Robotic frame winding: prefabricated fibre structures as formwork and reinforcement for digitally fabricated shell-like concrete elements

Abstract The integration of reinforcement in digital fabrication with concrete has led to the development of various approaches, many of which are constrained by the requirements of the concrete printing process. In contrast, the aim here was to investigate the robotic production of complex reinforcement structures as a primary process which supports the application of concrete and therefore acts as stay-in-place formwork that creates shaping potential beyond conventional printing processes. Based on the concept of combining the robotic processes of Fibre Winding and Shotcrete 3D Printing (SC3DP), the presented methodology comprised design explorations, fabrication variations, the realisation of a real-scale demonstrator and the assessment of the structural performance. Accordingly, an automated process for the fabrication of thin-shell double-curved reinforced concrete elements with controlled thickness and homogeneous concrete distribution was developed and characterised. Following this approach in the future will not only contribute to fabrication-informed design but also minimise concrete use and formwork waste.