An Integrated Design-to-Production Workflow for Cement-Based Blocks via Robotic Magnetic Manipulation of Discrete Reinforcements

This study presents a proof-of-concept design-to-production framework (D2PF) integrating a 6-axis industrial robotic arm with a custom electromagnetic end effector to organise discrete metallic elements within cement-based blocks. The system enables non-contact, field-based manipulation of magnetically responsive elements (office pins), forming programmable reinforcement patterns guided by predefined toolpath geometries. Toolpaths are generated using parametric design environments (Rhino/Grasshopper) and executed via robotic control software (KUKA|prc), enabling controlled aggregation and repositioning through electromagnetic actuation. Key parameters include robot speed, toolpath repetitions, wire winding count, magnetic force regulation, and reinforcement geometry. To assess feasibility, three cement-based blocks (25 × 25 × 5 cm) with spiral and circular reinforcement configurations, along with an unreinforced reference block, were produced and evaluated using an adapted three-point bending procedure. Results indicate that magnetically formed reinforcements improve flexural performance and enhance crack-bridging capacity compared to the unreinforced sample. The workflow offers an accessible pathway for material-aware robotic manufacturing and non-contact reinforcement strategies in cement-based construction.