Scaled-Down Simulation and Analysis of On-Site Robotic Fabrication and Construction (2025-07)¶

The Canadian construction industry faces challenges in accessing remote sites, resulting in logistical and environmental issues. Robotic construction, especially in situ or on-site assembly with industrial robots, offers a promising solution. This paper explores the feasibility and impact of on-site fabrication and construction (OSF&C) by performing a scaled down simulation with two UR5e Universal Robots. The study utilizes additive manufacturing (AM) for key construction elements to achieve increased performance. The case study involves the fabrication of a complex pentagonal-cross section bridge structure consisting of foam beams and 3D-printed brackets. The methodology includes detailed description of the fabrication and stacking procedures, material handling optimization, and human-robot interaction. The study proposes a scaled-down robotic simulation approach, which is then used to evaluate production consistency and time, demonstrating the benefits of utilizing additive manufacturing into OSF&C.