Skip to content

Automated Robotic Assembly Planning of Space Trusses for Injection 3D Concrete Printing (2025-08)

10.1016/j.autcon.2025.106440

 Xiao Yinan,  Vandenberg Aileen,  Lowke Dirk,  Mai (née Dressler) Inka,  D'Acunto Pierluigi,  Kloft Harald,  Hack Norman
Journal Article - Automation in Construction, Vol. 179, No. 106440

Abstract

Injection 3D Concrete Printing (I3DCP) is an emerging fabrication technique that enables spatial concrete extrusion within a carrier liquid, reducing gravitational effects and allowing the creation of complex space trusses. However, I3DCP introduces new challenges in toolpath planning due to material rheology and mechanical constraints. This paper introduces an automated planning method tailored for I3DCP, integrating a constraint satisfaction problem (CSP)-based sequence planner with a Cartesian motion planner. The sequence planner uses heuristic local search with forward checking and backtracking, while the motion planner addresses end-effector redundancy with kinematic and velocity constraints. The method is validated by fabricating a 3-meter-span pedestrian bridge using a stationary 6-axis robotic arm and tested on multiple prototypes of increasing geometric complexity through simulation, demonstrating its effectiveness and scalability for intricate structural designs.

24 References

  1. Adams Thomas, Heuer Christoph, Brell-Cokcan Sigrid (2022-03)
    Dynamic 3D Print-Head for Spatial Strand-Extrusion of Fiber-Reinforced Concrete:
    Requirements, Development and Application
  2. Agustí-Juan Isolda, Habert Guillaume (2016-11)
    Environmental Design Guidelines for Digital Fabrication
  3. Benamara Abdeslam, Pierre Alexandre, Kaci Abdelhak, Mélinge Yannick (2020-07)
    3D Printing of a Cement-Based Mortar in a Complex Fluid Suspension:
    Analytical Modeling and Experimental Tests
  4. Bhooshan Shajay, Bhooshan Vishu, Megens Johannes, Casucci Tommaso et al. (2022-09)
    Print-Path Design for Inclined-Plane Robotic 3D Printing of Unreinforced Concrete
  5. Bhooshan Shajay, Mele Tom, Block Philippe (2017-09)
    Equilibrium-Aware Shape Design for Concrete Printing
  6. Breseghello Luca, Naboni Roberto (2022-05)
    Tool-Path -Based Design for 3D Concrete Printing of Carbon-Efficient Architectural Structures
  7. Chee Ryan, Tan Wei, Goh Wei, Amtsberg Felix et al. (2018-09)
    Concrete Fabrication by Digitally Controlled Injection
  8. Chovghi Frederic, Richter Christiane, D'Acunto Pierluigi (2025-07)
    Fabrication-Aware Structural Form-Finding for Additive Manufacturing:
    An Equilibrium-Based Approach
  9. Hack Norman, Lauer Willi (2014-04)
    Mesh Mould:
    Robotically Fabricated Spatial Meshes as Reinforced Concrete Formwork
  10. Hack Norman, Mai (née Dressler) Inka, Brohmann Leon, Gantner Stefan et al. (2020-03)
    Injection 3D Concrete Printing (I3DCP):
    Basic Principles and Case Studies
  11. Lim Sungwoo, Buswell Richard, Le Thanh, Austin Simon et al. (2011-07)
    Developments in Construction-Scale Additive Manufacturing Processes
  12. Lin Yuxin, Bayramvand Alireza, Meibodi Mania (2025-04)
    Towards Lightweight Structure:
    Coupling Topology Optimization with Non-Planar 3D Concrete Printing
  13. Lowke Dirk, Anton Ana-Maria, Buswell Richard, Jenny Ercan et al. (2024-09)
    Digital Fabrication with Concrete Beyond Horizontal Planar Layers
  14. Lowke Dirk, Dini Enrico, Perrot Arnaud, Weger Daniel et al. (2018-07)
    Particle-Bed 3D Printing in Concrete Construction:
    Possibilities and Challenges
  15. Lowke Dirk, Vandenberg Aileen, Pierre Alexandre, Thomas Amaury et al. (2021-07)
    Injection 3D Concrete Printing in a Carrier Liquid:
    Underlying Physics and Applications to Lightweight Space Frame Structures
  16. Mai (née Dressler) Inka, Freund Niklas, Lowke Dirk (2020-01)
    The Effect of Accelerator Dosage on Fresh Concrete Properties and on Inter-Layer Strength in Shotcrete 3D Printing
  17. Neudecker Stefan, Bruns Christopher, Gerbers Roman, Heyn Jakob et al. (2016-05)
    A New Robotic Spray Technology for Generative Manufacturing of Complex Concrete-Structures without Formwork
  18. Roux Charlotte, Kuzmenko Kateryna, Roussel Nicolas, Mesnil Romain et al. (2022-11)
    Life Cycle Assessment of a Concrete 3D Printing Process
  19. Schutter Geert, Lesage Karel, Mechtcherine Viktor, Nerella Venkatesh et al. (2018-08)
    Vision of 3D Printing with Concrete:
    Technical, Economic and Environmental Potentials
  20. Wan Qian, Wang Li, Ma Guowei (2022-07)
    Continuous and Adaptable Printing Path Based on Transfinite Mapping for 3D Concrete Printing
  21. Wan Qian, Yang Wenwei, Wang Li, Ma Guowei (2023-04)
    Global Continuous Path-Planning for 3D Concrete Printing Multi-Branched Structure
  22. Xiao Yinan, Hack Norman, Kloft Harald, Lowke Dirk et al. (2025-03)
    Constraint-Based Form-Finding of Space Trusses for Injection 3D Concrete Printing Through Vector-Based Graphic Statics
  23. Xiao Yinan, Khader Noor, Vandenberg Aileen, Lowke Dirk et al. (2022-06)
    Injection 3D Concrete Printing (I3DCP) Combined with Vector-Based 3D Graphic Statics
  24. Yang Wenwei, Wang Li, Ma Guowei, Feng Peng (2023-06)
    An Integrated Method of Topological-Optimization and Path-Design for 3D Concrete Printing

0 Citations

BibTeX
@article{xiao_vand_lowk_mai.2025.ARAPoSTfI3CP,
  author            = "Yinan Xiao and Aileen Vandenberg and Dirk Lowke and Inka Mai (née Dressler) and Pierluigi D'Acunto and Harald Kloft and Norman Peter Hack",
  title             = "Automated Robotic Assembly Planning of Space Trusses for Injection 3D Concrete Printing",
  doi               = "10.1016/j.autcon.2025.106440",
  year              = "2025",
  journal           = "Automation in Construction",
  volume            = "179",
  pages             = "106440",
}
Formatted Citation

Y. Xiao, “Automated Robotic Assembly Planning of Space Trusses for Injection 3D Concrete Printing”, Automation in Construction, vol. 179, p. 106440, 2025, doi: 10.1016/j.autcon.2025.106440.

Xiao, Yinan, Aileen Vandenberg, Dirk Lowke, Inka Mai (née Dressler), Pierluigi D'Acunto, Harald Kloft, and Norman Peter Hack. “Automated Robotic Assembly Planning of Space Trusses for Injection 3D Concrete Printing”. Automation in Construction 179 (2025): 106440. https://doi.org/10.1016/j.autcon.2025.106440.