01 Fakultät Architektur und Stadtplanung

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    Cross-sectional 4D-printing : upscaling self-shaping structures with differentiated material properties inspired by the large-flowered butterwort (Pinguicula grandiflora)
    (2023) Sahin, Ekin Sila; Cheng, Tiffany; Wood, Dylan; Tahouni, Yasaman; Poppinga, Simon; Thielen, Marc; Speck, Thomas; Menges, Achim
    Extrusion-based 4D-printing, which is an emerging field within additive manufacturing, has enabled the technical transfer of bioinspired self-shaping mechanisms by emulating the functional morphology of motile plant structures (e.g., leaves, petals, capsules). However, restricted by the layer-by-layer extrusion process, much of the resulting works are simplified abstractions of the pinecone scale’s bilayer structure. This paper presents a new method of 4D-printing by rotating the printed axis of the bilayers, which enables the design and fabrication of self-shaping monomaterial systems in cross sections. This research introduces a computational workflow for programming, simulating, and 4D-printing differentiated cross sections with multilayered mechanical properties. Taking inspiration from the large-flowered butterwort (Pinguicula grandiflora), which shows the formation of depressions on its trap leaves upon contact with prey, we investigate the depression formation of bioinspired 4D-printed test structures by varying each depth layer. Cross-sectional 4D-printing expands the design space of bioinspired bilayer mechanisms beyond the XY plane, allows more control in tuning their self-shaping properties, and paves the way toward large-scale 4D-printed structures with high-resolution programmability.
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    Extension of computational co-design methods for modular, prefabricated composite building components using bio-based material systems
    (2023) Zechmeister, Christoph; Gil Pérez, Marta; Dambrosio, Niccolo; Knippers, Jan; Menges, Achim
    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.
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    Autonomous robotic additive manufacturing through distributed model‐free deep reinforcement learning in computational design environments
    (2022) Felbrich, Benjamin; Schork, Tim; Menges, Achim
    The objective of autonomous robotic additive manufacturing for construction in the architectural scale is currently being investigated in parts both within the research communities of computational design and robotic fabrication (CDRF) and deep reinforcement learning (DRL) in robotics. The presented study summarizes the relevant state of the art in both research areas and lays out how their respective accomplishments can be combined to achieve higher degrees of autonomy in robotic construction within the Architecture, Engineering and Construction (AEC) industry. A distributed control and communication infrastructure for agent training and task execution is presented, that leverages the potentials of combining tools, standards and algorithms of both fields. It is geared towards industrial CDRF applications. Using this framework, a robotic agent is trained to autonomously plan and build structures using two model-free DRL algorithms (TD3, SAC) in two case studies: robotic block stacking and sensor-adaptive 3D printing. The first case study serves to demonstrate the general applicability of computational design environments for DRL training and the comparative learning success of the utilized algorithms. Case study two highlights the benefit of our setup in terms of tool path planning, geometric state reconstruction, the incorporation of fabrication constraints and action evaluation as part of the training and execution process through parametric modeling routines. The study benefits from highly efficient geometry compression based on convolutional autoencoders (CAE) and signed distance fields (SDF), real-time physics simulation in CAD, industry-grade hardware control and distinct action complementation through geometric scripting. Most of the developed code is provided open source.
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    Toward reciprocal feedback between computational design, engineering, and fabrication to co-design coreless filament-wound structures
    (2024) Kannenberg, Fabian; Zechmeister, Christoph; Gil Pérez, Marta; Guo, Yanan; Yang, Xiliu; Forster, David; Hügle, Sebastian; Mindermann, Pascal; Abdelaal, Moataz; Balangé, Laura; Schwieger, Volker; Weiskopf, Daniel; Gresser, Götz T.; Middendorf, Peter; Bischoff, Manfred; Knippers, Jan; Menges, Achim
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    Weather-responsive adaptive shading through biobased and bioinspired hygromorphic 4D-printing
    (2024) Cheng, Tiffany; Tahouni, Yasaman; Sahin, Ekin Sila; Ulrich, Kim; Lajewski, Silvia; Bonten, Christian; Wood, Dylan; Rühe, Jürgen; Speck, Thomas; Menges, Achim
    In response to the global challenge of reducing carbon emissions and energy consumption from regulating indoor climates, we investigate the applicability of biobased cellulosic materials and bioinspired 4D-printing for weather-responsive adaptive shading in building facades. Cellulose is an abundantly available natural material resource that exhibits hygromorphic actuation potential when used in 4D-printing to emulate motile plant structures in bioinspired bilayers. Three key aspects are addressed: (i) examining the motion response of 4D-printed hygromorphic bilayers to both temperature and relative humidity, (ii) verifying the responsiveness of self-shaping shading elements in lab-generated conditions as well as under daily and seasonal weather conditions for over a year, and (iii) deploying the adaptive shading system for testing in a real building facade by upscaling the 4D-printing manufacturing process. This study demonstrates that hygromorphic bilayers can be utilized for weather-responsive facades and that the presented system is architecturally scalable in quantity. Bioinspired 4D-printing and biobased cellulosic materials offer a resource-efficient and energy-autonomous solution for adaptive shading, with potential contributions towards indoor climate regulation and climate change mitigation.
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    Co-design of a natural fiber-timber hybrid structural system using dual-robot coreless filament winding
    (2026) Duque Estrada, Rebeca; Kannenberg, Fabian; Chen, Tzu-Ying; Guo, Yanan; Knippers, Jan; Menges, Achim
    This paper presents the co-design methods for a new hybrid load-bearing system as a strategy for advancing bio-based architecture. Timber and natural fiber polymer composites (NFPC) are combined into a hybrid system, offering opportunities to leverage their strengths while balancing the use of natural resources. The system performs synergistically, with each material fulfilling complementary roles. Timber extrapolates its structural function by acting as an embedded frame for the fibers to be wound on. The paper presents computational methods designed to optimize material performance while integrating functionalities and fabrication opportunities. A dual-robot winding method is presented as a solution for balancing winding tension in the structure during fabrication. The hybrid system is demonstrated through the design and construction of a pavilion, the first to combine flax fibers with a partially bio-based resin and timber into a dual-robotically fabricated structure on an architectural scale. The project represents further advancements in multi-robot fabrication and a novel material approach toward bio-based hybrid systems in architecture.