Self-interlocking 3D Printed Joints for Modular Assembly of Space Frame Structures

Abstract

This paper presents a novel system of 3D printed self-interlocking space frame structures that are designed to facilitate automatic assembly using robots or drones. The research focuses on fundamental geometrical investigations of connection mechanisms enabled by additive manufacturing (AM) and their computational framework. It seeks to find out in which way AM can advance the design of space frame structures in order to enable automation in the AEC industry. The developed system consists of bespoke 3d printed connections and carbon fiber tubular members harvesting the geometric freedom that AM allows in order to encode multiple details. The novelty of the method lies in the customization of the joints to enable a hybrid scheme of standard and automated assembly. The system operates in a two-step process: humans assemble light rigid modules in a prefabrication facility and later these modules are assembled on-site in a quick fashion using mobile robots. The paper describes multiple investigations of connection mechanisms and joint designs that were tested through physical prototypes. The investigations focus on different self-interlocking mechanisms that address local demands in the structural system. Finally, the prototypes presented are assembled simulating the robotic unit due to the short span of the project.