Digital method and automated robotic setup for producing variable-density and arbitrary shaped metallic meshes

A method for producing three-dimensional, highly variable lattice or mesh structures by means of a mobile manufacturing device, wherein the mobile manufacturing device is moved on a two-dimensional plane, and manufactured by means of an end-effector, a three-dimensional lattice or mesh structure by providing wires in horizontal as well as in non-horizontal orientation and at least one of bending and connecting a plurality of these wires, the method comprising:

• laying down some wires horizontally at defined vertical distances and in prescribed lengths in three-dimensional space;
• bending the laid horizontal wires at prescribed points by prescribed angles;
• grasping and feeding other wires vertically in discrete steps of varying lengths;
• controlling with the mobile manufacturing device a spatial arrangement of the horizontal wires and the vertical wires using a three-dimensional parametric model;
• forming cross-wire connections by bringing the horizontal wires and the vertical wires together;
• welding the cross-wire connections together to form cross-wire joints;
• and
• cutting the vertical wires at varying lengths.