Lost and Bound: Adaptive Detailing with Robotic Additive Joining for Reclaimed Steel

Abstract

Following circular economy principles, steel components can be reprogrammed to be used over multiple life cycles. However, reclaimed building components typically present superficial alterations, often cut away as waste, reducing member sizes and resource efficiency. As an alternative to pre-processing steel parts to bring them back to known standard shapes, this work shows a computational detailing strategy and additive joining approach to adapt to variable, uneven geometries. The method includes digitizing the material stock, integrating the building elements' as-is surface conditions into a node's design, planning robotic procedures with as-built data, and robotic joining with in-place wire and arc additive manufacturing (IPWAAM). The approach profits from the large design space of robotic manufacturing, enabling high-strength material placement with a widespread welding technology in the construction industry. The results of two node prototypes demonstrate a highly malleable connection strategy for reusing imprecise steel elements to meet tolerances that would otherwise require extensive manual labor or pre-processing. With this contribution, we aim to put forward the role that adaptive robotic building strategies can play in supporting the reuse of building components.