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<p>The use of expanded polystyrene (EPS) in architectural facades offers versatility and efficiency, particularly for curved designs. However, integrating openings like windows poses challenges in material use and waste management. Previous research introduced a zero-waste manufacturing (ZWM) workflow utilizing robotic hot wire cutting to create doubly curved EPS facades without fenestration, avoiding waste. This study extends the ZWM approach by incorporating openings through segmented facade patches and advanced cutting strategies, maintaining residue below 2% of the total volume on average. The refined process balances material efficiency and design flexibility, contributing to sustainable practices in complex architectural forms.</p>

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Zero Waste Manufacturing Design Approach of Doubly Curved EPS Fenestration Facades Using Robotic Hotwire Cutting

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Tamara Miljković,
  • Marko Jovanović,
  • Ivana Bajšanski

摘要

The use of expanded polystyrene (EPS) in architectural facades offers versatility and efficiency, particularly for curved designs. However, integrating openings like windows poses challenges in material use and waste management. Previous research introduced a zero-waste manufacturing (ZWM) workflow utilizing robotic hot wire cutting to create doubly curved EPS facades without fenestration, avoiding waste. This study extends the ZWM approach by incorporating openings through segmented facade patches and advanced cutting strategies, maintaining residue below 2% of the total volume on average. The refined process balances material efficiency and design flexibility, contributing to sustainable practices in complex architectural forms.