Sensing and Augmenting for Adaptive Assembly Strategies

This paper introduces an innovative integrated approach to design, simulate, and testassembly strategies that adapt to tolerances and geometric variations. Traditional Designfor Assembly (DfA) methods, while effective for well-known materials and predetermineddesign parameters, exhibit limitations in addressing unknown parameters andunpredictable material behavior. Our research employs techniques such as 3D scanning,laser projection, and early 1:1 prototyping to develop a flexible adaptive assembly model,accommodating last-minute structural and site condition changes.We demonstrate our novel workflow through the assembly and installation of a largescale demonstrator at the AEDES gallery in Berlin, consisting of 24 variable-size 3Dprinted panels attached to a brick wall. By creating an initial assembly model using earlydetailing and a preliminary assembly sequence, we maximized the number of adaptabledesign parameters. An agent-based model was utilized to identify wall connectionlocations based on site constraints and fastener accessibility. Upon completing panelproduction, we used industrial laser projectors to compare digital files to actual piecesand 3D scanning to acquire accurate panel connection positions. This informationenabled the regeneration of connection points with precise angles and dimensions andinformed the final assembly sequence. On-site laser projection facilitated the efficientassembly of the structure. Our approach paves the way for more accurate and adaptableconstruction methods in complex architectural projects