Periodic Reporting for period 1 - UniversalTimberSlab (Computational design, fabrication and engineering methods for unconstrained, highly resource efficient, point-supported timber slabs in multi-storey buildings)
Reporting period: 2024-10-01 to 2025-09-30
This project aims to develop new computational design, engineering, and robotic fabrication methods for a point-supported multi-story timber building system. The goal is to create a sustainable and affordable alternative to reinforced concrete (RC) slabs — one that can be widely used, safely built, and easily scaled with digital tools.
Although timber construction has strong political and public support, its use in the building industry remains limited. This is mainly due to a lack of planning expertise and the technical constraints of current timber systems. Our project seeks to overcome these challenges by developing a disruptive timber building system and advanced digital technologies that greatly expand how wood can be used in multi-story buildings.
Unlike traditional grid-based systems, our approach allows designers to create custom building layouts that better fit complex urban sites. It can achieve design and performance standards typically only possible with concrete slabs.
The new system offers:
• 30–60% higher material efficiency, thanks to improved structural performance and reduced waste.
• The ability to build 140–250% more slab area using the same amount of wood.
• The potential to cut embodied carbon in the EU by 32 Mt CO2e per 1% increase in timber market share by 2050.
• 30% lower structural height compared to current timber systems, allowing for more compact buildings, greater ceiling heights, and better use of limited urban space.
By combining computational design, engineering automation, and digital fabrication, the system will be scalable, efficient, and flexible. This means higher wood construction rates can be achieved even with limited material supply and skilled labor.
Although timber construction has strong political and public support, its use in the building industry remains limited. This is mainly due to a lack of planning expertise and the technical constraints of current timber systems. Our project seeks to overcome these challenges by developing a disruptive timber building system and advanced digital technologies that greatly expand how wood can be used in multi-story buildings.
Unlike traditional grid-based systems, our approach allows designers to create custom building layouts that better fit complex urban sites. It can achieve design and performance standards typically only possible with concrete slabs.
The new system offers:
• 30–60% higher material efficiency, thanks to improved structural performance and reduced waste.
• The ability to build 140–250% more slab area using the same amount of wood.
• The potential to cut embodied carbon in the EU by 32 Mt CO2e per 1% increase in timber market share by 2050.
• 30% lower structural height compared to current timber systems, allowing for more compact buildings, greater ceiling heights, and better use of limited urban space.
By combining computational design, engineering automation, and digital fabrication, the system will be scalable, efficient, and flexible. This means higher wood construction rates can be achieved even with limited material supply and skilled labor.
During the reporting period, the Universal Timber Slab (UTS) project achieved major progress toward developing a scalable, high-performance, and sustainable alternative to reinforced concrete floor systems. Many building system variations of the UniversalTimberSlab were investigated and two highly promising variations chosen for further investigation. The work further integrated computational design, structural engineering, robotic fabrication, and life-cycle assessment into a unified digital–physical building system.
A modular computational framework was developed for the automated design and segmentation of point-supported slab geometries. This enables the generation of detailed UniversalTimberSlab designs for complex, irregular building layouts and provides standardized data interfaces between disciplines. Using this system, 99 benchmark slab geometries were generated. For these benchmark slabs, segmentation and lamella geometries were computed on top of which structural, acoustics, fabrication and LCA simulations were completed – resulting in performance data for a total of 7000 different benchmark instances of the UniversalTimberSlab. The computed data builds the foundation for upcoming training of surrogate models for each disciplinary simulation model.
A total of nine different fabrication process variations to fabricate UniversalTimberSlab segments were conceived and analysed in detail. Three of these variations show promising potential for both feasibility (i.e. certifiability) and cost effectiveness. Further, a novel nail-press-gluing process investigated through detailed mechanical testing as well as the design and construction of a specialized robotic end-effector.
A modular computational framework was developed for the automated design and segmentation of point-supported slab geometries. This enables the generation of detailed UniversalTimberSlab designs for complex, irregular building layouts and provides standardized data interfaces between disciplines. Using this system, 99 benchmark slab geometries were generated. For these benchmark slabs, segmentation and lamella geometries were computed on top of which structural, acoustics, fabrication and LCA simulations were completed – resulting in performance data for a total of 7000 different benchmark instances of the UniversalTimberSlab. The computed data builds the foundation for upcoming training of surrogate models for each disciplinary simulation model.
A total of nine different fabrication process variations to fabricate UniversalTimberSlab segments were conceived and analysed in detail. Three of these variations show promising potential for both feasibility (i.e. certifiability) and cost effectiveness. Further, a novel nail-press-gluing process investigated through detailed mechanical testing as well as the design and construction of a specialized robotic end-effector.
We developed computational design methods capable of segmenting slabs with irregular column layouts, supporting automated design generation. The design engine was built using modular scripting in Rhino and Grasshopper, generating high-resolution slab models, including segmentation and detailed lamella arrangements. This was tested for different building blocks considering spans from 3 to 12 meters. A robust, federated data schema—implemented via BHoM—is in use, guaranteeing smooth interoperability between design models, structural simulation tools, LCA analysis, and fabrication code generation workflows. Data interface protocols support versioning, automated data transfer, and integration of feedback loops, enabling reciprocal adaptation of design based on simulation and performance data.
Definition of Benchmark simulations and joint requirements contribute to the long-term goal of structural performance in comparison to state-of-the-art multi-storey buildings. Results show the UTS system can perform better than state-of-the-art building systems, although further work and testing must be realized to experimentally prove the performance of the system. A method for both the automated simulation and dimensioning of the UTS system for a wide variety of geometries and cases have been delivered successfully. The simulation results must be proven and calibrated experimentally in reporting period 2.
Nine fabrication process variants were defined and benchmarked. Three variations were identified as most promising for throughput and immediate industrial application. A highly innovative nail-press gluing process was conceived. This press-free nail-press gluing was validated with a custom robotic end-effector and in detailed mechanical tests. Trials show stable consolidation without timber damage and industrial-quality milling on cured assemblies, establishing a controllable, repeatable process basis for test specimens. This process will be used for lab prototyping to de-risk hardware investments while keeping results transferable. Fabrication time, cost, energy and material quantity KPIs were computed for all benchmark slabs and a consolidated benchmark dataset was used to inform decision making on further strategic development steps.
Parameters for the evaluation of reliable fabrication quality have been defined and applied to nine different lamination variants to uncover possible uncertainties and shortcomings. The adhesive database defines the exact manufacturing conditions that need to be met for a given adhesive in order to implement it in a certifiable production process. The characterization of an innovative adaptation of the nail-press gluing method using wood-based nails (variant V1) was commenced on the basis of experimental tests.
Generative design methods were integrated through novel interfacing methods with the highly specialized Siemens SimCenter platform to perform expert acoustic simulations of the UniversalTimberSlab.
A novel LCA modelling method by harmonising existing frameworks and standards for timber products in the construction sector was developed and proposed to the LCA community.
Overall the UniversalTimberSlab project has been developing not only an innovative building system with appropriate modelling, simulation and robotic fabrication processes, but also has achieved already several methodological innovations that are applicable beyond the UniversalTimberSlab system.
Definition of Benchmark simulations and joint requirements contribute to the long-term goal of structural performance in comparison to state-of-the-art multi-storey buildings. Results show the UTS system can perform better than state-of-the-art building systems, although further work and testing must be realized to experimentally prove the performance of the system. A method for both the automated simulation and dimensioning of the UTS system for a wide variety of geometries and cases have been delivered successfully. The simulation results must be proven and calibrated experimentally in reporting period 2.
Nine fabrication process variants were defined and benchmarked. Three variations were identified as most promising for throughput and immediate industrial application. A highly innovative nail-press gluing process was conceived. This press-free nail-press gluing was validated with a custom robotic end-effector and in detailed mechanical tests. Trials show stable consolidation without timber damage and industrial-quality milling on cured assemblies, establishing a controllable, repeatable process basis for test specimens. This process will be used for lab prototyping to de-risk hardware investments while keeping results transferable. Fabrication time, cost, energy and material quantity KPIs were computed for all benchmark slabs and a consolidated benchmark dataset was used to inform decision making on further strategic development steps.
Parameters for the evaluation of reliable fabrication quality have been defined and applied to nine different lamination variants to uncover possible uncertainties and shortcomings. The adhesive database defines the exact manufacturing conditions that need to be met for a given adhesive in order to implement it in a certifiable production process. The characterization of an innovative adaptation of the nail-press gluing method using wood-based nails (variant V1) was commenced on the basis of experimental tests.
Generative design methods were integrated through novel interfacing methods with the highly specialized Siemens SimCenter platform to perform expert acoustic simulations of the UniversalTimberSlab.
A novel LCA modelling method by harmonising existing frameworks and standards for timber products in the construction sector was developed and proposed to the LCA community.
Overall the UniversalTimberSlab project has been developing not only an innovative building system with appropriate modelling, simulation and robotic fabrication processes, but also has achieved already several methodological innovations that are applicable beyond the UniversalTimberSlab system.