Fabrication Projects

Projects / Fabrication Projects

Fabrication Projects

Overview

This page collects selected digital fabrication projects that connect computational design with physical making, from robotic toolpaths and pick-and-place experiments to CNC-produced, full-scale plywood structures.

Jump to: ROBOTISM • INTEGRITY • CLIMATE‑RESPONSIVE FACADE

Parametric design Plywood structures Robots + CNC Assembly planning

ROBOTISM: Robotic Fabrication Workshop (Pick & Place + Light Painting)

Workshop project • Group work • KUKA KR6 (KRC2/KRL) • Rhino/Grasshopper toolpaths

Completed plywood pavilion fabricated through a robotic pick-and-place workflow

Summary

ROBOTISM is a 10-day workshop project in robotic fabrication and computational design. Working in teams, we learned the fundamentals of robot programming and toolpath thinking, then applied them in two tracks: (1) light painting using robot-generated motion paths, and (2) pick-and-place fabrication using a KUKA KR6 equipped with a pneumatic gripper. The final outcome was a full-scale plywood pavilion assembled from robot-placed components and completed with a collaborative human–robot fastening workflow.

KUKA KR6 KRC2 + KRL Rhino + Grasshopper G-code Pick & Place 18mm plywood

Project at a glance

Context

Workshop project • Group work • Robotic fabrication + computational design

Institution: University of Tehran
Role: Design, software, and fabrication
Robot platform: KUKA KR6 with KRC2 controller
Supervisor: Dr. Ramtin Haghnazar (and team)

Key constraints

Material limit: ~40 m² of 18mm plywood
Robot reach: ~1.6 m (influenced segmentation and assembly planning)
Process requirement: collision-aware paths and stable intermediate states

Outcomes

Light-painted drawings generated from Grasshopper-defined curves and robot motion paths
Pick-and-place prototypes exploring stability, stacking logic, and assembly sequencing
A fabricated pavilion split into 9 transportable sections and assembled on campus

Workshop process

The workshop began with an introduction to KRL syntax and the fundamentals of generating machine-readable motion instructions. After the initial training, we worked in small groups through a sequence of exercises aimed at building intuition for toolpaths, robot constraints, and fabrication-ready geometry.

1) Toolpath thinking

We practiced defining continuous motion paths and understanding how speed, continuity, and reach constraints shape what is fabricable.

2) From parametric curves to motion

Curves were authored in Rhino/Grasshopper, then translated into robot-readable instructions (G-code/KRL workflow depending on the exercise).

3) Physical validation

Each digital path/sequence was validated in the real workspace—checking collisions, grip reliability, and whether the assembly remains stable during placement.

Exercise 1: Light painting

For the first exercise, we defined continuous curve patterns in Grasshopper 3D and used them to generate a robot motion path. After producing the corresponding instructions, we mounted a simple LED on the robot head and captured long-exposure photographs while the robot traced the curves in space.

Light painting experiment: robot draws a continuous figure using an LED — Light painting in the lab using an LED tool mounted on the robot.

Light painting experiment: curve pattern traced in space — Parametric curve pattern translated into robot motion.

Light painting experiment: spiral-like pattern captured by long exposure — Exploring continuity, speed, and curvature in a single uninterrupted path.

Exercise 2: Pick & place prototypes

In the next exercise, each group designed a structure using wooden pieces with fixed dimensions and counts. The objective was to assemble the structure via pick-and-place while ensuring stability throughout the sequence—prioritizing an assembly logic that could stand without relying on screws or glue during placement.

Robot pick and place prototype: early stacking test — Early stacking tests to verify grip, alignment tolerance, and stability.

Robot pick and place prototype: placement sequence — Sequencing matters: stable intermediate states reduce failure during placement.

Robot pick and place prototype: taller stack — Iterating on geometry and stacking logic to increase height while maintaining balance.

Final product: Plywood pavilion

After the introductory tasks, teams proposed pavilion concepts at the scale of 1:1. Given the available material (~40 m² of 18mm plywood), designs were reviewed by a jury and one concept was selected for fabrication. The final design was refined and prepared for robotic assembly.

Segmentation + assembly planning

Because the robot reach was limited (~1.6 m) and the build site introduced placement constraints, the arch was divided into transportable sections. The strategy was to halve the arch and split the halves into 4 and 5 parts (a total of 9 sections).

Form finding option 2 — Contoured surface

Form finding option 3 — Locating plywoods

Form finding option 4 — The nine sections

Connection strategy

Two approaches were explored for connecting pieces during assembly: (1) a robotic gluing routine using a glued roller, or (2) a collaborative workflow where a person fastens parts after robot placement using a pneumatic nail gun. Due to time constraints and practical considerations, the collaborative method was selected for the final build.

Robot placing plywood components along a curved wall — Robotic placement along the pavilion curve with a human-in-the-loop fastening strategy.

Montage showing simulation, robotic fabrication, and on-site assembly — Process montage: simulation views, workshop fabrication scenes, and on-site installation steps.

On-site installation

The fabricated sections were transported to campus and assembled on site. Installation was completed in approximately two hours, demonstrating how up-front planning (segmentation, sequencing, and connection strategy) can make large-scale fabrication workflows feasible within tight workshop timelines.

On-site assembly: lifting a pavilion section — Transporting and positioning a fabricated section.

On-site assembly: fastening and alignment — Collaborative assembly: alignment + fastening during installation.

On-site assembly: team completing the pavilion — Final adjustments as the pavilion geometry is locked in place.

What this project demonstrates

Bridging parametric design and fabrication

Parametric geometry becomes fabrication-ready only when translated into stable sequences, tolerances, and collision-aware robot motions.

Designing for constraints

Robot reach, end-effector behavior, and material limits directly shape form, segmentation, and assembly strategy.

Human–robot collaboration

Hybrid workflows (robot placement + human fastening) can be a practical solution for time-limited contexts such as workshops and rapid prototyping.

One-page portfolio

ROBOTISM one-page project composite with abstract, render, and workflow diagram — Tip: open the full-size version to read the diagrams and captions.

INTEGRITY: Nexorade Plywood Pavilion

Academic project • Group work • University of Art • Role: conceptualization, fabrication

INTEGRITY pavilion: full-scale Nexorade plywood structure installed outdoors

Summary

INTEGRITY is a full-scale plywood pavilion developed as a digital fabrication project using a Nexorade structural logic. The project was designed and tested digitally, produced from 18 mm plywood sheets using CNC cutting, and assembled on site using screwed connections (no adhesives).

Nexorade structure 18mm plywood CNC cutting Screw assembly Full-scale installation

Project at a glance

Project details

Type: Academic project (group work)
Institution: The University of Art
Role: Conceptualization, design development, and fabrication
Supervisor: Dr. Ramtin Haghnazar (and team)

Material + making

Material: 18 mm plywood sheets
Production: CNC-based digital fabrication
Assembly: screw-fastened elements and on-site installation

Goal

Translate a parametric surface into a buildable lattice
Develop repeatable element logic and connection details
Validate constructability through full-scale prototyping and assembly

Parametric workflow

The digital pipeline starts with defining main curves and a guiding surface, then generating a lattice pattern that is adjusted by rotating and extending elements to achieve structural continuity. Element geometry and connection details are finalized to support straightforward assembly and accurate positioning during fabrication.

Diagram sequence: main curves, surface generation, pattern drawing, rotating and extending elements — Diagram sequence: curves → surface → pattern → element rotation/extension → pavilion form.

Element development diagrams showing extrusion, extension, and final element shaping for assembly — Element development: extrusion along surface normals, extension logic, and final element shaping for assembly.

Fabrication and assembly

After digital testing and finalization, elements were produced and labeled for assembly. CNC milling supported accurate cuts and alignment features, while the on-site build relied on screw fastening and coordinated lifting/positioning to form the final pavilion geometry.

CNC milling operation producing plywood parts — CNC cutting/milling used to produce plywood components.

Applying finish to plywood elements — Assembly procedure.

Screw fastening during assembly — On-site positioning to complete the final structure.

Close-up view of the Nexorade lattice and connections — Detail view: Nexorade lattice geometry and repetitive element logic that supports the global form.

One-page portfolio

INTEGRITY one-page project composite with abstract, render, and workflow diagram — Tip: open the full-size version to read the diagrams and captions.

CLIMATE‑RESPONSIVE FACADE (CRF): Biomimetic Kinetic Shading Inspired by Chameleon Eyes

Academic project

Project board for the Climate-Responsive Façade (CRF) showing concept, module system, and prototype

Summary

Climate‑Responsive Façade (CRF) is a biomimetic, textile-based kinetic envelope prototype designed to improve visual comfort (daylight quality + glare control) in hot and arid climates. Inspired by how chameleons move their eyes independently, each façade module can adjust its aperture and orientation in real time, enabling localized shading responses for different zones behind the same façade.

The workflow connects parametric design (Rhino/Grasshopper + Python) to daylighting simulations (ClimateStudio/Radiance), then validates the system through a physical prototype actuated by linear actuators and controlled via an Arduino with LDR light sensors. The result is a façade concept that offers granular control over daylight penetration while preserving openness and reducing discomfort glare.

Biomimicry Kinetic facade Rhino + Grasshopper ClimateStudio / Radiance Arduino + LDR Linear actuators Fabric prototyping

Project at a glance

Context

Type: Academic project (group work)
Institution: The Pars University
Supervisor: Dr. Matin Alaghmandan
Role: Conceptualization, software development, simulation, prototyping

System concept

Module geometry: regular hexagon (high packing efficiency + multi-directional response)
Mechanism: 3 fixed arms + 3 movable arms controlling the opening
Skin: stretch textile that tolerates multi-direction movement while staying taut
Control modes: manual (user-defined) and responsive (sensor + sun-path driven)

Biomimetic idea and module behavior

Chameleon eyes used as biomimetic inspiration — Biomimetic reference: chameleons track targets with independently moving eyes, inspiring independent module motion across the facade.

CRF module shown in fully open and fully closed states — Each hexagonal unit can open/close its aperture by coordinating three movable arms against a fixed frame.

3D model of a unit showing how the opening changes — Sun-path driven configuration studies that map solar angles to module states.

Physical prototype: actuation + textile behavior

The prototype validates real-time adaptability using a lightweight structure and a stretch-fabric skin. Three linear actuators drive the movable arms of each unit; LDR sensors read local light levels and feed the controller; and an Arduino UNO coordinates actuation through relays. The stretch textile accommodates multi-direction motion while maintaining continuous surface tension.

Mechanism diagram showing how arms and fabric create the opening — Mechanism study: arm movement + fabric deformation define the aperture geometry.

Physical prototype showing closed and open states — Prototype validation: open/closed states achieved via actuator-driven arms and a tensioned textile skin.

Video demo

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What this project demonstrates

Multi-scale integration

Bridges biomimetic concept design, parametric control logic, simulation evaluation, and physical prototyping in one pipeline.

Granular comfort control

Independent modules allow localized shading responses—supporting comfort without forcing a single global “open/closed” facade state.

Soft kinetics

Stretch textiles enable richer motion and lighter mechanisms compared to rigid-panel systems—well-suited for responsive envelope research.

One-page portfolio

CRF one-page project composite with abstract, render, and workflow diagram — Tip: open the full-size version to read the diagrams and captions.

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