Robotic Construction of Thin-tile Vaulting

Recently, the necessity to design and build structures in a less material-intensive way has brought attention to the material waste produced during their construction. While traditional thin-tile vaults demonstrate inherently efficient and falseworkless construction, free-form vault geometries often rely on disposable carton falsework, or CNC-cut plywood, contributing to construction waste. This paper investigates an alternative paradigm for free-form thin-tile vault construction, demonstrating that geometry-informed forms can eliminate construction waste while significantly reducing reliance on complex robotic systems. Through material, curvature, and tiling pattern studies, the research identifies critical constraints when a single robotic arm assembles a free-form, thin-tile vault without formwork, falsework, or auxiliary robotic support. The scaled prototype serves as a proof of concept and a framework for evaluating constructability, failure modes, and challenges. The findings suggest a pathway towards more sustainable free-form masonry workflows that balance material efficiency, construction intelligence, and technological advancements.