Bahar Bagheri

This paper discusses the development of integrated design-to-production frameworks for Robotic Concrete 3D Printing (RC3DP) of context-specific urban furniture projects. The study focuses on two main objectives: developing computational methods for continuous toolpath planning of bespoke components and examining integrated frameworks to make design-to-production systems more socio-environmentally inclusive and tailored to specific contexts. Following an introduction to outline the key challenges of continuous robotic concrete 3D printing, the paper is organized into two sets of case studies. The first set explores curved-based continuous 3D printing for surface-based design strategies, and the second set investigates voxel-based approaches for volumetric design 3D printing. Curve-based projects consisted of three case studies. The first case uses an AI-enabled generative system to translate a porous, cellular structure to a continuous toolpath with variable heights. The second case study is based on a workflow using a controlled reaction-diffusion algorithm as a generative strategy to create continuous infill for complex geometries. The third project focuses on growing larger than the size of the production setup by testing the assembly of multiple printed components, all produced with continuous toolpaths. The workflows and projects are developed as an integral part of a graduate-level digital design and fabrication course focusing on inclusive automation and robotic concrete 3D printing. Therefore, in addition to sharing the details of the developed computational design to production methodologies, the paper discusses the research findings from pedagogical lenses. Building on these cases, the investigation advances to the development of a generative system centered on voxels, employing a tetrahedron structure. This volumetric approach simultaneously produces external surface tectonics and internal infill through a seamless toolpath. The paper concludes by presenting sets of guidelines and future directions for both the introduced curve and voxel-based approaches in Robotic Concrete 3D printing, emphasizing the early integration of computational and fabrication intelligence into the design process.

Materialization practices in the architecture and building industry have evolved with the advancement of manufacturing and information technologies. This evolution is evident across various design and production phases, with a pronounced impact on prototyping. Advances in design and fabrication tools have empowered prototypes, integral in any production cycle, to furnish a growing array of information and feedback for designers and manufacturers. In this context, prototypes have transformed from merely showcasing data-driven building solutions to presenting socio-environmentally conscious systems. Innovation in prototyping connects the initial design and construction stages to the operational phase, creating a seamless transition throughout the project lifecycle. This chapter provides a range of definitions and prototypical case studies for smart prototyping by identifying practiced approaches in integrated design to production workflows. This chapter introduces three paradigms for smart prototyping: Digital prototyping focuses on data-driven design for mass customization, phygital prototyping involves mixed-reality-enabled design and assembly, and thirdly collaborative prototyping explores human-machine hybrid intelligence and co-production in architectural and urban contexts. The chosen case studies in this chapter and how they are categorized aim to provide a comprehensive overview of smart prototyping, covering projects conducted in both research and practice. This chapter concludes with potential future trends and the role of emerging and evolving mediums of prototyping for smart design and construction.

The application of Augmented Reality (AR) in construction is transforming how non-expert users engage with complex assembly processes, with its potential to foster broader community involvement in urban space production remaining underexplored. This paper presents an integrated framework that incorporates AR-enabled phygital instructions with timber dowel structures, facilitating the active participation of non-experts in the design-to-production process of an urban community food podium. By leveraging AR and computational design, the system bridges the gap between expert and non-expert users, enabling wider participation in the construction process while maintaining precision through robotic fabrication and step-by-step digital guidance. Tested within a graduate-level course and showcased at a public event, the project aims to empower community members to engage in production and assembly, offering insights into participatory urban design and co-production. The results demonstrate the capacity of augmented fabrication to enhance human agency, making complex construction tasks accessible and collaborative, and paving the way for resource-driven, community-enabling urban developments.

This research explores the design-to-production computational framework of a Timber Dowel System, emphasizing an integrated computational workflow informed by fabrication and assembly feedback. This workflow incorporates contextual and fabricability parameters, enabling a parametric framework optimized for performance, adaptability, and scalability. The initial design process utilized a modular plug-and-play approach, employing manually controlled surfaces and poly-surfaces to explore flexible geometries and structural configurations. Two full-scale prototypes were developed using AR-guided assembly and robotic milling, addressing production challenges such as dowel placement precision, material limitations, and assembly feasibility. Feedback from these prototypes informed refinements in the computational framework, translating into practical parameters to improve structural integrity and procedural efficiency. A horizontal orientation was prioritized due to its standalone stability, while multiple extensions of the initial basket prototype were analysed to evaluate and study the system performance under varied geometric configurations. By integrating community-driven requirements and contextual considerations, this research lays the groundwork for a multi-criteria framework that supports informed design variation and facilitates collaborative co-production workflows.