Creating terracotta panels through grayscale image processing and robotic hotwire cut molds

This research presents a method for fabricating relief terracotta panels, utilizing polystyrene molds shaped by robotic hotwire cutting. A crucial aspect of this work is the use of grayscale images as input for generating toolpaths for hotwire cutting, bridging the gap between digital image processing in computer graphics and the physical creation of architectural elements. The process integrates computational tools with fabrication constraints and material properties to generate an integrated design approach. Utilizing computational tools, we generate toolpaths that translate grayscale images into tangible tile patterns. These patterns are formed by ridges, designed to accurately depict the grayscale images while ensuring functional tiling. The methodology synergizes traditional clay handling techniques with digital modeling, providing crucial data for material handling during drying and baking stages. The research presents a significant contribution to the realm of architectural design and computer graphics. It demonstrates the potential of image processing techniques in conjunction with robotic fabrication for creating built environments. The final tiles’ appearance, evaluated using the peak signal-to-noise ratio (PSNR), exhibits values between 20 dB and 30 dB, aligning within the realms of acceptable image resemblance according to established image compression standards. [Display omitted] •Implements an integrated design approach for creating relief terracotta panels using robotically fabricated molds.•Utilizes an optimized method combining grayscale image sampling, marching squares algorithm, and genetic algorithms to generate robotic toolpaths.•Offers a diverse range of toolpath options to create varied ridges for relief terracotta panels in terms of amount, disposition, width, and depth.•Employs peak signal-to-noise ratio for validating the resemblance of tangible relief panels to the initial grayscale image.