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Hierarchical Discrete Lattice Assembly: An Approach for the Digital Fabrication of Scalable Macroscale Structures

Miana Smith, Paul Arthur Richard, Alexander Htet Kyaw, Neil Gershenfeld

TL;DR

This work addresses the challenge of fabricating structures at meter scales by integrating simple, printable, self-aligning lattice blocks with modular mobile robots (MILAbot) and a live digital twin that coordinates planning, simulation, and execution. The core contributions include a voxelization-to-compounded-block pipeline, a hierarchical lattice design that enables stable, self-aligning assembly, a modular inchworm robot family for scalable throughput, and a digital twin that links design, planning, and real-time control. Validation is shown through voxelization, path planning, and robotic fabrication of meter-scale objects, with comparative throughput and mechanical performance analyses. The approach promises scalable, cost-effective, and adaptable fabrication for architecture, infrastructure, and potentially in-space manufacturing, while outlining clear avenues for improving voxelization generalization, feeder management, control calibration, and material choices.

Abstract

Although digital fabrication processes at the desktop scale have become proficient and prolific, systems aimed at producing larger-scale structures are still typically complex, expensive, and unreliable. In this work, we present an approach for the fabrication of scalable macroscale structures using simple robots and interlocking lattice building blocks. A target structure is first voxelized so that it can be populated with an architected lattice. These voxels are then grouped into larger interconnected blocks, which are produced using standard digital fabrication processes, leveraging their capability to produce highly complex geometries at a small scale. These blocks, on the size scale of tens of centimeters, are then fed to mobile relative robots that are able to traverse over the structure and place new blocks to form structures on the meter scale. To facilitate the assembly of large structures, we introduce a live digital twin simulation tool for controlling and coordinating assembly robots that enables both global planning for a target structure and live user design, interaction, or intervention. To improve assembly throughput, we introduce a new modular assembly robot, designed for hierarchical voxel handling. We validate this system by demonstrating the voxelization, hierarchical blocking, path planning, and robotic fabrication of a set of meter-scale objects.

Hierarchical Discrete Lattice Assembly: An Approach for the Digital Fabrication of Scalable Macroscale Structures

TL;DR

This work addresses the challenge of fabricating structures at meter scales by integrating simple, printable, self-aligning lattice blocks with modular mobile robots (MILAbot) and a live digital twin that coordinates planning, simulation, and execution. The core contributions include a voxelization-to-compounded-block pipeline, a hierarchical lattice design that enables stable, self-aligning assembly, a modular inchworm robot family for scalable throughput, and a digital twin that links design, planning, and real-time control. Validation is shown through voxelization, path planning, and robotic fabrication of meter-scale objects, with comparative throughput and mechanical performance analyses. The approach promises scalable, cost-effective, and adaptable fabrication for architecture, infrastructure, and potentially in-space manufacturing, while outlining clear avenues for improving voxelization generalization, feeder management, control calibration, and material choices.

Abstract

Although digital fabrication processes at the desktop scale have become proficient and prolific, systems aimed at producing larger-scale structures are still typically complex, expensive, and unreliable. In this work, we present an approach for the fabrication of scalable macroscale structures using simple robots and interlocking lattice building blocks. A target structure is first voxelized so that it can be populated with an architected lattice. These voxels are then grouped into larger interconnected blocks, which are produced using standard digital fabrication processes, leveraging their capability to produce highly complex geometries at a small scale. These blocks, on the size scale of tens of centimeters, are then fed to mobile relative robots that are able to traverse over the structure and place new blocks to form structures on the meter scale. To facilitate the assembly of large structures, we introduce a live digital twin simulation tool for controlling and coordinating assembly robots that enables both global planning for a target structure and live user design, interaction, or intervention. To improve assembly throughput, we introduce a new modular assembly robot, designed for hierarchical voxel handling. We validate this system by demonstrating the voxelization, hierarchical blocking, path planning, and robotic fabrication of a set of meter-scale objects.
Paper Structure (34 sections, 2 equations, 19 figures, 1 table)

This paper contains 34 sections, 2 equations, 19 figures, 1 table.

Table of Contents

  1. Introduction
  2. Related Work
  3. Scalable Building Systems
  4. Continuously Fabricated Systems
  5. Sectioned Fabrication and Assembly
  6. Discrete Assembly
  7. Robotic Fabrication Systems
  8. Static Gantries
  9. Industrial Arms
  10. Material-Robot Systems
  11. Synthesis
  12. System Overview
  13. Software Implementation
  14. Voxelization
  15. Building Sequence
  16. ...and 19 more sections

Figures (19)

  • Figure 1: An overview of the lattice type and building blocks used in this project. The basic lattice type is an edge-connected octet lattice, which is decomposed into an extended cuboctahedron-octet, which is then compounded into different arrangements for robotic assembly.
  • Figure 2: (Top) An example of tiling 2x2 offset voxel blocks to establish a first layer or overhang, with red arrows indicating the axes of potential extension. (Bottom) Beyond the first layer, layers can achieve interconnection through staggering layers.
  • Figure 3: Simulation overview illustrating the four main elements: MILAbot, support stairs, voxel feed, and target structure.
  • Figure 4: Top: Data flow from web-based simulation to MILAbot through middleware. Bottom: Digital twin synchronized with physical execution.
  • Figure 5: (Top) A 4x2x2 block of FFF printed PLA octet lattice with printability features added. (Bottom) Screw-release snap fit used for vertical connections.
  • ...and 14 more figures