Robotic Sand Shaping for Reusable Formworks: From toolpath design to emergent shapes and patterns in cast form

This paper introduces a research project that involves using a 6-axis robotic arm to shape kinetic sand. The goal is to create reusable and reconfigurable sandformworks with intricate patterns and textures for casting concrete. When kinetic sand is compacted, it creates emergent “material shapes “ on the sand surface due to material spring-back. The research aims to identify the causal relationships between the robot’s toolpath design, material and fabrication parameters, and emergent material formations. This will allow for a fine level of control over the designprocess of sand formworks for casting concrete panels without any formwork waste. The paper also reviews existing literature on reconfigurable formworks, presents the workflows for robotic sand shaping, and provides examples of concrete panels cast on sand formworks generated using these workflows.