KUKA robots demonstrate perspectives for robotic production in architecture

“The field of biomimetic research is one of our key areas of focus,” explains Professor Achim Menges, Director of the ICD. “Shapes, materials and structures found in nature often exhibit a greater degree of material efficiency and functionality than conventional construction methods.” The pavilion for the BUGA is based on the outer shell of a sea urchin: this consists of plates that grow individually. Each of the 376 elements of the wooden pavilion is absolutely unique. The robots bond them using wooden panels and beams from laminated veneer lumber. The pentagonal, hexagonal or heptagonal coffers are 16 cm thick and have a hollow interior. The pavilion spans 30 meters – without any beams or supports inside. “This form of lightweight construction is unprecedented on a global scale. Without robotic production, the high variance in the parts would have been unthinkable,” says Hans Jakob Wagner, research assistant and doctoral student at the ICD.

“The robot bonds the wooden panels precisely and efficiently. This is important because the adhesive only remains fluid for a limited time,” explains Matthias Buck, Managing Director of BEC GmbH. Furthermore, specific conditions such as the application quantity and uniformity have to be met. Moreover, considering the weight of the individual elements – a coffer weighs up to 200 kg – robots reduce the workload. Another advantage: during milling, the dimensional tolerance of the robotic production process is less than 0.3 mm. Matthias Buck also praises the adaptability of the KUKA robots: “We even have the option of making changes to the construction plan of certain elements during the production process.” This offers the construction industry and timber construction industry innovative opportunities: robot systems can help to deal with the growing demands for larger quantities and affordable solutions.