Foam cutting for an architectural installation using industrial robot arm: Calibration, error, and deviation analysis

Robot arm with hot wire cutting is one of the emerging techniques used to carve foam in architectural fabrication. A literature review revealed that there is very little research information related to procedures or calibration techniques. This study aimed to present a pedagogical procedure for using the robotic arm with hot wire cutting. The procedure was tested and demonstrated through various conditions that occur during operations. First, the basic structure of a hot wire cutter was described and different feed rates and heat strengths with the cutter were calibrated to determine the appropriate setting values and effects. In addition, toolpath settings are discussed to minimize deviations in the cutting process. The procedure was evaluated based on the roles of tools, design practices and materials in the robotic fabrication. The data collected and optimal conditions established from the test were used to fabricate architectural components. Then, a test model was developed and its components were sliced into appropriate sizes, followed by physical piece-by-piece cutting. The pieces were assembled sequentially and their assemblages were compared with the expected results. The study was concluded with observations that the objectives expected for the fabrication of the test model were met using the tool. Further, the advantages and drawbacks of the process were addressed. In addition, the interactive relation of digital design and robotic fabrication, as well as their contribution to architectural design, was significantly emphasized. •After setting up a hot wire cutter mounted on the industrial robot arm, different feed rates and heat strengths with the cutter were tested to find appropriate setting values and testing effects. Additionally, toolpath settings were discussed to minimize deviations in the cutting process.•While developing a test model to demonstrate the operation of the tool that are not presently in commercial use, the model was sliced into appropriate sizes and elected to perform necessary assembly tests. Then, we discussed the extent to which the objectives expected for the fabrication of the test model are met using the tool, addressing the advantages and drawbacks of the overall process, and evaluating the projec's performance.•Because there are was very little research information related to methodical procedures or calibration techniques, the data gained from this research will contribute towards enhancing the collaborative process