Industrialization of architectural components and technological advances have had a significant impact on how we design and build. These developments, resulting in mass-produced and panelized architectural components, have rationalized building construction. However, they often do not reveal the true potential of the inherent qualities of malleable materials. This research investigates the bespoke design potentials of combining a cementitious plaster, with a robotic spraying and forming process, and proposes an adaptive thin-layer additive manufacturing method for plasterwork. Research goals address an on-site construction system that is capable of performing continuous robotic plaster spraying on building elements. To support the understanding of the complex-to-simulate material behavior in this process, systematic studies and physical testing are proposed to be conducted to collect empirical knowledge and data. The goal is to explore bespoke surface qualities, with minimal waste, moving away from the modular and standardized form of the material. The paper presents the preliminary results and findings of the method that aims addressing the challenge of an adaptive construction system capable of performing continuous fabrication, for which mobile robots are proposed to be deployed.

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Embedded in a long tradition of craftsmanship, inside or outside building surfaces, is often treated with plaster, which plays both functional and ornamental roles. Today, plasterwork is predominantly produced through rationalized, time-, and cost-efficient processes, used for standardized building elements. These processes have also gained interest in the construction robotics field, and while such approaches target the direct automation of standardized plasterwork, they estrange themselves from the inherent qualities of this malleable material that are well known from the past. This research investigates the design potentials of robotic plaster spraying, proposing an adaptive, thin-layer vertical printing method for plasterwork that aims to introduce a digital craft through additive manufacturing. The presented work is an explorative study of a digitally controlled process that can be applied to broaden the design possibilities for the surfaces of building structures. It involves the spraying of multiple thin layers of plaster onto a vertical surface to create volumetric formations or patterns, without the use of any formwork or support structures. This article describes the experimental setup and the initial results of the data collection method involving systematic studies with physical testing, allowing to develop means to predict and visualize the complex-to-simulate material behavior, which might eventually enable to design with the plasticity of this material in a digital design tool.

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