Actuatorless reconfigurable multipoint formwork using a multifunctional collaborative robotic arm for carbon fiber reinforced polymer (CFRP) panels fabrication

This research examines the geometric repeatability and feasibility of an actuator-free adjustable multipoint formwork system designed for the construction of non-planar carbon fiber reinforced polymer (CFRP) panels. Conventional reconfigurable tools tend to use embedded actuators that increase complexity and costs. This research attempts to solve the problem of achieving consistent positional accuracy in coreless filament winding without the use of embedded actuation by merging the processes of formwork cross-section configuration and composite filament winding using a single collaborative robotic system. The proposed methodology includes formwork design using a single unified computational workflow that incorporates surface discretization, automated pin placement, collision avoidance, and robotic winding trajectory planning. The system's performance was

assessed using the fabrication of four identical anticlastic panels. Geometric repeatability was evaluated using structured light scanning, cloud-to-mesh deviation analysis, and repeated-measures ANOVA. The results showed that although a global shift in depth of about 1-2mm was present between configurations, the spatial deviation pattern across the pin array was highly consistent after normalization, indicating the opportunity actuator-free systems present for composite manufacturing.

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