Abstract Concrete is a highly versatile construction material, not only for the reason that it has excellent properties in terms of structural performance, building physics, availability and price, but also because it can be moulded into virtually any shape regardless of its geometric complexity. However, even though current digital design tools allow to effortlessly design and calculate structures, which are exploiting these properties, this potential remains all too often unrealized. This is due to the fact that geometrically complex concrete structures require expensive, one-of-a kind formwork, which can often not be reused or even recycled. Consequently, the current practice for producing non-standard curvilinear architecture in reinforced concrete is neither ecologically sustainable nor economically feasible for a broader range of architectural typologies. Additive Manufacturing (AM) processes, like 3D printing with concrete, on the other hand, currently struggle with the integration of structural reinforcement, limiting the technique to predominantly compression-loaded applications. This research addresses both issues and proposes Mesh Mould, a robotic fabrication process that unifies concrete formwork and structural reinforcement, and hence potentially reduces formwork waste and construction costs for non-standard reinforced concrete constructions. The development of a fully automated robotic fabrication process involved various research disciplines, including architecture, material science, mechanical engineering, robotics as well as civil engineering. This paper describes the technological developments of the Mesh Mould construction system that were necessary to meet the challenges of 1:1 construction. The results are demonstrated in a final loadbearing structure, the Mesh Mould wall of the DFAB HOUSE on NEST.

中文翻译：

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用于非标准混凝土结构机器人原位制造的结构原位模板：真实比例的建筑演示器

摘要 混凝土是一种用途广泛的建筑材料，不仅因为它在结构性能、建筑物理、可用性和价格方面具有优异的性能，还因为它几乎可以模制成任何形状，而不管其几何复杂性如何。然而，即使当前的数字设计工具允许毫不费力地设计和计算利用这些特性的结构，但这种潜力仍然常常未被实现。这是因为几何复杂的混凝土结构需要昂贵的、独一无二的模板，这些模板通常不能重复使用，甚至不能回收。最后，目前在钢筋混凝土中生产非标准曲线建筑的做法在生态上既不可持续，也不经济上适用于更广泛的建筑类型。另一方面，增材制造 (AM) 工艺，例如使用混凝土进行 3D 打印，目前正在努力整合结构加固，将技术限制在主要是压缩载荷的应用中。这项研究解决了这两个问题并提出了网格模具，这是一种机器人制造工艺，可将混凝土模板和结构钢筋统一起来，从而有可能减少非标准钢筋混凝土结构的模板浪费和施工成本。全自动机器人制造过程的开发涉及各种研究学科，包括建筑、材料科学、机械工程、机器人以及土木工程。本文描述了为应对 1:1 施工挑战所必需的网状模具施工系统的技术发展。结果在最终的承重结构中得到了证明，即 NEST 上 DFAB HOUSE 的网状模具墙。