- Researchers at the University of Kassel have developed a process using 0.5-millimeter-thick wood veneers wound and glued by ABB robots
- These lightweight constructions can add storeys to existing buildings and modernize structures
- The method involves creating ceiling elements and supporting pillars from wound veneer wood, resulting in optimized load-bearing properties This sustainable approach offers an alternative to traditional construction materials.
When engineers envision modern lightweight construction, carbon and glass fiber often come to mind. However, researchers at the University of Kassel have introduced an innovative approach using 0.5-millimeter-thick wood veneers wound and glued by robots. This method enables high-strength, stable, and extremely lightweight constructions, offering new possibilities for sustainable architecture.
The process involves creating ceiling elements and supporting pillars from wound veneer wood. These structures are exceptionally lightweight, making them ideal for adding storeys to existing buildings or modernizing and extending structures. Wood, as a renewable resource, plays a crucial role in sustainable construction.
Complex Challenges, Robot-Controlled Production
Veneer wood retains the microstructural properties of the original wood, allowing stable constructions with minimal thickness and weight. The veneer tape (48 mm wide and 0.5 mm thick) must be applied without folds or creases and glued with high pressure. Precise alignment of the natural grain direction within the components is essential for load-bearing effectiveness. Unlike traditional construction, no presses can be used, necessitating high tensile forces during application.
ABB robots are used for development and production. The robots perform complex and variable movements to wind the veneer tape around the formwork element. Algorithms synchronize robot arm movements with the rotational movement of the raw body being wrapped. The application ensures optimal tension and uses polyurethane wood glue for adhesion.
Three-Dimensional Complexity
Working with millimeter precision on three-dimensionally complex structures is challenging. Each layer takes on different dimensions, requiring precise application of the veneer tape. Imagine wrapping a strip of paper around a vase without creases—it’s a delicate process.
This innovative approach combining sustainability, lightweight construction, and precise robot control to create high-strength wooden structures is opening possibilities for architectural creativity and resource-efficient building methods.
Grasshopper: The Algorithmic Modeling Editor
Grasshopper empowers designers with a visual programming approach. Unlike traditional modeling methods, it allows users to create models by assembling “nodes” (components) and connecting them with “wires.” The magic lies in parameterized design—changes in parameters have an immediate effect on the modeling, enabling dynamic adjustments.
Developed by Prof. Eversmann and his team, the “Robot Components” plugin is open source. It seamlessly integrates with ABB robots, enabling intuitive planning and simulation of construction processes within 3D models. Moreover, it automatically generates program code for precise robot control. Safety testing is facilitated through ABB RobotStudio, allowing students to refine their code virtually and avoid costly real-world mishaps.
Precision optimization is crucial. Absolute measurements ensure the necessary precision for veneer processing. Initially, two compact ABB IRB 1200 industrial robots were used for model production. Later, experiences were transferred to larger systems—two IRB 4600s—via the “BBSR Research Prototype” competition. The IRB 4600 boasts minimal interference surface and radius, allowing close placement to workpieces. Its impressive reach (up to 2.55 meters) facilitates versatile applications.
Towards Sustainable Façade Profiles
The success of algorithmic, parameter-oriented control inspires further development. The ultimate goal: sustainable façade profiles that reduce reliance on aluminum, a material with a significant carbon footprint.
In summary, this interdisciplinary approach - combining software development, robotics, and craftsmanship - ushers in a new era for wood processing.
A mutual commitment to sustainability and innovation
The University of Kassel has forged a strong partnership with ABB Robotics, leveraging their cutting-edge technology for research purposes. Unlike traditional applications, where robots are used for routine tasks, the university explores novel ways to enhance construction processes and architectural design. ABB Robotics actively supports this vision by providing hardware components and expert assistance.
ABB’s robots offer unparalleled precision in component manufacturing. Unlike conventional construction methods, which often require on-site adjustments, these robots produce flawless pieces directly. The result? Streamlined construction processes and reduced rework. Moreover, the integration of 3D algorithms allows for intricate and lightweight shapes—triangular, polygonal, round, or asymmetrical—opening exciting possibilities for architects and designers.
