Developing a computational approach towards a performance based design and robotic fabrication of fibrous skin structures

Abstract This research investigates the underlying concepts existing in the works of Pier Luigi Nervi in the design and fabrication of ribbed concrete floor systems. A new methodology for the design and fabrication of fiber composite structures is developed which translates Nervi’s techniques into computational strategies for pattern based analysis and design of complex fiber composite skin structures. This research uses the concept of principal stress patterns in a computational approach to inform fiber orientation and density in the design and fabrication of light weight structural skins made of fiber reinforced polymer composites. The computational process integrates form finding of the global geometry of the skin structure based on fabrication constraints with stress pattern simulation towards the development of a performative fiber layout that responds to structural requirements as well as fabrication constraints. The global geometry of the structural skin is parametrically modeled and controlled through a generative code based on robotic fabrication constraints. The skin geometry is analyzed to create principal stress patterns which will inform the orientation and density of reinforcing fibers in an iterative process by controlling its response to design criteria. Geometric complexity of resulting structures necessitates application of a consistent and controllable fabrication method. Incorporating robotic fiber placement techniques as a means of fabrication will result in a precise layout of fibers ensuring a predictable response to structural loads.