Reconfigurable Structural Robotic Assembly: Interlocking 3D Aggregations with Self-Aligning Compound Nested Lattice Modules
Authors: Alexander Htet Kyaw, Miana Smith, Paul Richard, Neil Gershenfeld
Abstract
Robotic construction systems often treat the material system and the robot as separate design problems, locating intelligence primarily in hardware, sensing, motion planning, and control. This project instead investigates how geometric intelligence can be encoded within architected material systems to simultaneously address requirements for robotic grasping, self-alignment, reversible connection, structural performance, and three-dimensional aggregation. We introduce a self-aligning compound nested lattice module composed of conjoined cuboctahedral-octahedral units. The cuboctahedral features of the modules provide defined surfaces for robotic grasping and alignment, while the octahedral features incorporate screw-releasable snap-fit connectors and corresponding receptors. Additionally, we present a nested arrangement that enables interlocking aggregation along the x, y, and z axes. We demonstrate the system through furniture and architectural scale structures assembled using both a robotic arm and mobile assembler. The resulting configurations include seating, spanning structures, surfaces, and vertical frames. Compression testing of the compound module produced a stiffness of 4,556 N/mm, a maximum load of 3,445 N, and a compressive modulus of 17.5 MPa. The modules can also be disassembled and reused across different configurations, supporting reconfigurable and circular construction.
This paper presents Tessellated Biomes, a cyber-physical framework for the adaptive robotic construction and reconfiguration of modular multi-material assemblies. It challenges the linear lifecycle of standard construction by fusing (1) local microfactory fabrication, (2) discrete multi-material optimization, and (3) distributed robotic assembly into a unified circular process of spatial adaptation. The research details methods for the digital fabrication of self-aligning modular primitives in multiple materials (PLA, timber, and concrete) produced in local microfactories; the aggregation and optimization of these primitives into compression-based discrete structures; and the deployment of custom quadrupedal robots that collaboratively relocate material into realized physical aggregations. The framework is validated through the fabrication, optimization, and robotic assembly of discrete structures. Together, these results position Tessellated Biomes as a model for resilient, reconfigurable architecture.
Accurate localization remains a key challenge in swarm robotics, particularly for self-reconfigurable systems that must identify relative positions to form diverse structures. Most existing approaches rely on external tracking infrastructure or high-cost sensors, which limit scalability and deployment in unstructured environments. In this paper, we propose a novel contact-driven localization method for modular robots that leverages only local communication through binary contact information (whether two robots are physically connected or not). To exploit these contact cues, we introduce a virtual-force framework in which robots iteratively refine their poses attracting toward dock-connected neighbors and repelling from non-connected ones. The method requires no external infrastructure and relies only on minimal onboard sensing. Simulations show effective localization during the assembly of towers and cantilevers, enabling accurate, scalable, free-form self-assembly.
Mohammadali Rashidioun, Michael Sosa, Petras Swissler
An interlocking assembly is an assembly in which component parts are connected purely through their geometric arrangement, without relying on external connectors such as glue and nails. Such assemblies have been widely used in a variety of real-world applications due to their structural stability. The problem of generating interlocking assemblies is generally formulated as a shape decomposition problem, where a target 3D object represented as a voxel grid is partitioned into a prescribed number of interlocking pieces. We observe that generating interlocking assemblies is inherently a sequential decision-making problem, where an agent repeatedly decides which piece each voxel should be assigned to. Inspired by the observation, we propose the first reinforcement learning framework RL-Lock for generating interlocking assemblies, without relying on handcrafted search heuristics as existing works did. RL-Lock combines structured action chunking with MCTS-guided policy-value learning to efficiently navigate the large combinatorial search space for interlocking assembly generation. We demonstrate through experiments that RL-Lock allows effective generation of interlocking assemblies, especially for challenging cases in which existing approaches take too long or even fail to find a valid solution.