Weaving Tectonics: Algorithmically Optimised Robotic FRP Weaving of Large Scale Planar Forms

Steel reinforced concrete is a widely used material for constructing large spanning planar building elements due to its strength, durability, and low cost, but its environmental impact, long fabrication time, and relatively low structural performance demonstrate the need for innovation. To address these issues, this study proposes a novel design methodology and fabrication method that integrates robotic Fibre Reinforced Polymer (FRP) woven reinforcement that is optimized using a Multi-Weight Bi-directional Evolutionary Structural Optimization (MW-BESO) algorithm. The optimized FRP reinforcement is then cast in epoxy resin to produce the large scale planar building element. The methodology is evaluated through a Tabletop prototype and other small-scale rapid prototypes, which demonstrate the successes, challenges, and limitations of this approach. The study outlines the material and methodological testing conducted to assess the effectiveness of using the MW-BESO algorithm with robotic FRP weaving and describes the workflow of transforming the resulting 3D MW-BESO geometry into a 2D robotic winding path for fabrication. The research shows that this methodology has the potential to reduce the environmental impact, stimulate innovative design solutions, and streamline the fabrication of large scale building elements, providing a promising avenue for the development of sustainable and efficient construction techniques.