This research proposes an integrated design-to-fabrication methodology for site-specific brick building envelopes that combines architectural design with climatic simulations and robotic assembly. Our approach takes inspiration from monolithic historic brickwork as an alternative to contemporary multi-layered building envelopes. Uniform-format bricks are geometrically and materially differentiated within custom-designed zoned brick bonds to achieve targeted climatic performance and architectural expression. The methodology consists of a hierarchical graph-based model, beginning with (1) a spatial cell network, defining rooms and their enclosing wall and slab elements, and extending to (2) detailed brick assembly graphs of selected wall elements, integrating attributes such as bond type, corners, and wall connections. Exterior wall bonds enable geometric variation in the façade zone, which is adapted using solar simulation data to generate self-shading patterns aimed at reducing surface temperatures. The proposed methodology was experimentally validated through a full-scale demonstrator of an exterior wall segment. Within this segment, the exterior zone of the monolithic brick bond was derived from site-specific solar analysis data to modulate the façade geometry, whereas the overall bond configuration combines structural and thermal insulation considerations. Field measurements and simulations show that the climate-informed brick articulation reduces exterior surface temperatures under peak solar load while only marginally affecting the U-value, indicating measurable self-shading benefits with limited impact on thermal transmittance. Our results suggest that robotic fabrication supports the alignment of construction constraints with climate-responsive design, enabling the realisation of materially efficient, functionally zoned, and architecturally differentiated monolithic masonry envelopes.
Addressing the need for resourcefulness in architectural design and construction, this research project bridges two key aspects: augmenting human craft with minimal technology to elucidate and leverage craft-related tacit knowledge in architecture, and developing a comprehensive analysis framework for these structures. Current augmented reality (AR) approaches in architectural construction predominantly rely on visual feedback systems—primarily head-mounted displays—followed by hand-held devices, that guide craftspersons according to pre-designed digital models with real-time updates during construction. In this context, it is investigated how motion capture can be used to develop a framework for machine learning during the prototyping of architectural filament structures at room scale. Minimal wearable technologies, in the form of motion trackers, record information from the physical model to create corresponding virtual structures. In order to employ statistical analysis models for generating these representations—and to develop a recommendation system for future iterations—it was initially necessary to ascertain what nature of information to provide, particularly for partially ordered systems in which tool-paths emerge during the construction process as opposed to being determined in advance. This research was conducted in three phases: first, gathering and visualising motion data from craftspersons during construction using wearable trackers; second, recording and conducting statistical analysis on the filament structure and corresponding graphs at the macro-scale; third, focusing on isolated edge creation and effects on the local and global structure. Through motion capture, statistical analysis and generative design processes, the process of making these structures is elucidated, their topology is described on a micro- and macro-scale and a preliminary prototype capable of generating future structures is presented. Thus, this research project introduces a multi-scale AR methodology with non-visual interfaces that minimises interference with craft processes while enabling the simultaneous observation of multiple craftspersons. Unlike conventional approaches, the Unity-based framework uses physical structures to inform digital models through iterative statistical analysis models, analysing emergent filament structures at both macro- and micro-scales. As a future perspective, these systems can be analysed to provide future craftspersons with real-time recommendations as an example of integrating tacit knowledge into the design of architectural material systems.
This paper presents the development of a co-designed timber assembly system with a mobile robotic platform for collective robotic construction (CRC) across three successive demonstrations. Iterative advances in the relationship between material, mechanical robot design, architectural design, and robotic control enable the system to advance from showcasing robotic capabilities, to realizing the planar assembly of timber struts, and finally to achieving the spatial construction of truss-like structures. The first two demonstrations established a foundation for scalable coordination between multiple small mobile robotic actuators and standardized, linear timber building elements they manipulate for 2D assembly. The third demonstration extended this CRC system to the construction of spatial assemblies, demonstrating real-time planning adjustments and the coordination of homogeneous robotic agents. This research argues that co-design, linking the various research aspects in CRC, can be leveraged in the development of systems to progressively meet more complex fabrication goals. The outcomes highlight the potential of CRC as an alternative approach to architectural construction compared to centralized, large-scale machinery workflows.
Hybrid digital fabrication offers a promising direction for overcoming the geometric and structural limitations inherent to layer-based 3D Concrete Printing (3DCP). Existing approaches often combine additive deposition with milling or trowelling in the hardened or green state, yet remain constrained by tool geometry, lateral cutting forces, and limited compatibility with early age concrete. This paper introduces Hybrid 3DCP methodology, a multi-instrument fabrication method that integrates robotic extrusion with ultrasonic excision, a low-force subtractive process capable of refining geometry within an extended temporal window in the early plastic phase of the concrete. The research demonstrates this approach through a full-scale parametric beam and column system. The taxonomy of excision operations characterises the geometric strategies enabled by ultrasonic procedures. These strategies operate within a controlled and extended temporal window compared to existing approaches. Results indicate that ultrasonic excision reduces surface roughness by more than half relative to non-ultrasonic cutting, improves dimensional reliability and geometric fidelity beyond additive-only fabrication, and enables interlocking joints with sharp transitions and sub-nozzle fine detail. The prototype shows how hybrid additive–subtractive workflows can produce expressive 3DCP components. The work demonstrates how fabrication sequencing, material behaviour and timing can be orchestrated to expand the design space of 3DCP, positioning ultrasonic excision as a viable subtractive technique for future hybrid construction systems and supporting the development of precise, adaptable, and tectonically rich concrete assemblies.
