@PHDTHESIS{20.500.11850/647367, copyright = {In Copyright - Non-Commercial Use Permitted}, year = {2023}, type = {Doctoral Thesis}, institution = {SNF}, author = {Leung, Pok Yin}, size = {499 p.}, abstract = {This thesis investigates the potential of distributed robotics systems in automating the assembly of timber structures, addressing the challenges of large-scale spatial manipulation and tight-fitting timber joint assembly, which are highly relevant for timber construction.Leveraging the highly automated process of machining timber parts using automatic joinery machines, the thesis investigates the next knowledge gap in the design-to-production workflow - automatic spatial assembly. Using timber frame structures with integral timber joints as a starting point, this thesis proposed a new fabrication system using Distributed Robotic Tools (DiRT) in collaboration with industrial robotic arms. The crucial breakthrough is the modular and remote operation nature of the tools, allowing the system to assemble a wide variety of timber joints and complex structures.This thesis also investigated an integrated design workflow. Design validation is identified as a critical aspect of the automated assembly process. This research proposes a practical three-tier validation process to evaluate a design, with quick feasibility feedback provided to the designer during the design process. It takes into consideration geometrical conflicts, robot limitations and tool setup to provide visual feedback on various problems to the designer. The research provides a proof-of-concept through the development of three full-scale timber frame demonstrators, each assembled using a single robotic arm and a set of custom-designed distributed assembly tools. The assembly tools include robotic clamps and screwdrivers for different types of lap joints, including planar and non-planar varieties. The findings showcased a viable method to assemble timber structures, mitigating well-known problems such as accumulated assembly error and instability during construction. The results also identified key challenges that are limiting the system efficiency, accuracy, reliability and success rate for the automated process, as well as discovering new opportunities for future research. These opportunities include establishing a generalizable DiRT assembly system, and expanding the range of joint types and building components that can be assembled.The thesis contributes software tools and system design patterns that are generalizable and reusable within the broader digital fabrication and construction automation community. For example, software for remote robot operation and synchronisation; Data structures and algorithms for robotically assembled structures; Methods for automating parsing designs into robotic programmes; and Task and Motion Planning (TAMP) techniques for assembly problems.Ultimately, this research contributes to ongoing efforts to harness the potential of robotics for creating more efficient and sustainable timber construction processes. Paving the way for the widespread adoption of automated construction processes within the architectural industry.}, keywords = {Integral Timber Joints; Distributed Robotic Tools; Digital Fabrication; Construction Robotics}, language = {en}, address = {Zurich}, publisher = {ETH Zurich}, DOI = {10.3929/ethz-b-000647367}, title = {DiRT: Distributed Robotic Tools for Spatial Timber Assembly with Integral Timber Joints}, school = {ETH Zurich} }

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@PHDTHESIS{20.500.11850/626069, copyright = {In Copyright - Non-Commercial Use Permitted}, year = {2023}, type = {Doctoral Thesis}, author = {Mitterberger, Daniela}, size = {219 p.}, abstract = {This research aims to establish adaptive digital fabrication processes that include human-machine collaboration in digital fabrication. In the past two decades, digital fabrication in architecture engineering and construction (AEC) has significantly advanced, enabling more complex, customised, and precise fabrication results. Even though most digital fabrication processes aim for full automation, they still require human participation for either material deposition, quality control, or finishing. While humans are still needed, current digital fabrication processes are not adaptive enough to include humans in the digital control logic. This inflexibility limits the robustness and autonomy of digital fabrication and its applicability in areas that are more difficult to automate, such as on-site fabrication or fabrication with more complex material systems. Therefore, this doctoral research aims to include human actions and decision-making in digital fabrication processes. This combination of human tacit knowledge and dexterity with the precision and endurance of machines has the potential to increase the productivity, adaptability and robustness of digital fabrication. To facilitate human-machine collaboration, this research establishes more adaptive digital fabrication processes, linking digital models with physical fabrication environments. For this, digital twins are developed to efficiently control and capture data from the entire fabrication process and all its components. These digital twins are linked with extended-reality interfaces, actuators and tracking systems to inform and track humans and machines during fabrication. The research results are obtained through physical experiments and four proof-of-concept case studies investigating various aspects of human-machine collaboration in architecture and digital fabrication. By solving practical and methodological challenges, this research demonstrates how human-machine collaboration supports a faster and more sustainable integration of digital fabrication in AEC. Furthermore, this thesis illustrates the aesthetic and technological benefits of such collaborative systems, as well as their potential to expand our repertoire of digital fabrication workflows.}, keywords = {Augmented Reality (AR); Digital fabrication; Robotic fabrication; Human-machine interaction; Extended reality; Architecture; Augmented reality fabrication; interactive fabrication}, language = {en}, address = {Zurich}, publisher = {ETH Zurich}, DOI = {10.3929/ethz-b-000626069}, title = {Augmented Human and Extended Machine:. Adaptive Digital Fabrication and Human-machine Collaboration for Architecture}, school = {ETH Zurich} }

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@PHDTHESIS{20.500.11850/626106, copyright = {In Copyright - Non-Commercial Use Permitted}, year = {2023}, type = {Doctoral Thesis}, author = {Xydis, Achilleas}, size = {288 p.}, abstract = {Acoustics are rarely included as a design driver in the early phases of design due to the multi-faceted nature of sound and the complex and time-consuming analysis process of room acoustics software. Inevitably this results in architectural spaces with poor acoustics, where treatment is either disregarded or focuses only on noise prevention using absorbent materials. However, most commonly used construction materials have sound-reflecting properties and can be configured into sound-diffusive surfaces. These surfaces can help reduce unwanted flattered echoes, colourisation, and image shift and create a more pleasant and comfortable environment without needing additional elements (e.g. absorption panels). Faster and simpler analysis tools are required to harness the potential of diffusion in architectural design.This dissertation presents a new data-driven approach to designing and evaluating the acoustic properties of architectural surfaces. It investigates the use of machine-learning techniques to study the mutual relationship between geometry and sound diffusion. It introduces a new acoustic dataset meant as a basis for training predictive machine-learning models. These models enable the creation of fast, less cumbersome, and reasonably accurate acoustics analysis tools. It proposes and implements a new automated multi-robotic data-acquisition method for collecting impulse responses from scale-modelled surfaces. It also develops computational tools to design and generate three-dimensional wall-like surface geometries. The geometrical characteristics of these surfaces are based on commonly used construction materials and techniques. A computational framework is developed in parallel to process the collected data and generate customisable and interactive visualisations for low- and high-dimensional data. This framework caters to both expert and non-expert users in acoustics, providing expert users with familiar descriptors and visualisations and introducing non-experts to simpler ones. Furthermore, to address users with no programming knowledge, it develops a web-based application enabling easy access to the collected dataset, the acoustic descriptors, and visualisations. It introduces a new workflow to the performance-driven acoustic design of sound-diffusing wall surfaces, allowing architects and designers to explore alternative wall designs with sound-diffusing properties, given a set of desired acoustic performance criteria.The proposed workflow has the potential to bring acoustics closer to the early phases of architectural design and enable a more integrative acoustic and architectural design exploration. Providing architects and acousticians with comprehensive and user-friendly tools for acoustics analysis can help integrate acoustics into the design process from the beginning rather than as an afterthought.}, keywords = {Architectural Acoustics; Dataset collection; Dataset; Computational Design; Machine Learning}, language = {en}, address = {Zurich}, publisher = {ETH Zurich}, DOI = {10.3929/ethz-b-000626106}, title = {Data Driven Acoustic Design}, school = {ETH Zurich} }

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@PHDTHESIS{20.500.11850/648606, year = {2023}, type = {Doctoral Thesis}, institution = {SNF}, author = {Cheibas, Ina}, size = {339 p.}, abstract = {Additive manufacturing is a rising trend in the construction field. It enables tailored facade designs that can incorporate environmental features like daylight, shading, ventilation, structural strength, and thermal conductivity. This potential enhances facade sustainability and energy efficiency attributes, achievable through recyclable mono-material components and integrated performances. However, the definitive demonstration of integrating environmental and fabrication parameters into computational facade design remains unrealized. This gap persists due to complex challenges in fabricating intricate building envelopes, necessitating consideration of numerous fabrication and environmental parameters, from accurate geometries, and good material properties to shading, daylight, air permeability, water tightness, and structural integrity.This research focuses on additive manufactured facade design strategies informed by both fabrication techniques and environmental considerations. The thesis provides fundamental design guidelines to support the fabrication of downcycled and multi-performative facade elements for light distribution and transmission, air permeability, water tightness, resistance to wind loads, and impact strength. The study employs both analytical and empirical methods to address three key criteria: (1) Design, (2) Material and fabrication, and (3) Environmental performance evaluation. The design process and guidelines (1) are thoroughly explored, encompassing the integration of fabrication and multiple environmental performances into a single mono-material element. Subsequently, material and fabrication methods (2) are analyzed through experimental testing at an architectural scale, utilizing a robotic arm and thermoplastic polymer material extrusion. Finally, performance evaluation (3) serves as the results validation of several large-scale prototypes. This approach opens up new possibilities for creating environmentally responsible architectural facades that push the boundaries of sustainable design.}, keywords = {additive manufacturing; 3D Printing Facade; environmental performance; thermoplastics}, language = {en}, address = {Zurich}, publisher = {ETH Zurich}, DOI = {10.3929/ethz-b-000648606}, title = {Additive Manufactured Facade. Integrative design of complex additive manufactured geometries informed by fabrication and multi-performative environmental parameters}, school = {ETH Zurich} }

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@PHDTHESIS{20.500.11850/604464, copyright = {In Copyright - Non-Commercial Use Permitted}, year = {2023}, type = {Doctoral Thesis}, author = {Ercan Jenny, Selen}, size = {195 p.}, language = {en}, address = {Zurich}, publisher = {ETH Zurich}, DOI = {10.3929/ethz-b-000604464}, title = {Robotic Plaster Spraying. Crafting Surfaces with Adaptive Thin-Layer Printing On-Site}, school = {ETH Zurich} }

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@PHDTHESIS{20.500.11850/627524, year = {2023}, type = {Doctoral Thesis}, institution = {SNF}, author = {Burger, Joris Jan}, size = {236 p.}, abstract = {No other building material has influenced our contemporary built environment like concrete has. Its qualities include high structural strength, widespread availability, and the ability to take almost any form. Typically, concrete building elements are given their shape using formwork made from timber or steel. However, the fabrication of these formworks is labour-intensive and wasteful, especially for complex, non-standard concrete structures. The difficulty of formwork fabrication is one of the reasons why designs in concrete tend to be standardised and confined to orthogonal shapes. Although standard shapes in concrete are simple to construct, they often use more material than structurally necessary. In contrast, one defining characteristic of material-efficient concrete structures is that they typically have complex, non-standard geometries. As the concrete construction industry is responsible for a large portion of anthropogenic CO2 emissions, sustainability must be considered a key driver in the design and fabrication process of architectural concrete structures. Therefore, effective methods for producing non-standard formwork must be developed to enable material-efficient concrete structures. This research responds to these challenges and investigates the use of robotically 3D printed formwork to expand geometrical freedom and allow for the prefabrication of material-efficient concrete structures. Several types of structural building elements are explored through the design and fabrication of prototypes. The architectural potential of this fabrication process is explored through three case studies: a non-standard structural column, an optimised floor slab, and a pavilion combining both elements. The results of this research expand the possibilities for digital design and fabrication of non-standard concrete elements, aiding the transition toward more sustainable construction using concrete.}, keywords = {3D Printing; Concrete; Formwork; Digital Fabrication; Architecture}, language = {en}, address = {Zurich}, publisher = {ETH Zurich}, DOI = {10.3929/ethz-b-000627524}, title = {Robotically 3D Printed Formwork for Concrete Structures}, school = {ETH Zurich} }

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