The research described in this paper is dedicated to the use of continuous fibers as reinforcement for additive manufacturing, particularly using Shotcrete. Composites and in particular fiber reinforced polymers (FRP) are increasingly present in concrete reinforcement. Their corrosion resistance, high tensile strength, low weight, and high flexibility offer an interesting alternative to conventional steel reinforcement, especially with respect to their use in Concrete 3D Printing. This paper presents an initial development of a dynamic robot-based manufacturing process for FRP concrete reinforcement as an innovative way to increase shape freedom and efficiency in concrete construction. The focus here is on prefabricated fiber reinforcement, which is concreted in a subsequent additive process to produce load-bearing components. After the presentation of the fabrication concept for the integration of FRP reinforcement and the state of the art, a requirements analysis regarding the mechanical bonding behavior in concrete is carried out. This is followed by a description of the development of a dynamic fiber winding process and its integration into an automated production system for individualized fiber reinforcement. Next, initial tests for the automated application of concrete by means of Shotcrete 3D Printing are carried out. In addition, an outlook describes further technical development steps and provides an outline of advanced manufacturing concepts for additive concrete manufacturing with integrated fiber reinforcement.

The construction industry is facing a dual challenge: an increasing demand for new buildings on the one hand and the urgent need to drastically reduce emissions and waste on the other. One promising field of research to face these challenges comprises additive manufacturing (AM) technologies. Through these advanced methods, digital workflows between design and fabrication can be implemented to optimise the form and structure, unlocking new architectural freedom while ensuring sustainability and efficiency. However, to drive this transformation in construction, the new technologies must be investigated in large-scale applications. One of these fast-emerging AM techniques is Shotcrete 3D Printing (SC3DP). The present research documents the 1:1 scale manufacturing process, from digital to real, of a building section utilising SC3DP. A workflow and production steps, spanning from design over manufacturing to assembly, are introduced. The architectural design, reinforced by computational methods, was iteratively refined to adapt to manufacturing constraints. The paper also emphasises the importance of a digital twin in ensuring seamless data integration and real-time adjustments during construction. By incorporating reinforcement techniques such as short rebar insertion and robotic fibre winding, this study demonstrates the structural capabilities achievable with SC3DP. In summary, the implementation of comprehensive digital workflows utilising computational design, automated data acquisition and data flow, as well as robotic fabrication is presented to demonstrate the potential of AM methods in construction. Furthermore, this paper provides a perspective on potential future research paths and opportunities inherent in leveraging the innovative SC3DP technique.

Whereas entire houses are reported to be built by means of 3D Concrete Printing (3DCP), automated integration of reinforcement is still a vastly unresolved challenge and - undoubtfully - a crucial requirement for widespread adoption of 3DCP in construction practice. The disruptive technology of 3DCP opens up the chance to overcome insufficiencies of conventional steel reinforcement and its rationalised orthogonal use. This paper discloses a field of options for future construction by exploring possible reinforcement strategies for different kinds of cement-based Additive Manufacturing techniques using continuous textile fibres. A methodology is introduced to identify, compare and assess new processes for integration of fibre reinforcement based on robotic winding. Two novel approaches will be described regarding Large Particle 3D Concrete Printing and Shotcrete 3d Printing. Respective case studies will be presented in order to give a basic proof of concept.

Composite structures in aeroplanes are often thin-walled and lightweight, resulting in significant compliance, which presents a handling and assembly challenge due to the associated part deformations. In order to counteract these deformations, the parts are held in their specified geometry using stiff and correspondingly heavy fixtures or jigs. Mobile industrial robots are very versatile and widely used in industrial volume production, but they are limited in their payload capacity. High-rate production of large aerospace modules requires highly automated flexible assembly processes. The approach presented in this paper is to combine mobile units with lightweight assembly jigs that have the capability of deformation compensation. The subject of the study is a high-rate assembly process for flap modules using an Autonomous Industrial Mobile Manipulator (AIMM) and a lightweight end effector. The end effector has a shape compensation function, implemented by an integrated Stewart platform, which enables the compensation of manufacturing tolerances as well as gravity effects. The compensation function is used in a closed loop and counteracts shape deviations by appropriate fixture shape adjustments. The paper reports on the conceptual design of the assembly scenario, the design of the end effector, its realization and the successful experimental demonstration at 1:1 scale.

The integration of load path compliant fibre reinforcement structures into additive manufactured concrete elements opens up new potential in the field of construction. The new design language made possible by 3D concrete printing requires reinforcement structures to be provided in a highly individual shaped manner. Digital and robot-based production processes make it possible to produce on-site, on demand, fully automated and just-in-time. In this paper, a concept for an on-site ready fibre reinforcement production is presented. Based on previous works a Dynamic Winding Machine (DWM) for the on-demand production of individualizable reinforcement strands is developed. The concept and technical functionalities of the machine are presented in detail. The functionality is validated based on the production of single reinforcement bars as well as the production of entire, additively manufactured and reinforced concrete structures. With an industrial robot and adjusted end effectors, freely shaped reinforcement structures can be produced automatically. Different concepts for the use of the DWM with mobile robots are discussed. Due to the flexibility of the process, both filigree reinforcement structures, e.g. for use in particle bed printing, and large structures, e.g. for combination with Shotcrete 3D Printing, can be produced.