Adaptation of robotic coreless filament winding methodologies for lathe-type winding of fibre-composite building components

Abstract

While the architecture, engineering, and construction (AEC) industry faces increasing pressure to reduce carbon emissions and resource depletion, the adoption of sustainable technologies and advanced fabrication methods remains limited. Lathe-type filament winding (LFW) of fibre-reinforced polymers (FRP) enables the fabrication of lightweight, high-strength components with compatibility for digital manufacturing and structural optimization; however, its application in architecture is limited by inherent geometric constraints. Robotic coreless filament winding (RCFW) leverages the advantages of FRP and increases geometric freedom and material efficiency by eliminating the need for formwork, but its adoption in industry faces challenges. The research presented here explores the production of RCFW typologies using LFW equipment, expanding the LFW solution space via a new computational workflow with minor hardware modifications. This is achieved through three primary methods: a feasibility assessment that evaluates the requirements of RCFW against the capabilities of LFW; a custom path planner and post-processor that adapt and extend RCFW path-planning strategies for use with LFW; and a novel machine control architecture that uses the LFW controller to calculate motion commands and generate G-code in real time. The methods are developed through a prototype and evaluated through the serial production of fibre-composite building components for an architectural-scale building demonstrator.