Robotic coreless filament winding for hyperboloid tubular composite components in construction

Novel fabrication methods are necessary to capitalize on the high strength-to-weight ratio of composites engineered for construction applications. This paper presents prefabrication strategies for geometrically-complex building elements wound out of Glass and Carbon Fiber Reinforced Polymers (G/CFRP). The research focuses on Robotic Coreless Filament Winding (RCFW), a technology that eliminates formwork, proposing upscaling and industrialization strategies combined with updated robot programming and control methods. Our application addresses the prefabrication of hyperboloid, tubular components with differentiated geometry and fiber layout. We examine how the proposed methods enabled the industrial prefabrication of a building-scale G/CFRP dome structure and discuss the industrial process relative to key fabrication parameters. Highlighting the interdisciplinary nature of the research, we envisage future directions and applications for RCFW in construction. Overall, we find that synergy between academia and industry is essential to meeting research, productivity, and certification goals in the rather conservative building industry.