According to UCL, a paper in Science Robotics has introduced Aerial Additive Manufacturing (Aerial AM) as a disruptive force in the construction industry. Developed by researchers from EPFL, Empa, Imperial College London, and University College London, the study explores how aerial robots equipped for 3D printing can address global housing and infrastructure challenges through scalable, sustainable solutions.
Unlike traditional construction or ground-based robotics, aerial robots operate with unbounded scalability, allowing them to build at height and in remote or hazardous environments.
Five steps to autonomous construction drones: The full potential of aerial AM will only unfold when drones are increasingly able to act autonomously. The autonomy framework presented in the study ranges from simple flight route tracking to the highest level, in which drones analyse the construction environment, detect errors and continuously adapt the design. Source: UCL.
The paper outlines three key Aerial AM strategies, including the discrete placement of individual building units (e.g., bricks), fabrication using tensioned cables, and continuous extrusion-based 3D printing. Each method offers distinct benefits depending on structural requirements and site conditions.
Manufacturing on Demand
The research introduces a five-level autonomy framework to manage complex tasks like flight coordination, precision material deposition, and large-scale project scalability. This framework addresses the major technical hurdles facing real-world deployment.
Sustainability is central, and Aerial AM enables the use of lightweight materials and reduces reliance on labor-intensive processes, promoting safer construction and lower environmental impact. Yet challenges remain. Material durability, outdoor localisation systems, and multi-robot coordination are identified as key bottlenecks. Overcoming these will be critical to transitioning from laboratory trials to real-world adoption.
The Aerial AM applications fall into three main categories: Discrete Aerial AM (constructing structures with modular units), Tensile Aerial AM (constructing tensile structures with linear elements), and Continuous Aerial AM ( constructing structures with continuous material deposition). Source: UCL.
To support this shift, Empa and UCL launched the ‘DroneHub’, a state-of-the-art testbed within Empa’s NEST building. “Construction drones can be tested here under real conditions, further developed and brought to market maturity,” said Mirko Kovač, lead researcher on the project.
As cities expand and infrastructure demand rises, Aerial AM offers a promising path toward responsive, modular, and sustainable building techniques. Early demonstrations – including rapid repairs and prefabricated assemblies – signal a future where drones aren’t just for delivery or surveillance, but for constructing the built environment itself.
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Author: Edward Wakefield
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