Embedded frame filament winding: a dual-robot fabrication method for timber–fiber hybrid structures

Natural fiber polymer composites have emerged as bio-based alternatives to synthetic materials in load-bearing fiber structures. Their integration with other natural materials enables the creation of hybrid systems that enhance structural performance, resource efficiency, and architectural design. This paper introduces Embedded Frame Filament Winding, a fabrication method that integrates timber frames into the coreless filament winding process. In this case, timber serves both as a support during the fabrication and as a permanent structure, sharing load transmission with the fibers. The interdependence of natural fiber polymer composites and timber introduces uncertainties, requiring higher tolerances and tailored fabrication strategies. This paper focuses on the required robotic adaptations, including customized strategies for anchoring fibers into timber, a path-planning method to address distinct geometry types, and a dual-robot setup that enables simultaneous winding. A comprehensive computational framework linked design, structural analysis, and fabrication, resulting in a research pavilion that demonstrates the potential of bio-based hybrid systems in architecture.