Extension of Computational Co-Design Methods for Modular, Prefabricated Composite Building Components Using Bio-Based Material Systems

Robotic coreless filament winding using alternative material systems based on natural fibers and bio-based resin systems offers possible solutions to the productivity and sustainability challenges of the building and construction sector. Their application in modular, prefabricated structures allows for material-efficient and fast production under tightly controlled conditions leading to high-quality building parts with minimal production waste. Plant fibers made of flax or hemp have high stiffness and strength values and their production consumes less non-renewable energy than glass or carbon fibers. However, the introduction of natural material systems increases uncertainties in structural performance and fabrication parameters. The development process of coreless wound composite parts must thus be approached from the bottom up, treating the material system as an integral part of design and evaluation. Existing design and fabrication methods, as well as equipment, are adjusted to emphasize material aspects throughout the development, increasing the importance of material characterization and scalability evaluation. The reciprocity of material characterization and the fabrication process is highlighted and contributes to a non-linear, cyclical workflow. The implementation of extensions and adaptations are showcased in the development of the livMatS pavilion, a first attempt at coreless filament winding using natural material systems in architecture.