IntCDC RP12-3

Load-bearing structures made of natural fiber composites, such as those developed in the Cluster of Excellence IntCDC, in some cases weigh only one-fiftieth of comparable concrete structures. For fully bio-based structural systems, however, two challenges remain central: reliable prediction of structural behavior and efficient use of material. The project therefore develops an integrated approach to the computational design and engineering of hybrid natural fiber–timber composite structures that combines image-based analysis, mechanical analysis, real-time monitoring, and context-aware visualization. It builds on the preceding project RP12-2 in which a computational co-design framework for coreless filament-wound fiber composite building systems was developed. The focus is on three limitations: slow and error-prone data integration, the high variability of natural fiber materials, and the limited load-bearing capacity of joints, which largely governs structural failure.

The project advances natural fiber building systems and coreless filament winding toward circularity and resource efficiency. Natural fibers such as flax, hemp, and jute are used in combination with fully bio-based resins. Multi-material systems are investigated that take into account both structural performance and fabrication with multiple cooperating robots. Combining design support and fiber optic sensing with optimization algorithms, redundancy distributions, and the visualization of uncertainties is intended to improve prediction accuracy and reduce material demand. ITFT derives process parameters of fiber deposition from the strain data of fiber optic sensors, assesses deposition quality, and uses robotically placed sensors to monitor structural behavior during mechanical testing. Sensor- and image-based feedback links fabrication data to the digital model in real time. This enables cyber-physical prefabrication in which robotic process parameters are adapted on the fly and safety is assessed continuously and automatically. Novel fiber-based joint geometries maintain continuous fiber paths and reduce local stress concentrations. Modular system concepts make it possible to extend and retrofit existing buildings and thus contribute to urban densification. Finally, the developed methods, materials, and systems are validated on a building-scale demonstrator. Software tools and validated datasets are made available via IntCDC and the research data repository DaRUS, supporting knowledge transfer toward resource-efficient, circular construction.

Project Duration
April 2026 – March 2029

Project Team
University of Stuttgart, Institute for Textile and Fiber Technologies (ITFT)
Aakash Sahu, Dr.-Ing. Larissa Born, Prof. Dr.-Ing. Götz T. Gresser

University of Stuttgart, Institute for Structural Mechanics (IBB)
Nicolai Grünvogel, Prof. Dr.-Ing. habil. Manfred Bischoff

University of Stuttgart, Institute of Building Structures and Structural Design (itke)
Tzu-Ying Chen, Prof. Dr.-Ing. Jan Knippers

University of Stuttgart, Institute for Computational Design and Construction (ICD)
Nikoletta Christidi, Prof. Achim Menges

University of Stuttgart, Visualization Research Center (VISUS) / Institute for Visualization and Interactive Systems (VIS)
Daniel Klötzl, Nelusa Pathmanathan, Prof. Dr. Daniel Weiskopf

Funding
Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) under Germany’s Excellence Strategy – EXC 2120/2 – 390831618 (Cluster of Excellence “Integrative Computational Design and Construction for Transformative Architecture”, IntCDC).