Realization of Topology Optimized Concrete Structures Using Robotic Abrasive Wire-Cutting of Expanded Polystyrene Formwork

This paper presents a new method for cost-effective realization of topology optimized structures using robotic abrasive wire-cutting of expanded polystyrene formwork. Topology optimization has shown potential for generating material efficient designs and increasing performance in architectural structures. However, the method results in complex, structural morphologies which frustrate efficient construction of said structures. To overcome this, and make the realization of the potential of topology optimization feasible in general construction, new approaches are needed. We propose an integrated method of ruled surface rationalization and robotically controlled abrasive wire-cutting of formwork parts in Expanded Polystyrene. The method is demonstrated through robotic production of EPS formwork using a pilot abrasive wire-cutting end-effector on a containerized robotic work cell with an ABB IRB 6700 industrial manipulator, extended with external rotary axis. The usability of the formwork is demonstrated through the construction of a 21 m, prefabricated demonstrator structure using Ultra High Performance Concrete.