Sasa Zivkovic

Open Source Factory Cornell University

Christopher Battaglia
Cornell University

Democratizing Large-Scale Fabrication Systems

ABSTR ACT
Open source frameworks have enabled widespread access to desktop-scale additive manufac- 1 Cornell Robotic Construction
Laboratory (RCL): Daedalus Open
turing technology and software, but very few highly hackable large-scale or industrial open source
Source 3D printer capable of
equipment platforms exist. As research trajectories continue to move towards large-scale experi- printing concrete at full scale in
mentation and full-scale building construction in robotic and digital fabrication, access to industrial 2016.

fabrication equipment is critical. Large-scale digital fabrication equipment usually requires extensive
start-up investments which becomes a prohibitive factor for open research. Expanding on the idea
of the Fab Lab as well as the RepRap movement, the Open Source Factory takes advantage of
disciplinary expertise and trans-disciplinary knowledge in construction machine design accumulated
over the past decade. With the goal to democratize access to large-scale industrial fabrica-
tion equipment, this paper outlines the creation of two full-scale fabrication systems: a RepRap
based large-scale 3-axis open source CNC gantry and a 6-axis industrial robot system based on a
decommissioned KUKA KR200/2. Both machines offer radically different economic frameworks
for implementing research in advanced full scale robotic fabrication into contexts of pedagogy, the
research lab, practice, or small scale local building industry. This research demonstrates that such
equipment can be implemented by building on the current knowledge base in the field. If indus-
trial robots and other large-scale fabrication tools become accessible for all, the collective sharing
of research and the development of new ideas in full-scale robotic building construction can be
substantially accelerated.

660
INTRODUCTION
Over the past two decades, the Open Source movement has
enabled an exchange of ideas and has grown from a concept
in the software industry (DiBona and Ockman 1999) to a
widespread and diverse phenomenon. Embracing a culture of
hacking, the sharing of information, and the advancement of
new technology, the open source movement has enabled access
to a whole range of tools and software protocols. The idea of
open source hardware, perhaps best embodied in the Arduino
microcontroller developed in 2005 (Banzi 2008), has facilitated
a radical paradigm shift and lowered the threshold of expertise
necessary to create and design actuated robots. This has also
made possible more advanced software and hardware platforms
such as the RepRap 3D printers, which have revolutionized
access to additive manufacturing tools. Prior to the develop-
ment of Arduino, the emergence of the idea of the Fab Lab at
MIT (Mikhak et al. 2002; Gershenfeld 2008; Gershenfeld 2012)
drastically shifted the social construct surrounding technological
development by empowering communities to create their own
tools and thereby actively innovate solutions for pressing local
issues. A Fab Lab is equipped with design tools and fabrication
equipment, as well as material documentation, allowing users of
the laboratory to design and fabricate electronic components,
physical hardware, and software. The original Fab Lab equip-
ment was remarkably affordable and cost only about $13,500
but has since expanded to include some more costly equipment
such as a laser cutter, a large CNC mill, and a 3D printer, among
other items. On the brink of the Fourth Industrial Revolution
and Industry 4.0 (Schwab 2016), the notion of personalized,
connected, and distributed manufacturing is gaining further rele-
vance. The idea of proliferated mass customization is inextricably
linked to the availability of distributed places of manufac-
turing (Carpo 2011). However, while ideas exist to implement
new scales of manufacturing, as demonstrated by the IAAC
MiniBuilders project, the high cost of large-scale industrial fabri-
cation equipment remains a prohibitive factor in this equation.
In architecture academia, there exist select facilities capable
of advanced research in digital fabrication at the building scale.
At ETH Zurich, the Gramazio and Kohler research laboratory
(Kohler, Gramazio and Willmann 2014) has recently implemented
a large-scale robotic laboratory with four 6-axis robots capable
of pursuing research at the building scale. The Institute for
Computational Design and Construction (ICD) at University of
Stuttgart led by Achim Menges, working in collaboration with the
Institute for Building Structures and Structural Design (ITKE) led
by Jan Knippers, is another example of an academic entity with
the capacity to do research at full scale as demonstrated in their
various pavilion projects (Doerstelman et al. 2015; Knippers et
al. 2015). There are select other academic institutions or maker
spaces with similar facilities and access to large industrial robotic
arms such as the Autodesk Build Spaces. Yet, more broadly, once
outside of the realm of certain academic institutions or leading
companies, access to large-scale fabrication equipment is limited.
Moreover, tools in professional maker spaces often cannot be
manipulated to the extent necessary. What if large-scale fabrica-
tion tools were economically affordable and open source? With
very limited means, a recent graduate in architecture could found
a start-up or architecture office focusing on robotic fabrication.
Small local companies in the building industry could have access
to advanced fabrication equipment. Architecture research labora-
tories across the world could build their own industrial machines
and work at full scale (Figure 1). To further advance the field of
computational design in architecture, we need an open source
movement for industrial fabrication equipment.
BACKGROUND
The goal of the Open Source Factory project is to question
current modes of tool acquisition and to democratize access to
large-scale fabrication equipment. Faced with the predicament of
not having access to a large-scale robotic arm, the research team
developed a low-cost strategy to set up a laboratory capable of
contributing to pressing disciplinary concerns in robotic fabri-
cation and construction. In a first project phase, a large 3-axis
CNC gantry system was developed based on the RepRap 3D
printer platform. In a second phase, a decommissioned 6-axis
industrial robotic arm that previously served as a welding robot
at General Motors was revitalized and put back into operation.
Both machines were equipped with a range of custom built end
effectors including a concrete printing nozzle, a plastic extruder,
a foam printing nozzle, a chainsaw, a band saw, as well as a CNC
spindle.
The RepRap Platform
The RepRap (Replicating Rapid-prototyper) 3D printers started
a revolution in the sector of small scale additive manufacturing
(Figure 2). Almost overnight, RepRap democratized 3D printing
technology by giving access to hardware, firmware, and software
protocols. It is estimated that the number of RepRaps grew from
4 machines in 2008 to 2500 machines only a few months later
(Jones et al. 2011). Today, there are millions of RepRap deriv-
ative 3D printers across the globe. One key to the RepRap's
success is that the concept is highly adaptable and customizable.
At desktop scale, there are various printer sizes, axis configura-
tions, and machines that can be equipped with different types
of extruders, heated beds, or cooling fans. The RepRap operates
from an Arduino platform with either Marlin or Sprinter firmware
protocols that regulate motor movements, extrusion rates, and
temperature sensors. Software such as Repetier Host, Cura, or
Pronterface control the printer’s parameters in coordination with
ACADIA 2017 | DISCIPLINES + DISRUPTION 661
its firmware. Importing .stl files generated in Rhino or any other
3-D modeling software, G-code tool paths can be generated
with integrated stand-alone programs such as Cura or Slic3r.
Using Silkworm, an extension for the Rhino Grasshopper plugin,
custom G-code tool paths can be generated and manipulated.
Geometries are usually printed in either PLA or ABS plastic but
modified versions of the machine have been used to print in
a whole range of materials including, among others, sugar, choco-
late, salt, wood, recycled plastic, glass, or clay.
The majority of desktop 3-D printers are used for representa-
tional prototyping at small scales. However, when aiming to
investigate additive manufacturing processes at the scale of a
large prototype or architectural installation, high cost profes-
sional equipment is usually needed to conduct research. To
pursue a research project in full-scale concrete additive manu-
facturing, the research team built a large open source 3D printer
based on the RepRap platform from the ground up. Some
large-scale 3D printers based on open source information and
capable of printing concrete have been built, but information
on hardware, firmware, and software modification is currently
not publicly available. The most notable recent examples of
self-fabricated large-scale gantry printers have been developed
by Andrey Rudenko, a Minnesota based engineer/inventor who
built his machine in 2014, and Alex Le Roux, a Texas based engi-
neering student. Both machines are capable of printing concrete
and have successfully demonstrated that the RepRap platform
provides a suitable foundation for large-scale prototyping.
Decommissioned Industrial Robotic Arms
Equipment upgrades, factory closings, and relocations in the
car manufacturing industry have created a sizable market of
second hand industrial robots from the early 2000s. Specialized
business asset acquisition companies acquire factory equipment
in bulk amounts and re-sell used machinery across the United
States. There are similar companies in various other countries,
many of which have online stores on Ebay or similar platforms.
In the U.S., there is broad availability of KUKA robots that were
recently decommissioned by either Ford or General Motors.
At the time of purchase of our robotic arm, the business asset
acquisition company contacted had about 700 KUKA industrial
robots such as the KR150, KR200, or KR350 in stock. A decom-
missioned industrial robotic arm such as a KUKA KR200/2 with
a KRC2 control unit from 2003 can be purchased for about
$8,000 - a fraction of the cost of a new system (Figure 3). This
constitutes a paradigm shift in the access to large-scale robotic
fabrication technology and indicates that functional professional
fabrication hardware is becoming considerably more affordable
under certain circumstances. A used robot is not an open source
system, however with the advent of small open source desktop
662
robotic arms, a used system can be seen as an intermediary step -
or alternative - towards a fully open source industrial robotic arm.
Advancements in control software for industrial robotic
systems further expand access to the technology. With Rhino
Grasshopper plugins such as HAL (Schwartz 2013) or KUKA|prc
(Braumann and Brell-Cokcan 2011), the operation of full-scale
industrial manufacturing systems can be seamlessly integrated in
workflows familiar to architects and designers. Not open source,
but compared to proprietary software by industrial robot manu-
facturers, both programs are very economical when considering
their capability. The combination of affordable hardware options,
robotic control units such as the KRC2 which are old but not yet
obsolete, as well as the availability of robotic control software
makes used industrial robotic arms a feasible alternative to new
systems.
METHOD
Hacking fabrication equipment has become integral to the
design process and is part of the disciplinary domain of archi-
tecture. Over the past decade, architecture as a discipline has
accumulated new knowledge and skill sets critical to engineering
highly complex construction tools, in collaboration with other
disciplines or single-handedly. For the most part, this knowledge
is applied to the design of robotic end effectors. It is evident
that there is now a critical amount of disseminated knowledge
in hacking and machine design which enables a subsequent
leap in scale. Emerging from this shared archive of hacking, the
Open Source Factory research project focuses on disseminating
information about how to economically build or set up common
industrial fabrication tools such as a 3-axis CNC gantry and a
6-axis robotic arm.
Daedalus: A RepRap-Based Large-Scale 3-A xis CNC Gantry
Named after the mythical master craftsman Daedalus, the
research team developed a CNC gantry machine based on
the RepRap platform (Figure 4 and 5). The machine is loosely
analogous to the Prusa Mendel printer. The goal was to create a
usable build area of approximately 6 x 6 x 6 feet. A lightweight
steel frame was constructed with 16-gauge 1-inch square steel
profiles which were welded into a total of six box frames with a
width of 6 inches and connected approximately every two feet
(Figure 7 and 8). Three box frames were attached together with
bolts and 1/4-inch steel plates in a U-shape to form the gantry
system. The gantry touches the ground at both open ends of the
U-shaped frame. To provide stability perpendicular to the gantry,
the frames were triangulated on each side and a steel frame base
was built to support four standard-duty V-groove track casters
on each side.
Open Source Factory Zivkovic, Battaglia
 2 Desktop Scale RepRap 3D Printer
in 2012.
3 Used KUKA KR200/2 with Welding
Equipment Attached.
4 Daedalus 3D-Printer Parts
5 Daedalus Open Source Full-Scale
RepRap-based 3D Printer in 2016.
3 4
For moving the gantry across the ground along the Y-axis, two
double linear rails were constructed out of 1-inch angle irons.
The rails sit under the U-shaped base frame which is made of
three additional box frames. Two 5/8-inch hardened precision
shafts with tapped holes were mounted on matching support
rails that were connected to the vertical members of the gantry
frame to enable Z-axis movement. This arrangement was chosen
over a threaded rod to allow for rapid movement speeds in the
vertical dimension. Two 5/8-inch hardened precision steel shafts
span across the gantry to form the X-axis movement system. The
X-Axis system is supported by two steel plates attached to a total
of four mounted linear ball bearings which move the entire X-axis
in the Z-direction. The X-axis (location of the nozzle) is supported
by three linear ball bearings attached to the steel shafts spanning
across the gantry. In a later iteration of the printer, the X-axis
rails were replaced by a 16-gauge 1-inch square steel profile with
a self-built linear bearing made of skateboard wheel bearings to
fix stability issues. The Z-axis motor is positioned at one of the
corners on top of the gantry and attached as an extension to
the frame with a steel plate. The Y-axis motor sits at one of the
corners of the base frame attached with a steel plate extension
as well. The X-axis motor is attached to the X-axis system which
moves along the Z-axis. A counterweight system of around 100
lbs was installed to reduce moment forces acting on the motor
by the weight of the X-axis arrangement. Both the Z and Y-axis
motors transfer power via a 1-inch hardened precision drive
shaft to two 1-inch timing belts with pulleys at each end. Motors
are connected to the drive shafts via a flexible shaft coupling hub.
All drive shafts are connected to the frame with steel mounted
5
ball bearings. The X-axis motor transfers movement directly into
a 3/4-inch timing belt with one pulley at each end.
The electrical hardware and software systems are based on
standard RepRap firmware and software packages. Daedalus is
controlled by an Arduino Mega 2560 microcontroller extended
with a RAMPS 1.4 shield. In a small desktop 3D printer, all
NEMA-17 motors are powered by a small 12V power supply.
Due to considerably higher weight and resistance in a large
machine, three high torque and high speed NEMA 34 CNC
stepper motors with a capacity of 13Nm (1841oz.in) were used.
Each motor requires a 350W 60V 5.9A power supply as well as
a separate stepper motor driver. Motors, power supplies, and
matching drivers were ordered as part of a CNC router kit and
were wired together with the end stops according to the wiring
diagram shown in Figure 9.
The motors were connected to the drivers with 16-gauge wire.
Wires were twisted according to the Twisted Pair method in
order to avoid crosstalk issues between motor frequencies and
end stop signals (Bell 1881). Marlin firmware was used and modi-
fied to reflect new pin configurations and stepper motor turn
ratios in coordination with the size of timing belt pulleys (Table 1).
The free software Repetier Host was connected to the Arduino
board to operate the printer. Some minor adjustments such as
printer bed size or speed were made in the software.
With access to basic metal working tools (MIG welder, angle
grinder, chop saw) and some standard power tools (drill and
ACADIA 2017 | DISCIPLINES + DISRUPTION 663
impact driver), the Daedalus Open Source Printer can be
constructed for about $6000 which is a fraction of the cost
of a professional CNC gantry of that size (Table 2). There is a
very active online community providing support for questions
related to wiring, troubleshooting, or installation of firmware
at the desktop scale. The Daedalus project consulted forums
such as 3dprintboard.com, 3dprintingforum.org, GitHub, and
forums.reprap.org, among others. The Daedalus platform is highly
versatile and can support a variety of end effectors. Thus far,
the research team has developed a gravity fed concrete printing
nozzle, a two-component foam printing nozzle, and a prelimi-
nary plastic printing nozzle. However, the printer could easily be
modified to perform CNC milling or other fabrication procedures
that require a large 3-axis gantry system.
Dionysus: Reviving a Decommissioned 6-A xis KUK A
KR200/2 Industrial Robot
In Greek mythology, Dionysus came back from the dead. Among
a strong interest in ritual madness, resurrection is something he
has in common with the used KUKA KR200/2 robot. The KUKA
robot arm was purchased based on its general specifications
which make it suitable for full scale research in digital fabrication.
It has a 200-kg payload, approximate reach of 3000 mm, high
motion speed, and six axes. The large-scale industrial robotic arm
was previously a welding robot for GM (Figure 6).
A KUKA system was selected due to broad availability of this
type of robotic arm, as well as rigorous documentation online.
Before purchasing the robot, the team extensively researched
information about the KUKA KR200 platform on robot-forum.
com - an invaluable resource on used industrial robots of all
kind. Mechanically, large-scale robotic arms have not changed
considerably over the past 15 years, except for minor improve-
ments in speed, weight, sensing technology, and accuracy.
However, robotic control units evolved greatly which reflects the
general acceleration in the evolution of information technology.
As a price-performance compromise, a KUKA KRC2 control unit
running Windows 95 with the KUKA operating system KSS 4.16
was selected because compared to the older KRC1 controls, the
KRC2 is capable of easily adding an additional driver for a 7th
axis (a rotating table or linear rail) and capable of communicating
between multiple robots. Replacement parts for the system are
readily available in the event of a malfunction, or the desire to
build an open source 7th axis using KUKA motors and drivers.
The KRC2 also has more memory and can process substantially
more lines of code.
Self-installing a used robotic arm requires a certain amount of
infrastructural hacking and comfort with non-standard proce-
dures. In a first step, the GM welding gear was stripped off and
664
all unnecessary attachments removed from the robot. Because
of a concrete floor thickness of only 4 inches, a steel frame foun-
dation with concrete counterweights was designed and installed.
An inner frame of 1/4-inch-thick 3 x 4 inch tubing was built to
align with the base of the robot. Forming a cross-shape for lateral
support, four additional foundation units that measure roughly 3
x 3 feet were welded and bolted around the center module. Each
of those units contains two reinforced concrete counterweights
that together weigh about 500 lbs. The foundation platform
weighs a total of approximately 2600 lbs and was designed to be
easily taken apart and moved.
The robotic arm is attached to the steel platform by eight M24
bolts. Ideally, however, the robot is either anchored into the
ground on a steel plate or a new foundation is cast. The current
steel platform has some minor issues with vibrations but due to
low movement speeds in current projects there are no accuracy
problems during fabrication. Most of the older generation indus-
trial robots of comparable size require 480V 3phase operating
voltage. A 208V single phase to 480V 3phase 15 kVA step-up
transformer had to be installed for sufficient power. A safety cage
and safety gate switch were installed to prevent access to the
robot while powered.
Security systems for KUKA models used by GM were bypassed
by modifying the X11 / CC1 Harting plug and physically bridging
connections (Figure 10). Batteries on the KRC2 were past their
lifetime and had to be replaced to prevent loss of critical data
during the shutdown procedure. With all infrastructure in place
and properly connected to the KRC2 control unit, the robot
was turned on. Shorting the pinout for PWR_ON (pins 7-8) on
the motherboard resolved initial computer startup issues. After
the KUKA operating system booted successfully, controls were
turned to expert mode and certain GM model variables were
checked and altered (Table 3). Soft limits were checked and
changed according to the robot data sheet. Once the robot
was successfully jogged in T1 mode, it was mastered. For the
mastering process, a custom dial gauge was built modifying one
of the mastering port caps (Figure 11).
After all axes were successfully mastered according to the dial
mastering instructions in the KUKA manual, KUKA|prc was
used to generate movement tool paths and add end effector
information into the system. Thus far the robot was success-
fully equipped with custom built chainsaw, band saw, and CNC
spindle end effectors. Depending on the given infrastructure, the
Dionysus system can be built for about $10,000–$15,000 (Table
4), which is a fraction of the cost of a new industrial robot of that
size.
Open Source Factory Zivkovic, Battaglia
 6

6 Kuka Kr200/2 arriving to Rand Hall

at Cornell University

7 Daedalus 3D Printer: Exploded

axonometric

8 Daedalus 3D Printer: axonometric

9 Arduino Mega 2560 Ramps 1.4

Shield Wiring Diagram

8 9

ACADIA 2017 | DISCIPLINES + DISRUPTION 665

 Table 4

10

Table 1

Table 2

11

Table 1 Critical Modifications of Marlin 10 CC1/X11 Harting Plug

Firmware for Daedalus 3D Printer Modifications for GM Safety
Systems Bypass
Table 2 Daedalus 3D Printer Budget
Overview
11 Custom Dial Gauge Mastering Tool
welded to KUKA mastering port
Table 3 Critical Modifications to KUKA
cap
Operating Syatem KSS 4.16

Table 4 Dionysus KUKA KR200/2

Budget Overview
Table 3

666 Open Source Factory Zivkovic, Battaglia

RESULTS
Based on the RepRap 3D printer platform, a large-scale 3-axis
CNC gantry system was built. Furthermore, a decommissioned
KUKA KR200/2 industrial robot was revitalized for digital
fabrication purposes. Both systems can be very economically
implemented into a research laboratory, architecture office, or
building industry context. Thus far, both hacked fabrication
systems - Daedalus and Dionysus - are performing with a high
degree of accuracy and reliability. Both machines have become
fully functional large-scale fabrication equipment for the Robotic
Construction Laboratory (RCL) at Cornell University. In a project
called Additive Architectural Elements in collaboration with
HANNAH Design, RCL 3D printed a series of full scale concrete
building components exploring corbelling strategies in common
building components such as windows, doors, columns, and
walls (Figure 12). As part of his master of architecture thesis
at Cornell University, Christopher Battaglia worked with RCL
on the development of a new, spatial 3D printing procedure
called Sub-additive 3D Printing which can be used to efficiently
construct double curved thin shell geometries (Figure 13). For
a recent advanced research design studio called Timber Villa
at Cornell University, RCL investigated the potential of robotic
fabrication in heavy log and timber construction (Figure 14).
These three research venues successfully demonstrate the
feasibility of utilizing open source frameworks or decommis-
sioned industrial equipment for research purposes. It is critical
to mention that the ability to fully hack, manipulate, and modify
open source machines yields wider possibilities for technical and
architectural innovation in these projects.
DISCUSSION AND OUTLOOK
The development of a fully open source industrial robotic arm
has been discussed in the open source community. There exist
preliminary open source desktop robotic arms such as 3D
Printable Robotic Arm by Andreas Hoelldorfer or the Thor Open
Source Arm by AngelLM. Unfortunately, both arms are currently
missing an inverse kinematics solver in their firmware. It will
take considerable effort to scale up these systems or resolve
issues around firmware, backlash, and payload. However, hacking
machines and equipment continues to evolve across disciplines
and within architecture schools. Pedagogically, there is tremen-
dous value in giving students the opportunity to contribute to
the design and set-up of small and large-scale fabrication tools.
Both presented machine projects were built in advanced research
studios at Cornell University. Investigating the entire process
from full-scale tool design to the development of a building logic
inherent to the tool used has enabled new discussions within
the design studio environment. Students in these investigative
studios developed a greater understanding of tool parameters
through building and hacking, allowing for innovative research
tangents unforeseen if they were first handed a fully functioning
fabrication platform. The ability to design and build machines
can also be applied on a more fundamental level. In his Creative
Architecture Machines studio at CCA, Jason Kelly Johnson and
his students question the relationship between architecture and
the tool of its production by starting with the design of highly
idiosyncratic machines and then redesigning the entire building
and manufacturing process based on their unique operational
logics and constraints (Johnson 2015). Another research example
of applications for novel construction machines is the Gramazio
and Kohler research group project Flight Assembled Architecture
(Willman et al. 2012). In the next decade, architects will progres-
sively design and develop more non-standard large-scale or
distributed construction tools, building a customized Open
Source Factory.
CONCLUSION
In architecture, research trajectories will continue to move
towards large-scale experimentation and full-scale building
construction in robotic and digital fabrication. The Open Source
Factory project aims to mediate a critical lack of access to
large-scale industrial fabrication tools by engaging in a discus-
sion about alternate economic trajectories for acquiring such
equipment and demonstrating the viability of open source type
tools. The ambition is to create widespread disruption across
institutions, practices, and local building industries by making an
extensive leap in scale possible sooner. The RepRap 3D printer
revolutionized access to desktop scale 3D printing. If industrial
robots and other large-scale fabrication tools become acces-
sible for all, the collective sharing of research and development
of new ideas in full-scale robotic building construction can be
substantially accelerated. Implementing affordable infrastructure
for mass-customization will enable a growth in personalized
and local manufacturing, ending the regime of industrialized
mass-production. Expanding on the idea of the Fab Lab as
well as the RepRap movement, the Open Source Factory takes
advantage of disciplinary expertise and knowledge accumulated
over the past decade. Architects are once more engaging in the
Vitruvian practice of construction machine design, creating novel
building protocols integral to new technologies in the process. It
is in our interest to democratize large-scale fabrication tools to
push and augment this agenda.
ACKNOWLEDGEMENTS
The Cornell Robotic Construction Laboratory (RCL) has received
generous support from: AAP College of Architecture, Art, and Planning;
the Department of Architecture at Cornell University, HANNAH Design
Office LLC, Unalam - Glulam for Commercial and Residential Purposes.
ACADIA 2017 | DISCIPLINES + DISRUPTION 667
 12

Gershenfeld, Neil. 2008. Fab: The Coming Revolution on Your Desktop—

NOTES
1. All Daedalus and Dionysus drawings, diagrams, complete 3D models,
as well as written information are available for download on GitHub
and the RCL website at the date of publication of this paper.
From Personal Computers to Personal Fabrication. New York: Basic Books.
Gershenfeld, Neil. 2012. "How to Make Almost Anything: The Digital
Fabrication Revolution." Foreign Affairs 91 (6): 43–57.

Jones, Rhys, Patrick Haufe, Ed Sells, Pejman Iravani, Vik Olliver, Chris
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IMAGE CREDITS
Figure 8: Jeremy Bilotti for HANNAH, 2016
Figure 7: Winnie Lu for Cornell Villa Additiva Studio, 2016
Figures 4, 6, and 10: Yichen Jia for Cornell Timber Villa Studio, 2017
Figures 5 and 13: Reuben Chen and Jeremy Bilotti for HANNAH, 2017
Figure 15: Reuben Chen for RCL, 2017
All other drawings and images by the authors.
12 Additive Architectural Elements
Project by Leslie Lok & Sasa
Zivkovic - Full-Scale Concrete
Printing
13 Sub-Additive Concrete 3D Printing
of Thin-Shell Geometries by
Christopher Battaglia
14 Robotic Irregular Log Cutting with
Custom Band Saw End Effector in
Cornell Timber Villa Studio
13 14
Sasa Zivkovic is an assistant professor at Cornell University where he
teaches graduate and undergraduate design studios as well as seminar
classes with a focus on digital fabrication, computation, and repre-
sentation. At Cornell, he directs the Robotic Construction Laboratory
(RCL), an interdisciplinary research group investigating advanced
materials and novel construction technology. Zivkovic is also a co-prin-
cipal of HANNAH, an architecture practice based in the United States
and Germany. HANNAH's research focuses on advancing traditional
building construction techniques by implementing new technologies and
processes of making, addressing subjects of rapid urbanization and mass
customized housing design.
Christopher A. Battaglia is a recent graduate from Cornell University
(M.Arch 17’) with an interest in digital fabrication, computation, and
material manipulation. Currently a Teaching Associate at Cornell
University, he has taught advanced options studios with a focus on
robotic and digital fabrication as well as introductory undergraduate
design studios. Battaglia is also a Lead Research Associate in the Robotic
Construction Lab (RCL) with interests in material and self-built digital
fabrication tools, producing both innovative material expressions
and structural efficiencies. Current research projects include three-
dimensional printing of concrete to produce structurally efficient shell
structures.
ACADIA 2017 | DISCIPLINES + DISRUPTION 669