Arash Adel

Salma Mozaffari, Daniel Ruan, William van den Bogert et al. · princeton

Fabrication uncertainty arising from tolerance accumulation, material imperfection, and positioning errors remains a critical barrier to automated robotic assembly in construction, particularly for contact-rich manipulation tasks governed by friction and geometric constraints. This paper investigates the deployment of diffusion policy learning on construction-scale industrial robots to enable robust, high-precision assembly under such uncertainty, using tight-fitting mortise and tenon timber joinery as a representative case study. Sensory-motor diffusion policies are trained using teleoperated demonstrations collected from an industrial robotic workcell equipped with force/torque sensing. A two-phase experimental study evaluates baseline performance and robustness under randomized positional perturbations up to 10 mm, far exceeding the sub-millimeter joint clearance. The best-performing policy achieved 100% success under nominal conditions and 75% average success under uncertainty. These results provide initial evidence that diffusion policies compensate for misalignments through contact-aware control, representing a step toward robust robotic assembly in construction under tight tolerances.

Jutang Gao, Arash Adel

Human-robot collaboration in construction is often challenged by limited robot-to-human communication and the need to adapt to tolerance accumulation arising from material and assembly uncertainties. We present an adaptive human-robot collaborative workflow for masonry construction that addresses communication limitations and tolerance accumulation, demonstrated through a brickwork case study in which a robot places bricks while a human applies adhesive. This workflow is enabled by two complementary mechanisms: 1) an end-effector-mounted projector that provides spatially registered, just-in-time projection guidance for manual adhesive application, and 2) laser scanning for feedback-driven grasping and placement pose correction. Together, these mechanisms enable adjustment of human and robotic actions in response to material variability and accumulated assembly tolerances. Full-scale experiments across conventional running-bond and nonstandard configurations demonstrate that projection guidance improves adhesive application consistency and reduces application time, while laser-based correction maintains level courses and avoids collision-prone failures associated with open-loop execution. These results indicate that integrating spatial projection with feedback-driven adaptation, enabled by material and as-built sensing, can mitigate tolerance accumulation and improve precision and robustness in human-robot collaborative construction.

Arash Adel, Daniel Ruan, Ruxin Xie

Climate change and resource depletion demand a shift from the dominant linear "take-make-use-dispose" paradigm of construction toward circular, low-waste practices. Material reuse offers a promising pathway by reducing raw material extraction, mitigating waste, and extending the service lifespan of carbon-sequestering materials such as timber. Realizing this potential, however, requires addressing technical and logistical challenges across both design and construction for accommodating heterogeneous, reclaimed material inventories. This paper presents an integrated framework that couples data-driven computational design with feedback-driven adaptive human-robot collaborative (co-robotic) fabrication and assembly to enable the realization of nonstandard structures made from reclaimed timber of varying length and geometries, supplemented with new off-the-shelf timber when necessary. The framework is validated through Timbrelyn, a built case-study installation that demonstrates how timber reuse can inform and enhance architectural expression. This work contributes to the development of integrated design-to-fabrication workflows that advance adaptive, feedback-driven methods to handle inventory constraints and reclaimed material uncertainties, facilitating material reuse in the design and construction of new buildings and structures.