Stress-informed non-planar additive manufacturing of solid wood veneer as reinforcement for prestressed shell structures

Abstract This research presents a novel approach to non-planar additive manufacturing by using solid wood veneer as reinforcement for prestressed and complex shell structures. Curved veneer ribs are robotically printed onto double-curved plywood panels, guided by principal stress lines derived from finite element analysis and translated into geodesic toolpaths. This stress-informed placement ensures efficient reinforcement in regions experiencing tensile and bending loads, offering a sustainable alternative to fiber-reinforced composites in architectural components requiring lightweight reinforcement. The fabrication process employs continuous wood veneer strips bonded with a polyurethane-enhanced hotmelt adhesive. This system enables rapid adhesion and gradual curing, transforming the process into a continuous, digitally controlled workflow that eliminates traditional forming methods like steam bending or vacuum pressing.