This project will focus on solutions that address this shortcoming by combining the lattice-like filaments with two-dimensional timber plates using mechanical fasteners. This project will explore the design space for such FRP-timber hybrid components, taking into account their architectural function, while at the same time enhancing their structural capabilities, with the timber plates redistributing live loads and the fibres providing structural depth to the system.

From a fabrication point of view, the timber plates can potentially become an integral part of the winding frame, reducing the complexity of the overall fabrication setup. This reduction in complexity will be the first step towards the goal of reducing the overall production time. This will also be achieved by using two robots to wind an element simultaneously. A central aspect of this research project will then be the exploration of the design space for FRP-timber hybrid elements enabled by the augmentation of the fabrication platform.

To address the issue of the high environmental footprint of the materials used to date for coreless filament wound (CFW) elements, this project will investigate alternative combinations of fibres (natural, renewable or semi-synthetic) and resin systems, building on the preliminary studies carried out in Research Project RP 11-1. The aim of this project will be to extend the range of materials suitable for CFW and to define sensible fibre-resin material combinations for specific building elements geometries and configurations.

PRINCIPAL INVESTIGATORS

Prof. Dr.-Ing. Jan Knippers
Institute of Building Structures and Structural Design (ITKE), University of Stuttgart
Prof. Achim Menges
Institute for Computational Design and Construction (ICD), University of Stuttgart

TEAM

Dr.-Ing. Marta Gil Pérez (ITKE)
Dr.-Ing. Christoph Zechmeister (ICD)
Tzu-Ying Chen (ITKE)
Rebeca Duque (ICD)

PEER-REVIEWED PUBLICATIONS

2024
1. Kannenberg, F., Zechmeister, C., Gil Pérez, M., Guo, Y., Yang, X., Forster, D., Hügle, S., Mindermann, P., Abdelaal, M., Balangé, L., Schwieger, V., Weiskopf, D., Gresser, G. T., Middendorf, P., Bischoff, M., Knippers, J., & Menges, A. (2024). Toward reciprocal feedback between computational design, engineering, and fabrication to co-design coreless filament-wound structures. Journal of Computational Design and Engineering, 11(3), Article 3. https://doi.org/10.1093/jcde/qwae048
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  @article{Kannenberg2024, abstract = {{Fiber-reinforced composites offer innovative solutions for architectural applications with high strength and low weight. Coreless filament winding extends industrial processes, reduces formwork, and allows for tailoring of fiber layups to specific requirements. A previously developed computational co-design framework for coreless filament winding is extended toward the integration of reciprocal design feedback to maximize design flexibility and inform design decisions throughout the process. A multi-scalar design representation is introduced, representing fiber structures at different levels of detail to generate feedback between computational design, engineering, and fabrication. Design methods for global, component, and material systems are outlined and feedback generation is explained. Structural and fabrication feedback are classified, and their integration is described in detail. This paper demonstrates how reciprocal feedback allows for co-evolution of domains of expertise and extends the existing co-design framework toward design problems. The developed methods are shown in two case studies at a global and component scale.}}, author = {Kannenberg, Fabian and Zechmeister, Christoph and Gil Pérez, Marta and Guo, Yanan and Yang, Xiliu and Forster, David and Hügle, Sebastian and Mindermann, Pascal and Abdelaal, Moataz and Balangé, Laura and Schwieger, Volker and Weiskopf, Daniel and Gresser, Götz T and Middendorf, Peter and Bischoff, Manfred and Knippers, Jan and Menges, Achim}, doi = {10.1093/jcde/qwae048}, eprint = {https://academic.oup.com/jcde/article-pdf/11/3/374/58347694/qwae048.pdf}, issn = {2288-5048}, journal = {Journal of Computational Design and Engineering}, month = {05}, number = 3, pages = {374-394}, title = {{Toward reciprocal feedback between computational design, engineering, and fabrication to co-design coreless filament-wound structures}}, url = {https://doi.org/10.1093/jcde/qwae048}, volume = 11, year = 2024 }
2023
1. Gil Pérez, M. (2023). Integrative structural design of non-standard building systems: coreless filament-wound structures as a case study (Vol. 49) [Dissertation, Institut für Tragkonstruktionen und Konstruktives Entwerfen, Universität Stuttgart]. https://doi.org/10.18419/opus-12879
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  @phdthesis{GilPerez_thesis, author = {Gil Pérez, Marta}, doi = {10.18419/opus-12879}, publisher = {Institut für Tragkonstruktionen und Konstruktives Entwerfen, Universität Stuttgart}, school = {University of Stuttgart}, title = {Integrative structural design of non-standard building systems: coreless filament-wound structures as a case study}, type = {Dissertation}, volume = 49, year = 2023 }
2. Gil Pérez, M., & Knippers, J. (2023). Integrative Structural Design of Non-Standard Building Systems: Bridging the Gap between Research and Industry. Technology Architecture + Design, 7:2, 244–260. https://doi.org/10.1080/24751448.2023.2246801
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  @article{Gilperez2023, author = {Gil Pérez, Marta and Knippers, Jan}, doi = {10.1080/24751448.2023.2246801}, journal = {Technology \textbar Architecture + Design }, month = {Circularity}, pages = {244-260}, title = {Integrative Structural Design of Non-Standard Building Systems: Bridging the Gap between Research and Industry}, volume = {7:2}, year = 2023 }
3. Gil Pérez, M., Mindermann, P., Zechmeister, C., Forster, D., Guo, Y., Hügle, S., Kannenberg, F., Balangé, L., Schwieger, V., Middendorf, P., Bischoff, M., Menges, A., Gresser, G. T., & Knippers, J. (2023). Data processing, analysis, and evaluation methods for co-design of coreless filament-wound building systems. Journal of Computational Design and Engineering, 10(4), Article 4. https://doi.org/10.1093/jcde/qwad064
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  @article{GilPérezData2023, abstract = {{The linear design workflow for structural systems, involving a multitude of iterative loops and specialists, obstructs disruptive innovations. During design iterations, vast amounts of data in different reference systems, origins, and significance are generated. This data is often not directly comparable or is not collected at all, which implies a great unused potential for advancements in the process. In this paper, a novel workflow to process and analyse the data sets in a unified reference frame is proposed. From this, differently sophisticated iteration loops can be derived. The developed methods are presented within a case study using coreless filament winding as an exemplary fabrication process within an architectural context. This additive manufacturing process, using fiber-reinforced plastics, exhibits great potential for efficient structures when its intrinsic parameter variations can be minimized. The presented method aims to make data sets comparable by identifying the steps each data set needs to undergo (acquisition, pre-processing, mapping, post-processing, analysis, and evaluation). These processes are imperative to provide the means to find domain interrelations, which in the future can provide quantitative results that will help to inform the design process, making it more reliable, and allowing for the reduction of safety factors. The results of the case study demonstrate the data set processes, proving the necessity of these methods for the comprehensive inter-domain data comparison.}}, author = {Gil Pérez, Marta and Mindermann, Pascal and Zechmeister, Christoph and Forster, David and Guo, Yanan and Hügle, Sebastian and Kannenberg, Fabian and Balangé, Laura and Schwieger, Volker and Middendorf, Peter and Bischoff, Manfred and Menges, Achim and Gresser, Götz T and Knippers, Jan}, doi = {10.1093/jcde/qwad064}, eprint = {https://academic.oup.com/jcde/article-pdf/10/4/1460/50882055/qwad064.pdf}, issn = {2288-5048}, journal = {Journal of Computational Design and Engineering}, month = {06}, number = 4, pages = {1460-1478}, title = {{Data processing, analysis, and evaluation methods for co-design of coreless filament-wound building systems}}, url = {https://doi.org/10.1093/jcde/qwad064}, volume = 10, year = 2023 }
4. Schlopschnat, C., Pérez, M. G., Zechmeister, C., Estrada, R. D., Kannenberg, F., Rinderspacher, K., Knippers, J., & Menges, A. (2023). Co-Design of Fibrous Walls for Multi-Story Buildings. In K. Dörfler, J. Knippers, A. Menges, S. Parascho, H. Pottmann, & T. Wortmann (Eds.), Advances in Architectural Geometry 2023 (pp. 235--248). De Gruyter. https://doi.org/10.1515/9783111162683-018
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  @inproceedings{Schlopschnat2023, address = {Berlin, Boston}, author = {Schlopschnat, Christoph and Pérez, Marta Gil and Zechmeister, Christoph and Estrada, Rebeca Duque and Kannenberg, Fabian and Rinderspacher, Katja and Knippers, Jan and Menges, Achim}, booktitle = {Advances in Architectural Geometry 2023}, doi = {10.1515/9783111162683-018}, editor = {Dörfler, Kathrin and Knippers, Jan and Menges, Achim and Parascho, Stefana and Pottmann, Helmut and Wortmann, Thomas}, groups = {Maison Fibre}, isbn = {9783111162683}, lastchecked = {2023-09-27}, pages = {235--248}, publisher = {De Gruyter}, title = {Co-Design of Fibrous Walls for Multi-Story Buildings}, url = {https://doi.org/10.1515/9783111162683-018}, year = 2023 }
5. Zechmeister, C., Gil Pérez, M., Knippers, J., & Menges, A. (2023). Concurrent, computational design and modelling of structural, coreless-wound building components. Automation in Construction, 151, 104889. https://doi.org/10.1016/j.autcon.2023.104889
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  @article{ZECHMEISTER2023104889, abstract = {Coreless filament winding extends established industrial processes, enabling the fabrication of building parts with minimal formwork. Since the part's final geometry is unknown until completed, it creates uncertainties for design and engineering. Existing architectural design workflows are insufficient, and industrial software packages cannot capture the complexity of self-deforming fibres to model complex fibre layups. This research introduces a feedback-based computational method conceived as four development cycles to design and evaluate fibre layups of large-scale architectural building components, and a multi-scalar digital-physical design and evaluation toolset to model and evaluate them at multiple resolutions. The universal applicability of the developed methods is showcased by two different architectural fibre structures. The results show how the systematization of methods and toolset allow for increased design flexibility and deeper integration of interdisciplinary collaborators. They constitute an important step towards a consolidated co-design methodology and demonstrate the potential to simultaneously co-evolve design and evaluation methods.}, author = {Zechmeister, C. and Gil Pérez, M. and Knippers, J. and Menges, A.}, doi = {10.1016/j.autcon.2023.104889}, issn = {0926-5805}, journal = {Automation in Construction}, pages = 104889, title = {Concurrent, computational design and modelling of structural, coreless-wound building components}, url = {https://www.sciencedirect.com/science/article/pii/S0926580523001498}, volume = 151, year = 2023 }
6. Zechmeister, C., Gil Pérez, M., Dambrosio, N., Knippers, J., & Menges, A. (2023). Extension of Computational Co-Design Methods for Modular, Prefabricated Composite Building Components Using Bio-Based Material Systems. Sustainability, 15(16), Article 16. https://doi.org/10.3390/su151612189
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  @article{su151612189, abstract = {Robotic coreless filament winding using alternative material systems based on natural fibers and bio-based resin systems offers possible solutions to the productivity and sustainability challenges of the building and construction sector. Their application in modular, prefabricated structures allows for material-efficient and fast production under tightly controlled conditions leading to high-quality building parts with minimal production waste. Plant fibers made of flax or hemp have high stiffness and strength values and their production consumes less non-renewable energy than glass or carbon fibers. However, the introduction of natural material systems increases uncertainties in structural performance and fabrication parameters. The development process of coreless wound composite parts must thus be approached from the bottom up, treating the material system as an integral part of design and evaluation. Existing design and fabrication methods, as well as equipment, are adjusted to emphasize material aspects throughout the development, increasing the importance of material characterization and scalability evaluation. The reciprocity of material characterization and the fabrication process is highlighted and contributes to a non-linear, cyclical workflow. The implementation of extensions and adaptations are showcased in the development of the livMatS pavilion, a first attempt at coreless filament winding using natural material systems in architecture.}, article-number = {12189}, author = {Zechmeister, Christoph and Gil Pérez, Marta and Dambrosio, Niccolo and Knippers, Jan and Menges, Achim}, doi = {10.3390/su151612189}, issn = {2071-1050}, journal = {Sustainability}, number = 16, title = {Extension of Computational Co-Design Methods for Modular, Prefabricated Composite Building Components Using Bio-Based Material Systems}, url = {https://www.mdpi.com/2071-1050/15/16/12189}, volume = 15, year = 2023 }
2022
1. Balangé, L., Harmening, C., Duque Estrada, R., Menges, A., Neuner, H., & Schwieger, V. (2022). Monitoring the production process of lightweight fibrous structures using terrestrial laser scanning. 5th Joint International Symposium on Deformation Monitoring, Valencia, Spain. https://doi.org/10.4995/JISDM2022.2022.13830
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  @inproceedings{balange2022monitoring, author = {Balangé, Laura and Harmening, Corinna and Duque Estrada, Rebeca and Menges, Achim and Neuner, Hans and Schwieger, Volker}, booktitle = {5th Joint International Symposium on Deformation Monitoring, Valencia, Spain}, doi = {10.4995/JISDM2022.2022.13830}, title = {Monitoring the production process of lightweight fibrous structures using terrestrial laser scanning}, year = 2022 }
2. Gil Pérez, M., Zechmeister, C., Kannenberg, F., Mindermann, P., Balangé, L., Guo, Y., Hügle, S., Gienger, A., Forster, D., Bischoff, M., Tarín, C., Middendorf, P., Schwieger, V., Gresser, G. T., Menges, A., & Knippers, J. (2022). Computational co-design framework for coreless wound fibre-polymer composite structures. Journal of Computational Design and Engineering, 9(2), Article 2. https://doi.org/10.1093/jcde/qwab081
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  @article{Gil_Perez_2022, abstract = {In coreless filament winding, resin-impregnated fibre filaments are wound around anchor points without an additional mould. The final geometry of the produced part results from the interaction of fibres in space and is initially undetermined. Therefore, the success of large-scale coreless wound fibre composite structures for architectural applications relies on the reciprocal collaboration of simulation, fabrication, quality evaluation, and data integration domains. The correlation of data from those domains enables the optimization of the design towards ideal performance and material efficiency. This paper elaborates on a computational co-design framework to enable new modes of collaboration for coreless wound fibre–polymer composite structures. It introduces the use of a shared object model acting as a central data repository that facilitates interdisciplinary data exchange and the investigation of correlations between domains. The application of the developed computational co-design framework is demonstrated in a case study in which the data are successfully mapped, linked, and analysed across the different fields of expertise. The results showcase the framework’s potential to gain a deeper understanding of large-scale coreless wound filament structures and their fabrication and geometrical implications for design optimization.}, author = {Gil Pérez, M and Zechmeister, C and Kannenberg, F and Mindermann, P and Balangé, L and Guo, Y and Hügle, S and Gienger, A and Forster, D and Bischoff, M and Tarín, C and Middendorf, P and Schwieger, V and Gresser, G T and Menges, A and Knippers, J}, doi = {10.1093/jcde/qwab081}, journal = {Journal of Computational Design and Engineering}, month = {04}, note = {M. Gil Perez and C. Zechmeister: first authors equal contribution. F. Kannenberg and P. Mindermann: second authors equal contribution.}, number = 2, pages = {310--329}, publisher = {Oxford University Press ({OUP})}, title = {Computational co-design framework for coreless wound fibre-polymer composite structures}, url = {https://doi.org/10.1093%2Fjcde%2Fqwab081}, volume = 9, year = 2022 }
3. Gil Pérez, M., Früh, N., La Magna, R., & Knippers, J. (2022). Integrative structural design of a timber-fibre hybrid building system fabricated through coreless filament winding: Maison Fibre. Journal of Building Engineering, 49, 104114. https://doi.org/10.1016/j.jobe.2022.104114
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  @article{Gil_Perez_2022, author = {Gil P{\'{e}}rez, Marta and Früh, Nikolas and La Magna, Riccardo and Knippers, Jan}, doi = {10.1016/j.jobe.2022.104114}, journal = {Journal of Building Engineering}, month = {05}, pages = 104114, publisher = {Elsevier {BV}}, title = {Integrative structural design of a timber-fibre hybrid building system fabricated through coreless filament winding: Maison Fibre}, url = {https://doi.org/10.1016%2Fj.jobe.2022.104114}, volume = 49, year = 2022 }
4. Gil Pérez, M., Guo, Y., & Knippers, J. (2022). Integrative material and structural design methods for natural fibres filament-wound composite structures: The LivMatS pavilion. Materials & Design, 217, 110624. https://doi.org/10.1016/j.matdes.2022.110624
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  @article{Gil_Perez_2022, abstract = {Coreless filament winding (CFW) is a novel fabrication technique that utilises fibre-polymer composite materials to efficiently produce filament wound structures in architecture while reducing manufacturing waste. Previous projects have been successfully built with glass and carbon fibre, proving their potential for lightweight construction systems. However, in order to move towards more sustainable architecture, it is crucial to consider replacing carbon fibre’s high environmental impact with other material systems, such as natural fibre. This paper evaluates several fibres, resin systems, and their required CFW fabrication adjustments towards designing and fabricating a bio-composite structure: the LivMatS Pavilion. The methods integrate structural design loops with material evaluation and characterisation, including small-scale and large-scale structural testing at progressive stages. The results demonstrate the interactive decision-making process that combines material characterisation with structural simulation feedback, leveraged to evaluate and optimise the structural design. The built pavilion is proof of the first successful coreless filament wound sustainable natural fibres design, and the developed methods and findings open up further research directions for future applications.}, author = {Gil Pérez, Marta and Guo, Yanan and Knippers, Jan}, doi = {10.1016/j.matdes.2022.110624}, issn = {0264-1275}, journal = {Materials & Design}, month = {05}, pages = 110624, publisher = {Elsevier {BV}}, title = {Integrative material and structural design methods for natural fibres filament-wound composite structures: The LivMatS pavilion}, url = {https://doi.org/10.1016%2Fj.matdes.2022.110624}, volume = 217, year = 2022 }
5. Gil Pérez, M., Zechmeister, C., Menges, A., & Knippers, J. (2022). Coreless filament-wound structures: toward performative long-span and sustainable building systems. In S. Xue, J. Wu, & G. Sun (Eds.), Proceedings of IASS Annual Symposia 2022: Innovation, Sustainability and Legacy (Vol. 2022, pp. 3366–3376). International Association for Shell and Spatial Structures (IASS).
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  @inproceedings{IASS2022gilperez, abstract = {Coreless filament winding (CFW) was developed in 2012 at the University of Stuttgart to reduce material waste during the fabrication of composite parts. This was achieved by diminishing the required formwork of state-of-the-art filament winding to discrete boundary frames. Then, impregnated fibers are wound between them, forming lightweight lattice structures. A series of pavilions at the University demonstrated the system's potential and enabled the transfer of CFW into practice, bringing along other engineering challenges, such as the requirement to prove structural integrity and safety. The BUGA Fibre Pavilion was the first long-span application using CFW. In this project, a series of full-scale structural tests successfully proved the structural capacity of the composite components. Maison Fibre expanded the research toward multi-story building systems and explored the combination of CFW components with timber plates as hybrid slabs. To improve the sustainability aspects of the system, the LivMatS Pavilion replaced the previously used carbon and glass fibers with natural fibers. This pavilion achieved different materiality, showing the potential of bio-composite filament wound structures. This paper describes and compares the design and engineering process in each system: long-span, hybrid slab, and natural fiber components, and reveals the potential and future research goals to achieve more sustainable building systems using CFW structures.}, author = {Gil Pérez, Marta and Zechmeister, Christoph and Menges, Achim and Knippers, Jan}, booktitle = {Proceedings of IASS Annual Symposia 2022: Innovation, Sustainability and Legacy}, editor = {Xue, Su-duo and Wu, Jin-zhi and Sun, Guo-jun}, eventdate = {September 19-22 2022}, eventtitle = {IASS/APCS 2022 Innovation, Sustainability and Legacy}, month = {09}, pages = {3366-3376}, publisher = {International Association for Shell and Spatial Structures (IASS)}, title = {Coreless filament-wound structures: toward performative long-span and sustainable building systems}, venue = {Beijing, China}, volume = 2022, year = 2022 }
6. Guo, Y., Gil Pérez, M., Serhat, G., & Knippers, J. (2022). A design methodology for fiber layup optimization of filament wound structural components. Structures, 38, 1125--1136. https://doi.org/10.1016/j.istruc.2022.02.048
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  @article{Guo_2022, abstract = {The applications of fiber-reinforced polymer (FRP) composites extend rapidly along with the development of new manufacturing techniques. However, due to the complexities introduced by the material and fabrication processes, the application of conventional structural design methods for construction members has been significantly challenging. This paper presents an alternative methodology to find optimum fiber layups for a given tube-shape geometry via a graphical optimization strategy based on structural performance requirements. The proposed technique employs simplified shell element models based on classical lamination theory (CLT) to avoid explicit fiber modeling in the FEA simulations. Lamination parameters are utilized to generate the reduced stiffness matrices for continuous multi-layer FRP lamination. The fiber layup of the component is retrieved from the optimal lamination parameters that maximize the structural performance. The case study results demonstrate that the developed method provides compact solutions, linking the structural design requirements with optimal fiber orientations and volumetric proportions. In addition, the determined solutions can be interpreted directly by the winding fabrication settings.}, author = {Guo, Yanan and Gil Pérez, Marta and Serhat, Gokhan and Knippers, Jan}, doi = {10.1016/j.istruc.2022.02.048}, journal = {Structures}, month = {04}, pages = {1125--1136}, publisher = {Elsevier {BV}}, title = {A design methodology for fiber layup optimization of filament wound structural components}, url = {https://doi.org/10.1016%2Fj.istruc.2022.02.048}, volume = 38, year = 2022 }
7. Guo, Y., Serhat, G., Gil Pérez, M., & Knippers, J. (2022). Maximizing buckling load of elliptical composite cylinders using lamination parameters. Engineering Structures, 262, 114342. https://doi.org/10.1016/j.engstruct.2022.114342
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  @article{Guo_2022, abstract = {Structural members made of fiber-reinforced polymers (FRP) attract increasing attention in the development of novel architectural systems that challenge the standard design methodologies. Cylindrical surfaces constitute one of the typical geometric sets obtained with the FRP component fabrication. This paper explores the influences of two geometric parameters on the buckling performance of elliptical cylinders: inverse slenderness (ratio of minimum diameter to height) and eccentricity (ratio of radii along semi-axes). The overall stiffness properties are defined using lamination parameters. This analysis method eliminates the dependency of optimal solutions on the initial assumptions regarding the laminate configuration, which needs to be explicitly described in multi-layer modeling. Finite element analyses are utilized to compute buckling loads of the cylinders under axial compression force and bi-axial bending moments. The optimal lamination parameters and buckling stresses are determined for various parameters, and the lamination parameters corresponding to the optimal and simple [±45°] angle-ply design points are presented in the lamination parameter plane via Miki's diagram. The results reveal the level of performance that can be achieved by a specific geometry and provide guidelines for the optimal design of elliptical laminated cylinders against buckling.}, author = {Guo, Yanan and Serhat, Gokhan and Gil Pérez, Marta and Knippers, Jan}, doi = {10.1016/j.engstruct.2022.114342}, issn = {0141-0296}, journal = {Engineering Structures}, month = {07}, pages = 114342, publisher = {Elsevier}, title = {Maximizing buckling load of elliptical composite cylinders using lamination parameters}, url = {https://www.sciencedirect.com/science/article/pii/S014102962200459X}, volume = 262, year = 2022 }
8. Mindermann, P., Gil Pérez, M., Kamimura, N., Knippers, J., & Gresser, G. T. (2022). Implementation of fiber-optical sensors into coreless filament-wound composite structures. Composite Structures, 290, 115558. https://doi.org/10.1016/j.compstruct.2022.115558
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  @article{Mindermann_2022, author = {Mindermann, Pascal and Gil Pérez, Marta and Kamimura, Naoki and Knippers, Jan and Gresser, Götz T.}, doi = {10.1016/j.compstruct.2022.115558}, journal = {Composite Structures}, month = {06}, pages = 115558, publisher = {Elsevier}, title = {Implementation of fiber-optical sensors into coreless filament-wound composite structures}, url = {https://doi.org/10.1016%2Fj.compstruct.2022.115558}, volume = 290, year = 2022 }
9. Mindermann, P., Pérez, M. G., Knippers, J., & Gresser, G. T. (2022). Investigation of the Fabrication Suitability, Structural Performance, and Sustainability of Natural Fibers in Coreless Filament Winding. Materials, 15(9), Article 9. https://doi.org/10.3390/ma15093260
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  @article{Mindermann_2022, author = {Mindermann, Pascal and Pérez, Marta Gil and Knippers, Jan and Gresser, Götz T.}, doi = {10.3390/ma15093260}, journal = {Materials}, language = {english}, month = {05}, number = 9, pages = 3260, publisher = {{MDPI} {AG}}, title = {Investigation of the Fabrication Suitability, Structural Performance, and Sustainability of Natural Fibers in Coreless Filament Winding}, url = {https://doi.org/10.3390%2Fma15093260}, volume = 15, year = 2022 }
2021
1. Bodea, S., Mindermann, P., Gresser, G. T., & Menges, A. (2021). Additive Manufacturing of Large Coreless Filament Wound Composite Elements for Building Construction. 3D Printing and Additive Manufacturing. https://doi.org/10.1089/3dp.2020.0346
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  @article{Bodea_2021, abstract = {Digitization and automation are essential tools to increase productivity and close significant added-value deficits in the building industry. Additive manufacturing (AM) is a process that promises to impact all aspects of building construction profoundly. Of special interest in AM is an in-depth understanding of material systems based on their isotropic or anisotropic properties. The presented research focuses on fiber-reinforced polymers, with anisotropic mechanical properties ideally suited for AM applications that include tailored structural reinforcement. This article presents a cyber-physical manufacturing process that enhances existing robotic coreless Filament Winding (FW) methods for glass and carbon fiber-reinforced polymers. Our main contribution is the complete characterization of a feedback-based, sensor-informed application for process monitoring and fabrication data acquisition and analysis. The proposed AM method is verified through the fabrication of a large-scale demonstrator. The main finding is that implementing AM in construction through cyber-physical robotic coreless FW leads to more autonomous prefabrication processes and unlocks upscaling potential. Overall, we conclude that material-system-aware communication and control are essential for the efficient automation and design of fiber-reinforced polymers in future construction.}, author = {Bodea, Serban and Mindermann, Pascal and Gresser, Götz T. and Menges, Achim}, doi = {10.1089/3dp.2020.0346}, journal = {3D Printing and Additive Manufacturing}, month = {08}, publisher = {Mary Ann Liebert Inc}, title = {Additive Manufacturing of Large Coreless Filament Wound Composite Elements for Building Construction}, url = {https://doi.org/10.1089%2F3dp.2020.0346}, year = 2021 }
2. Dambrosio, N., Zechmeister, N., Duque Estrada, R., Kannenberg, F., Gil Pérez, M., Schlopschnat, C., Rinderspacher, K., Knippers, J., & Menges, A. (2021). Design and development of an FRP-Timber hybrid building system for multi-story applications in architecture: Maison Fibre. In B. Farahi, B. Bogosian, J. Scott, J. L. García del Castillo y López, K. Dörfler, J. A. Grant, S. Parascho, & V. A. A. Noel (Eds.), Realignments: Toward Critical Computation - ACADIA 2021.
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  @inproceedings{dambrosio2021design, abstract = {This research demonstrates the development of a hybrid FRP-timber wall and slab system for multi-story structures. Bespoke computational tools and robotic fabrication processes allow for adaptive placement of material according to specific local requirements of the structure thus representing a resource-efficient alternative to established modes of construction. This constitutes a departure from pre-digital, material-intensive building methods, based on isotropic materials towards genuinely digital building systems using lightweight, hybrid composite elements. Design and fabrication methods build upon previous research on lightweight fiber structures conducted at the University of Stuttgart and expand it towards inhabitable, multi-story building systems. Interdisciplinary design collaboration based on reciprocal computational feedback allows for the concurrent consideration of architectural, structural, fabrication and material constraints. The robotic coreless filament winding process only uses minimal, modular formwork and allows for the efficient production of morphologically differentiated building components. The research results were demonstrated through Maison Fibre, developed for the 17th Architecture Biennale in Venice. Situated at the Venice Arsenale, the installation is composed of 30 plate like elements and depicts a modular, further extensible scheme. While this first implementation of a hybrid multi-story building system relies on established glass and carbon fiber composites, the methods can be extended towards a wider range of materials ranging from ultra-high-performance mineral fiber systems to renewable natural fibers.}, author = {Dambrosio, Niccolo and Zechmeister, Niccolo and Duque Estrada, Rebeca and Kannenberg, Fabian and Gil Pérez, Marta and Schlopschnat, Christoph and Rinderspacher, Katja and Knippers, Jan and Menges, Achim}, booktitle = {Realignments: Toward Critical Computation - ACADIA 2021}, editor = {Farahi, Behnaz and Bogosian, Biayna and Scott, Jane and García del Castillo y López, Jose Luis and Dörfler, Kathrin and Grant, June A. and Parascho, Stefana and Noel, Vernelle A. A.}, eventdate = {November 3rd - 6th}, eventtitle = {Realignments: Toward Critical Computation}, title = {Design and development of an FRP-Timber hybrid building system for multi-story applications in architecture: Maison Fibre}, venue = {online}, year = 2021 }
3. Gil Pérez, M., Rongen, B., Koslowski, V., & Knippers, J. (2021). Structural design assisted by testing for modular coreless filament-wound composites: The BUGA Fibre Pavilion. Construction and Building Materials, 301, 124303. https://doi.org/10.1016/j.conbuildmat.2021.124303
  - BibTeX
  BibTeX
  @article{Gil_Perez_2021, abstract = {The BUGA Fibre Pavilion was built in 2019 in the Bundesgartenschau (National Gardening exhibition) at Heilbronn, Germany. The pavilion consists of modular fibre-polymer composite components made out of glass and carbon fibres with an epoxy resin matrix. The fabrication technique employed, called coreless filament winding (CFW), is a variant from conventional filament winding where the core is reduced to minimum frame support. The fibres are wound between these frames, freely spanning and creating the resulting geometry through fibre interaction. For the structural design of these components, conventional modelling and engineering methods were not sufficient as the system cannot be adequately characterized in the early stage. Therefore, a more experimental design approach is proposed for the BUGA Fibre Pavilion, where different levels of detailing and abstraction in the FE simulations are combined with prototyping and structural testing. This paper shows the procedure followed for the design and validation of the structural fibre components. In this process, the simulations are used as a design tool rather than a way to predict failure, while mechanical testing served for the verification and validation of the structural capacity.}, author = {Gil Pérez, Marta and Rongen, Bas and Koslowski, Valentin and Knippers, Jan}, doi = {10.1016/j.conbuildmat.2021.124303}, issn = {0950-0618}, journal = {Construction and Building Materials}, month = {09}, pages = 124303, publisher = {Elsevier {BV}}, title = {Structural design assisted by testing for modular coreless filament-wound composites: The BUGA Fibre Pavilion}, url = {https://doi.org/10.1016%2Fj.conbuildmat.2021.124303}, volume = 301, year = 2021 }
4. Mindermann, P., Bodea, S., Menges, A., & Gresser, G. T. (2021). Development of an Impregnation End-Effector with Fiber Tension Monitoring for Robotic Coreless Filament Winding. Processes, 9(5), 806. https://doi.org/10.3390/pr905080
  - BibTeX
  BibTeX
  @article{mindermann2021development, abstract = {The manufacturing process of robotic coreless filament winding has great potential for efficient material usage and automation for long-span lightweight construction applications. Design methods and quality control rely on an adequate digital representation of the fabrication parameters. The most influencing parameters are related to the resin impregnation of the fibers and the applied fiber tension during winding. The end-effector developed in this study allows efficient resin impregnation, which is controlled online by monitoring the induced fiber tension. The textile equipment was fully integrated into an upscaled nine-axis robotic winding setup. The cyber-physical fabrication method was verified with an application-oriented large-scale proof-of-concept demonstrator. From the subsequent analysis of the obtained datasets, a characteristic pattern in the winding process parameters was identified. }, author = {Mindermann, Pascal and Bodea, Serban and Menges, Achim and Gresser, Götz T.}, doi = {10.3390/pr905080}, journal = {Processes}, month = {05}, pages = 806, title = {Development of an Impregnation End-Effector with Fiber Tension Monitoring for Robotic Coreless Filament Winding}, url = {https://www.mdpi.com/2227-9717/9/5/806}, volume = {9(5)}, year = 2021 }
5. Mindermann, P., Rongen, B., Gubetini, D., Knippers, J., & Gresser, G. T. (2021). Material Monitoring of a Composite Dome Pavilion Made by Robotic Coreless Filament Winding. Materials, 14(19), Article 19. https://doi.org/10.3390/ma14195509
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  BibTeX
  @article{mindermann2021material, abstract = {A hemispherical research demonstration pavilion was presented to the public from April to October 2019. It was the first large-scale lightweight dome with a supporting roof structure primarily made of carbon- and glass-fiber-reinforced composites, fabricated by robotic coreless filament winding. We conducted monitoring to ascertain the sturdiness of the fiber composite material of the supporting structure over the course of 130 days. This paper presents the methods and results of on-site monitoring as well as laboratory inspections. The thermal behavior of the pavilion was characterized, the color change of the matrix was quantified, and the inner composition of the coreless wound structures was investigated. This validated the structural design and revealed that the surface temperatures of the carbon fibers do not exceed the guideline values of flat, black façades and that UV absorbers need to be improved for such applications.}, author = {Mindermann, Pascal and Rongen, Bas and Gubetini, Drilon and Knippers, Jan and Gresser, Götz T.}, doi = {10.3390/ma14195509}, journal = {Materials}, month = {09}, number = 19, pages = 5509, publisher = {{MDPI} {AG}}, title = {Material Monitoring of a Composite Dome Pavilion Made by Robotic Coreless Filament Winding}, url = {https://doi.org/10.3390%2Fma14195509}, volume = 14, year = 2021 }
2020
1. Bodea, S., Dambrosio, N., Zechmeister, C., Gil-Perez, M., Koslowski, V., Rongen, B., Doerstelmann, M., Kyjanek, O., Knippers, J., & Menges, A. (2020). BUGA Fibre Pavilion: Towards Robotically-Fabricated Composite Building Structures. Fabricate 2020: Making Resilient Architecture, 234--243.
  - BibTeX
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  @article{bodea_buga_2020, author = {Bodea, Serban and Dambrosio, Niccolo and Zechmeister, Christoph and Gil-Perez, Marta and Koslowski, Valentin and Rongen, Bas and Doerstelmann, Moritz and Kyjanek, Ondrej and Knippers, Jan and Menges, Achim}, journal = {Fabricate 2020: Making Resilient Architecture}, pages = {234--243}, title = {{BUGA} {Fibre} {Pavilion}: {Towards} {Robotically}-{Fabricated} {Composite} {Building} {Structures}}, year = 2020 }
2. Gil Pérez, M., Rongen, B., Koslowski, V., & Knippers, J. (2020). Structural design, optimization and detailing of the BUGA fibre pavilion. International Journal of Space Structures, 0(0), Article 0. https://doi.org/10.1177/0956059920961778
  - BibTeX
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  @article{doi:10.1177/0956059920961778, abstract = { The BUGA fibre pavilion built in April 2019 at the Bundesgartenschau in Heilbronn, Germany, is the most recent coreless fibre winding research pavilion developed from the collaboration between ICD/ITKE at the University of Stuttgart. The research goal is to create lightweight and high-performance lattice composite structures through robotic fabrication. The pavilion is composed of 60 carbon and glass fibre components, and is covered by a prestressed ethylene tetrafluoroethylene (ETFE) membrane. Each of the components is hollow in section and bone-like in shape. They are joined through steel connectors at the intersecting nodes where the membrane is also supported through steel poles. The components are fabricated by coreless filament winding (CFW), a technique where fibre filaments impregnated with resin are wound freely between two rotating scaffolds by a robotic arm. This novel structural system constitutes a challenge for the designer when proving and documenting the load-carrying capacity of the design. This paper outlines and elaborates on the core methods and workflows followed for the structural design, optimization and detailing of the BUGA fibre pavilion. }, author = {Gil Pérez, Marta and Rongen, Bas and Koslowski, Valentin and Knippers, Jan}, doi = {10.1177/0956059920961778}, editor = {Adriaenssens, Sigrid and Baverel, Olivier and Behnejad, Alireza}, eprint = {https://doi.org/10.1177/0956059920961778}, journal = {International Journal of Space Structures}, month = {10}, number = 0, pages = 0956059920961778, title = {Structural design, optimization and detailing of the BUGA fibre pavilion}, url = {https://doi.org/10.1177/0956059920961778 }, volume = 0, year = 2020 }
3. Zechmeister, C., Bodea, S., Dambrosio, N., & Menges, A. (2020). Design for Long-Span Core-Less Wound, Structural Composite Building Elements. In C. Gengnagel, O. Baverel, & J. Burry (Eds.), Proceedings of the Design Modelling Symposium, Berlin 2019 (pp. 401--415). Springer International Publishing. https://doi.org/10.1007/978-3-030-29829-6_32
  - BibTeX
  BibTeX
  @inproceedings{Zechmeister_Design_2019, abstract = {The aim of this research is to showcase processes and methodologies for the design and development of long-span, core-less wound structural building elements for architectural applications. Departing from established, iterative design methods and a linear digital toolchain, integrative design strategies incorporate parameters like material and fabrication constraints, structural performance and architectural design from the very beginning, establishing feedback loops. This approach seems particularly promising with the architectural application of high performance, long-span fibre components in mind, given their vast range of different and often antagonistic requirements. Building upon previous research in the realm of fibre composites conducted at the Institute for Computational Design (ICD), novel strategies and methods for the design and development of long-span fibre composite components are discussed, based on the 2019 BUGA fibre pavilion, a full scale glass and carbon fibre structure developed for the Bundesgartenschau - a garden fair in Heilbronn, Germany.}, address = {Cham}, author = {Zechmeister, Christoph and Bodea, Serban and Dambrosio, Niccolo and Menges, Achim}, booktitle = {Impact: Design With All Senses}, doi = {https://doi.org/10.1007/978-3-030-29829-6_32}, editor = {Gengnagel, Christoph and Baverel, Olivier and Burry, Jane}, file = {33d58cca-d903-46b4-b579-5420b90a39ad:C\:\\Users\\ac131915\\AppData\\Local\\Swiss Academic Software\\Citavi 6\\ProjectCache\\amdi0te5hfdbkvr37r7ubdq1puiv7nkms1el1ieio\\Citavi Attachments\\33d58cca-d903-46b4-b579-5420b90a39ad.pdf:pdf}, isbn = {978-3-030-29829-6}, journal = {Proceedings of the Design Modelling Symposium, Berlin 2019}, pages = {401--415}, publisher = {Springer International Publishing}, title = {Design for Long-Span Core-Less Wound, Structural Composite Building Elements}, type = {Publication}, year = 2020 }
2019
1. Dambrosio, N., Zechmeister, C., Bodea, S., Koslowski, V., Gil Pérez, M., Rongen, B., Knippers, J., & Menges, A. (2019). Buga Fibre Pavilion: Towards an architectural application of novel fiber composite building systems. In K. Bieg, D. Briscoe, & C. Odom (Eds.), Acadia 2019: Ubiquity and Autonomy, proceedings of the 39th Annual Conference of the Association for Computer Aided Design in Architecture, Texas (pp. 140--149). Acadia Publishing Company.
  - BibTeX
  BibTeX
  @inproceedings{dambrosiobuga, author = {Dambrosio, Niccolo and Zechmeister, Christoph and Bodea, Serban and Koslowski, Valentin and Gil Pérez, Marta and Rongen, Bas and Knippers, Jan and Menges, Achim}, booktitle = {Acadia 2019: Ubiquity and Autonomy, proceedings of the 39th Annual Conference of the Association for Computer Aided Design in Architecture, Texas}, editor = {Bieg, Kory and Briscoe, Danelle and Odom, Clay}, isbn = {978-0-578-59179-7}, pages = {140--149}, publisher = {Acadia Publishing Company}, title = {Buga Fibre Pavilion: Towards an architectural application of novel fiber composite building systems}, year = 2019 }
2. Gil Pérez, M., Dambrosio, N., Rongen, B., Menges, A., & Knippers, J. (2019). Structural optimization of coreless filament wound components connection system through orientation of anchor points in the winding frames. In C. Lazaro, K.-U. Bletzinger, & E. Onate (Eds.), Proceedings of the IASS Annual Symposium 2019 – Structural Membranes 2019 Form and Force (Vol. 2019, pp. 1381--1388). International Association for Shell and Spatial Structures (IASS).
  - BibTeX
  BibTeX
  @inproceedings{gil-perez_structural_2019, author = {Gil Pérez, Marta and Dambrosio, Niccolo and Rongen, Bas and Menges, Achim and Knippers, Jan}, booktitle = {Proceedings of the IASS Annual Symposium 2019 – Structural Membranes 2019 Form and Force}, editor = {Lazaro, C. and Bletzinger, K.-U. and Onate, E.}, eventdate = {7-10 October 2019}, pages = {1381--1388}, publisher = {International Association for Shell and Spatial Structures (IASS)}, title = {Structural optimization of coreless filament wound components connection system through orientation of anchor points in the winding frames}, venue = {Barcelona, Spain}, volume = 2019, year = 2019 }

OTHER PUBLICATIONS

2021
1. Iori, T. (2021). La Maison Fibre o del robot Aracne che fila la casa del futuro. Rassegna di Architettura e Urbanistica, 164, Article 164.
  - BibTeX
  BibTeX
  @article{iori2021maison, author = {Iori, Tullia}, isbn = {978-88-229-0762-2}, issn = {0392-8608}, journal = {Rassegna di Architettura e Urbanistica}, language = {Italian}, month = {05}, number = 164, pages = {90-96}, title = {La Maison Fibre o del robot Aracne che fila la casa del futuro}, year = 2021 }
2. Speight, V. (2021). La fibre robotique. Hors Site Magazine.
  - BibTeX
  BibTeX
  @article{speight2021, author = {Speight, Virginie}, journal = {Hors Site Magazine}, language = {French}, title = {La fibre robotique}, year = 2021 }

DATA SETS

2024
1. Gil Pérez, M., Zechmeister, C., Dambrosio, N., Rongen, B., Menges, A., & Knippers, J. (2024). Material Testing Data for Coreless Filament Winding Using Small-Scale, Star-Type Specimens. DaRUS. https://doi.org/10.18419/darus-4358
  - BibTeX
  BibTeX
  @dataset{darus-4358_2024, author = {Gil Pérez, Marta and Zechmeister, Christoph and Dambrosio, Niccolo and Rongen, Bas and Menges, Achim and Knippers, Jan}, doi = {10.18419/darus-4358}, publisher = {DaRUS}, title = {Material Testing Data for Coreless Filament Winding Using Small-Scale, Star-Type Specimens}, unf = {UNF:6:i+7QKvYQfS2JkcEZo8B5mg==}, url = {https://doi.org/10.18419/darus-4358}, version = {V1}, year = 2024 }
2. Zechmeister, C., Dambrosio, N., Duque Estrada, R., Kannenberg, F., Schlopschnat, C., Bodea, S., Gil Pérez, M., Rongen, B., Knippers, J., & Menges, A. (2024). Component Data Protocols for the Fabrication of Coreless-Wound Structural Building Components in the BUGA Fibre Pavilion and Maison Fibre. DaRUS. https://doi.org/10.18419/darus-4350
  - BibTeX
  BibTeX
  @dataset{darus-4350_2024, author = {Zechmeister, Christoph and Dambrosio, Niccolo and Duque Estrada, Rebeca and Kannenberg, Fabian and Schlopschnat, Christoph and Bodea, Serban and Gil Pérez, Marta and Rongen, Bas and Knippers, Jan and Menges, Achim}, doi = {10.18419/darus-4350}, publisher = {DaRUS}, title = {Component Data Protocols for the Fabrication of Coreless-Wound Structural Building Components in the BUGA Fibre Pavilion and Maison Fibre}, url = {https://doi.org/10.18419/darus-4350}, version = {V1}, year = 2024 }
2023
1. Gil Pérez, M., Mindermann, P., Zechmeister, C., Forster, D., Guo, Y., Hügle, S., Kannenberg, F., Balangé, L., Schwieger, V., Middendorf, P., Bischoff, M., Menges, A., Gresser, G. T., & Knippers, J. (2023). Post-processed and normalized data sets for the data processing, analysis, and evaluation methods for co-design of coreless filament-wound structures. DaRUS. https://doi.org/10.18419/darus-3449
  - BibTeX
  BibTeX
  @dataset{darus-3449_2023, author = {Gil Pérez, Marta and Mindermann, Pascal and Zechmeister, Christoph and Forster, David and Guo, Yanan and Hügle, Sebastian and Kannenberg, Fabian and Balangé, Laura and Schwieger, Volker and Middendorf, Peter and Bischoff, Manfred and Menges, Achim and Gresser, Götz Theodor and Knippers, Jan}, doi = {10.18419/darus-3449}, publisher = {DaRUS}, title = {Post-processed and normalized data sets for the data processing, analysis, and evaluation methods for co-design of coreless filament-wound structures}, unf = {UNF:6:3jBvTQjaf+dWmcUwcF1GkA==}, url = {https://doi.org/10.18419/darus-3449}, version = {V1}, year = 2023 }
2. Gil Pérez, M., Zechmeister, C., Kannenberg, F., Mindermann, P., Balangé, L., Guo, Y., Hügle, S., Gienger, A., Forster, D., Bischoff, M., Tarín, C., Middendorf, P., Schwieger, V., Gresser, G. T., Menges, A., & Knippers, J. (2023). Object model data sets of the case study specimens for the computational co-design framework for coreless wound fibre-polymer composite structures. DaRUS. https://doi.org/10.18419/darus-3375
  - BibTeX
  BibTeX
  @dataset{darus-3375_2023, author = {Gil Pérez, Marta and Zechmeister, Christoph and Kannenberg, Fabian and Mindermann, Pascal and Balangé, Laura and Guo, Yanan and Hügle, Sebastian and Gienger, Andreas and Forster, David and Bischoff, Manfred and Tarín, Cristina and Middendorf, Peter and Schwieger, Volker and Gresser, Götz Theodor and Menges, Achim and Knippers, Jan}, doi = {10.18419/darus-3375}, publisher = {DaRUS}, title = {Object model data sets of the case study specimens for the computational co-design framework for coreless wound fibre-polymer composite structures}, url = {https://doi.org/10.18419/darus-3375}, version = {V1}, year = 2023 }

Prof. Achim Menges

Spokesperson Cluster of Excellence IntCDC

Phone: +49 711 685 82786

E-Mail

Prof. Dr.-Ing. Jan Knippers

Deputy Spokesperson

Phone: +49 711 685 83280

E-Mail

Hybrid FRP-Timber Building System and Material System Development

HYBRID FRP-TIMBER BUILDING SYSTEM AND MATERIAL SYSTEM DEVELOPMENT FOR LONG-SPAN STRUCTURES AND EXISTING BUILDING STOCK EXTENSIONS

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2022

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2021

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2020

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2021

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Prof. Achim Menges

Prof. Dr.-Ing. Jan Knippers

Cluster of Excellence IntCDC

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