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Integrative Computational Design and Construction for Architecture (T3.0)
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RP 14-1 – Cyber-Physical Prefabrication Platform for Fibre Composites

Cyber-Physical Prefabrication Platform for Fibre Composites

Research Project 14-1 (RP 14-1)

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IntCDC Reserach Project 14-1 – Cyber-Physical Prefabrication Platform for Fibre Composites

ADDITIVE CYBER-PHYSICAL PREFABRICATION PLATFORM FOR MULTIFUNC-TIONAL, MULTI-SCALE LOAD-ADAPTED FIBRE COMPOSITE BUILDING ELEMENTS INCLUDING FABRICATION SIMULATION AND DIGITAL TWIN

The aim of this project is to conceptualise and develop a reliable and fast cyber-physical prefabrication system (CPPS) that enables the fabrication of multifunctional, multi-scale load-adapted fibre composite materials using collaborating robots.

Part of the CPPS is a new fibre handling technology that exceeds the capabilities of the established fibre placement methods. Embedded sensors provide detailed process and material state monitoring, enabling a sophisticated process control, online path-adaptation and the creation of a digital twin of the part. The digital twin allows the structural integrity of the part to be verified. An additional goal of this project is to derive robot paths from a given part structure. The challenges here are mainly due to the complexity of the CPPS, which allows the simultaneous movement of multiple fibre handling systems, multiple robots and the part itself. In comparison to established path-planning approaches, path-planning becomes much more complex, requiring a sophisticated collision avoidance, kinematic redundancy resolution and detailed fabrication simulation. Finally, a new method for process modelling is developed to enable process control, digital twin construction and path planning, where a good trade-off between accuracy and speed needs to be implemented.

PRINCIPAL INVESTIGATORS

Prof. Dr.-Ing. Alexander Verl
Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW), University of Stuttgart
Prof. Achim Menges
Institute for Computational Design and Construction (ICD), University of Stuttgart
Prof. Dr.-Ing. Peter Middendorf
Institute of Aircraft Design (IFB), University of Stuttgart

TEAM

Dr.-Ing. Stefan Carosella (IFB)
Dr.-Ing. Armin Lechler (ISW)
Dr.-Ing. Tobias Schwinn (ICD)
Dr.-Ing. Christoph Zechmeister (ICD)
Jörg Dittmann (IFB)
Sebastian Hügle (IFB)
Marko Szcesny (IBB)
Martin Wolf (ISW)
Timo König (ISW)

PEER-REVIEWED PUBLICATIONS

2024
1. Carosella, S., Hügle, S., Helber, F., & Middendorf, P. (2024). A short review on recent advances in automated fiber placement and filament winding technologies. Composites Part B: Engineering, 287, 111843. https://doi.org/10.1016/j.compositesb.2024.111843
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  @article{Carosella_2024, abstract = {Recent advances in Automated Fiber Placement (AFP) and Filament Winding (FM) are driving steady improvements in technological understanding, enabling the production of more precise, cost- and material-efficient layups that pave the way for new applications. Evolving from automated Tape Laying Technology (ATL), AFP is a technology that not only mimics the manual laying process but also allows tailored fiber and tow alignment to deliver load-optimized patterns, stacking sequences and part structures leading to improved mechanical performance and significant waste reduction. The filament winding evolution towards automated Robotic Filament Winding put the technology in a position to manufacture highly complex lightweight structures in architecture. In this short review, recent developments in both automated fiber alignment technologies are presented and discussed, including the main advantages and materials used. Regarding the ATL and AFP process, developments in non-aerospace applications are considered. Besides a short overview of new placement technologies, advances in Tailored Fiber Placement (TFP) in the field of dry fiber placement are reported. Finally, new robotic filament winding applications in free-form and Coreless Filament Winding (CFW) in architecture are presented.}, author = {Carosella, Stefan and Hügle, Sebastian and Helber, Florian and Middendorf, Peter}, doi = {10.1016/j.compositesb.2024.111843}, issn = {1359-8368}, journal = {Composites Part B: Engineering}, month = {12}, pages = 111843, publisher = {Elsevier BV}, title = {A short review on recent advances in automated fiber placement and filament winding technologies}, url = {http://dx.doi.org/10.1016/j.compositesb.2024.111843}, volume = 287, year = 2024 }
2. 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, 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., 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, 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 }
2. König, T., Verl, A., & Lechler, A. (2023). Cornuspline Path Planning Algorithm for the Fabrication of Coreless Wound Fiber-Polymer Composite Structures. IECON 2023- 49th Annual Conference of the IEEE Industrial Electronics Society, 1–6. https://doi.org/10.1109/IECON51785.2023.10312385
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  @inproceedings{10312385, abstract = {Industrial robots are now used in a wide range of manufacturing processes. The increasing demands on quality and the complexity of the processes cannot always be met by the range of functions that are available in numerical control systems. In the coreless winding of fiber-polymer composites, it is important to keep the roving tension as constant as possible while maintaining a high processing speed. Currently, the winding paths are programmed via a number of control points. This results in a trade-off between lower process properties and higher processing speed with fewer control points. Conversely, finer interpolation of the path can improve process characteristics at lower processing speeds. With interpolation methods that are adapted to the process, new possibilities open up to overcome these trade-offs. This paper presents a spline path planning algorithm based on clothoids. This algorithm considers both the process requirements and the dynamic characteristics of the manufacturing unit. Furthermore, the algorithm is validated on a test contour and compared with established commercial methods.}, author = {König, Timo and Verl, Alexander and Lechler, Armin}, booktitle = {IECON 2023- 49th Annual Conference of the IEEE Industrial Electronics Society}, doi = {10.1109/IECON51785.2023.10312385}, issn = {2577-1647}, month = {10}, pages = {1-6}, title = {Cornuspline Path Planning Algorithm for the Fabrication of Coreless Wound Fiber-Polymer Composite Structures}, year = 2023 }
3. 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 }
4. 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, 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 }
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, Article July. https://doi.org/10.1016/j.autcon.2023.104889
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  @article{zechmeister2023concurrent, affiliation = {Zechmeister, C (Corresponding Author), Univ Stuttgart, Inst Computat Design & Construct ICD, Keplerstr 11, D-70174 Stuttgart, Germany. Zechmeister, C.; Menges, A., Univ Stuttgart, Inst Computat Design & Construct ICD, Keplerstr 11, D-70174 Stuttgart, Germany. Perez, M. Gil; Knippers, J., Univ Stuttgart, Inst Bldg Struct & Struct Design ITKE, Keplerstr 11, D-70174 Stuttgart, Germany. Zechmeister, C.; Perez, M. Gil; Knippers, J.; Menges, A., Univ Stuttgart, Cluster Excellence Integrat Computat Design & Cons, Keplerstr 11, D-70174 Stuttgart, Germany.}, author = {Zechmeister, Christoph and Gil Pérez, Marta and Knippers, Jan and Menges, Achim}, doi = {10.1016/j.autcon.2023.104889}, issn = {{0926-5805} and {1872-7891}}, journal = {Automation in construction}, language = {eng}, number = {July}, pages = 104889, publisher = {Elsevier}, research-areas = {Construction & Building Technology; Engineering}, title = {Concurrent, computational design and modelling of structural, coreless-wound building components}, unique-id = {WOS:000990783100001}, url = {https://www.sciencedirect.com/science/article/pii/S0926580523001498}, volume = 151, year = 2023 }
2022
1. 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, 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 }
2. Gil Pérez, M., Zechmeister, C., Menges, A., & Knippers, J. (2022). Coreless filament-wound structures: toward performative long-span and sustainable building systems. In S.-d. Xue, J.-z. Wu, & G.-j. 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 }
3. Hügle, S., Genc, E., Dittmann, J., & Middendorf, P. (2022). Offline Robot-Path-Planning and Process Simulation for the Structural Analysis of Coreless Wound Fibre-Polymer Composite Structures. Key Engineering Materials, 926, 1445–1453. https://doi.org/10.4028/p-970esd
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  @article{hugle2022, abstract = {In the coreless filament winding process (CFW) anchor points are wrapped with pre-impregnated fibre bundles (Towpregs) in a defined chronological order. With this process, fibre-polymer composite structures with a very high lightweight potential and very little material consumption can be created for different applications in the automotive, aeronautical, sports and architectural sector. The winding sequence and the fibre interaction thereby does have an influence on the final fibre architecture and thus on its structural behaviour. To take this into account a process chain for path planning and process simulation out of a design model is presented. To achieve flexible considerations of different design concepts a parameter-based method for the necessary path planning of the final three-dimensional fibre architecture is introduced. The approach is evaluated on different kinds of specimen.}, author = {H{\"{u}}gle, Sebastian and Genc, Enis and Dittmann, J{\"{o}}rg and Middendorf, Peter}, doi = {10.4028/p-970esd}, journal = {Key Engineering Materials}, month = {08}, pages = {1445--1453}, title = {Offline Robot-Path-Planning and Process Simulation for the Structural Analysis of Coreless Wound Fibre-Polymer Composite Structures}, volume = 926, year = 2022 }
4. Menges, A., Kannenberg, F., & Zechmeister, C. (2022). Computational co-design of fibrous architecture. Architectural Intelligence, 1, Article 1. https://doi.org/10.1007/s44223-022-00004-x
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  @article{Menges2022CoDesignFiber, abstract = {Fibrous architecture constitutes an alternative approach to conventional building systems and established construction methods. It shows the potential to converge architectural concerns such as spatial expression and structural elegance, with urgently required resource effectiveness and material efficiency, in a genuinely computational approach. Fundamental characteristics of fibre composite are shared with fibre structures in the natural world, enabling the transfer of design principles and providing a vast repertoire of inspiration. Robotic fabrication based on coreless filament winding, a technique to deposit resin impregnated fibre filaments with only minimal formwork, as well as integrative computational design methods are imperative to the development of complex fibrous building systems. Two projects, the BUGA Fibre Pavilion as an example for long-span structures, and Maison Fibre as an example of multi-storey architecture, showcase the application of those techniques in an architectural context and highlight areas of further research opportunities. The highly interrelated aesthetic, structural and fabrication characteristics of fibre nets are difficult to understand and go beyond a designer’s comprehension and intuition. An AI powered, self-learning agent system aims to extend and thoroughly explore the design space of fibre structures to unlock the full design potential coreless filament winding offers. In order to ensure feedback between all relevant design and performance criteria and enable interdisciplinary convergence, these novel design methods are embedded in a larger co-design framework. It formalizes the interaction of involved interdisciplinary domains and allows for interactive collaboration based on a central data model, serving as a base for design optimisation and exploration. To further advance research on fibre composites in architecture, bio-based materials are considered, continuing the journey of discovery of fibrous architecture to fundamentally rethinking design and construction towards a novel, computational material culture in architecture.}, author = {Menges, Achim and Kannenberg, Fabian and Zechmeister, Christoph}, doi = {10.1007/s44223-022-00004-x}, issn = {27316726}, journal = {Architectural Intelligence}, number = 1, pages = {6--}, refid = {Menges2022}, title = {Computational co-design of fibrous architecture}, url = {https://doi.org/10.1007/s44223-022-00004-x}, volume = 1, year = 2022 }
5. Wolf, M., Kaiser, B., Hügle, S., Verl, A., & Middendorf, P. (2022). Data Model for Adaptive Robotic Construction in Architecture. Procedia CIRP, 107, 1035–1040. https://doi.org/10.1016/j.procir.2022.05.104
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  @inproceedings{wolf2022model, author = {Wolf, Martin and Kaiser, Benjamin and Hügle, Sebastian and Verl, Alexander and Middendorf, Peter}, doi = {10.1016/j.procir.2022.05.104}, journal = {Procedia CIRP}, pages = {1035-1040}, publisher = {Elsevier BV}, title = {Data Model for Adaptive Robotic Construction in Architecture}, url = {https://doi.org/10.1016%2Fj.procir.2022.05.104}, volume = 107, 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. Bodea, S., Zechmeister, C., Dambrosio, N., Dörstelmann, M., & Menges, A. (2021). Robotic coreless filament winding for hyperboloid tubular composite components in construction. Automation in Construction, 126, 103649. https://doi.org/10.1016/j.autcon.2021.103649
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  @article{Bodea_2021, abstract = {Novel fabrication methods are necessary to capitalize on the high strength-to-weight ratio of composites engineered for construction applications. This paper presents prefabrication strategies for geometrically-complex building elements wound out of Glass and Carbon Fiber Reinforced Polymers (G/CFRP). The research focuses on Robotic Coreless Filament Winding (RCFW), a technology that eliminates formwork, proposing upscaling and industrialization strategies combined with updated robot programming and control methods. Our application addresses the prefabrication of hyperboloid, tubular components with differentiated geometry and fiber layout. We examine how the proposed methods enabled the industrial prefabrication of a building-scale G/CFRP dome structure and discuss the industrial process relative to key fabrication parameters. Highlighting the interdisciplinary nature of the research, we envisage future directions and applications for RCFW in construction. Overall, we find that synergy between academia and industry is essential to meeting research, productivity, and certification goals in the rather conservative building industry.}, author = {Bodea, Serban and Zechmeister, Christoph and Dambrosio, Niccolo and Dörstelmann, Moritz and Menges, Achim}, doi = {10.1016/j.autcon.2021.103649}, editor = {Skibniewski, Miroslaw J.}, issn = {0926-5805}, journal = {Automation in Construction}, month = {06}, pages = 103649, publisher = {Elsevier {BV}}, title = {Robotic coreless filament winding for hyperboloid tubular composite components in construction}, url = {https://doi.org/10.1016%2Fj.autcon.2021.103649}, volume = 126, year = 2021 }
3. Ellwein, C., Reichle, A., Herschel, M., & Verl, A. (2021). Integrative data processing for cyber-physical off-site and on-site construction promoting co-design. Procedia CIRP, 100, 451–456. https://doi.org/10.1016/j.procir.2021.05.103
  - BibTeX
  BibTeX
  @article{Ellwein_2021, abstract = {The term co-design describes a collaborative design process, usually across the boundaries of individual areas. A major aspect, and often an obstacle in the implementation of the co-design approach, is the establishment of a centralized data management system. In the past, the data management concept has been approached from different perspectives. Current approaches usually are oriented along the process chain and thus reflect a unidirectional flow of information. Neither the information feedback nor the reaction to adjustments in upstream model steps is supported, which makes continuous collaboration more difficult and at best reduces the co-design approach for continuous data usage. This paper addresses these weaknesses while outlining an integrative data processing concept enabling co-design between the domains of construction and industrial prefabrication. Geometrical information generated during architectural design and construction planning is reused for the production of components, manufacturing-related design adjustments are transferred back into the domain of construction. Changes throughout the entire process are centrally recorded. To ensure independence from the software tools used and to consider their great diversity, data exchange is largely based on standards, namely industry foundation classes and the standard for the exchange of product model data. In order to counteract the sequential processing according to a waterfall model and to support the co-design approach, the industrial prefabrication toolchain, consisting of computer-aided manufacturing software and downstream postprocessors, is largely automated, so that reprocessing of a workpiece for minor geometric adjustments no longer requires any interaction of the production planner.}, author = {Ellwein, Carsten and Reichle, Alexander and Herschel, Melanie and Verl, Alexander}, doi = {10.1016/j.procir.2021.05.103}, journal = {Procedia CIRP}, note = {31st CIRP Design Conference 2021 (CIRP Design 2021)}, pages = {451-456}, publisher = {Elsevier {BV}}, title = {Integrative data processing for cyber-physical off-site and on-site construction promoting co-design}, url = {https://www.sciencedirect.com/science/article/pii/S2212827121005746}, volume = 100, year = 2021 }
2020
1. Wolf, M., Elser, A., Riedel, O., & Verl, A. (2020). A software architecture for a multi-axis additive manufacturing path-planning tool. Procedia CIRP, 88. https://doi.org/10.1016/j.procir.2020.05.075
  - BibTeX
  BibTeX
  @inproceedings{wolf2019software, author = {Wolf, Martin and Elser, Anja and Riedel, Oliver and Verl, Alexander}, doi = {10.1016/j.procir.2020.05.075}, journal = {Procedia CIRP}, language = {en}, title = {A software architecture for a multi-axis additive manufacturing path-planning tool}, url = {http://www.sciencedirect.com/science/article/pii/S2212827120303966}, volume = 88, year = 2020 }
2. 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 }

OTHER PUBLICATIONS

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. Hügle, S., Thompson, A. J., Pei, M., Hallett, S. R., & Middendorf, P. (2024). Modeling Of A Realistic Fiber Bundle Architecture In The Robotic Coreless Filament Winding Process.
  - BibTeX
  BibTeX
  @conference{hugle2024modeling, address = {Leuven, Belgium}, author = {Hügle, Sebastian and Thompson, Adam J. and Pei, Micheal and Hallett, Stephen R. and Middendorf, Peter}, eventdate = {2024}, eventtitle = {TexComp-15}, title = {Modeling Of A Realistic Fiber Bundle Architecture In The Robotic Coreless Filament Winding Process}, year = 2024 }
3. Zechmeister, C., Dambrosio, N., Bodea, S., & Menges, A. (2024). Fiber Pattern Generation Tools for the Design of Long-Span, Core-Less Wound, Structural Composite Building Elements [DaRUS]. https://doi.org/10.18419/darus-4359
  - BibTeX
  BibTeX
  @dataset{darus-4359_2024, author = {Zechmeister, Christoph and Dambrosio, Niccolo and Bodea, Serban and Menges, Achim}, doi = {10.18419/darus-4359}, publisher = {DaRUS}, title = {Fiber Pattern Generation Tools for the Design of Long-Span, Core-Less Wound, Structural Composite Building Elements}, url = {https://doi.org/10.18419/darus-4359}, version = {V1}, year = 2024 }
4. 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 }
3. König, T., Verl, A., & Lechler, A. (2023). Replication Data for: Cornuspline path planning algorithm for the fabrication of coreless wound fiber-polymer composite structures [DaRUS]. https://doi.org/10.18419/DARUS-3577
  - BibTeX
  BibTeX
  @dataset{https://doi.org/10.18419/darus-3577, author = {König, Timo and Verl, Alexander and Lechler, Armin}, doi = {10.18419/DARUS-3577}, publisher = {DaRUS}, title = {Replication Data for: Cornuspline path planning algorithm for the fabrication of coreless wound fiber-polymer composite structures}, url = {https://darus.uni-stuttgart.de/citation?persistentId=doi:10.18419/darus-3577}, year = 2023 }

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., Bodea, S., & Menges, A. (2024). Fiber Pattern Generation Tools for the Design of Long-Span, Core-Less Wound, Structural Composite Building Elements [DaRUS]. https://doi.org/10.18419/darus-4359
  - BibTeX
  BibTeX
  @dataset{darus-4359_2024, author = {Zechmeister, Christoph and Dambrosio, Niccolo and Bodea, Serban and Menges, Achim}, doi = {10.18419/darus-4359}, publisher = {DaRUS}, title = {Fiber Pattern Generation Tools for the Design of Long-Span, Core-Less Wound, Structural Composite Building Elements}, url = {https://doi.org/10.18419/darus-4359}, version = {V1}, year = 2024 }
3. 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 }
3. König, T., Verl, A., & Lechler, A. (2023). Replication Data for: Cornuspline path planning algorithm for the fabrication of coreless wound fiber-polymer composite structures [DaRUS]. https://doi.org/10.18419/DARUS-3577
  - BibTeX
  BibTeX
  @dataset{https://doi.org/10.18419/darus-3577, author = {König, Timo and Verl, Alexander and Lechler, Armin}, doi = {10.18419/DARUS-3577}, publisher = {DaRUS}, title = {Replication Data for: Cornuspline path planning algorithm for the fabrication of coreless wound fiber-polymer composite structures}, url = {https://darus.uni-stuttgart.de/citation?persistentId=doi:10.18419/darus-3577}, year = 2023 }

Prof. Dr.-Ing. Peter Middendorf

Principal Investigator

Phone: +49 711 685 62411

E-Mail

Prof. Dr.-Ing. Dr. h.c. mult. Alexander Verl

Principal Investigator

Phone: +49 711 685 82422

E-Mail

Prof. Achim Menges

Spokesperson

Phone: +49 711 685 82786

E-Mail

Cyber-Physical Prefabrication Platform for Fibre Composites

ADDITIVE CYBER-PHYSICAL PREFABRICATION PLATFORM FOR MULTIFUNC-TIONAL, MULTI-SCALE LOAD-ADAPTED FIBRE COMPOSITE BUILDING ELEMENTS INCLUDING FABRICATION SIMULATION AND DIGITAL TWIN

PRINCIPAL INVESTIGATORS

TEAM

PEER-REVIEWED PUBLICATIONS

2024

BibTeX

BibTeX

2023

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BibTeX

2022

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2021

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BibTeX

2020

BibTeX

BibTeX

2019

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OTHER PUBLICATIONS

2024

BibTeX

BibTeX

BibTeX

BibTeX

2023

BibTeX

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DATA SETS

2024

BibTeX

BibTeX

BibTeX

2023

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Prof. Dr.-Ing. Peter Middendorf

Prof. Dr.-Ing. Dr. h.c. mult. Alexander Verl

Prof. Achim Menges

Cluster of Excellence IntCDC

Audience

Formalities

Services

Organization