Automated wall finishing system and method

A method of generating a wall or ceiling assembly using a mobile robotic coating system, the method comprising:

• providing a first assembly comprising a header and a footer with a plurality of studs extending between the header and the footer, the first assembly defining a planar face defined by respective faces of the header, the footer, and the plurality of studs;
• generating, by a computational planner, a model of the first assembly based at least in part on one or both of data obtained by a vision system of the mobile robotic coating system and a building plan acessed by the computational planner, the model including a mapping of a location of an opening and/or a feature of the first assembly;
• determining, based at least in part on the model, a plan for the mobile robotic coating system spraying a coating material onto specified locations of a plurality of pieces of flexible multi-layer substrate disposed on the planar face, the plan based at least in part on the location of the opening and/or the feature of the first assembly;
• and
• spraying, based at least in part on the plan, the coating material onto the plurality of pieces of flexible multi-layer substrate, the plurality of pieces of flexible multi-layer substrate including a first layer that is coupled to the plurality of studs and is impermeable to the coating material, and a second porous or mesh layer having voids where the coating material can enter and adhere, the spraying comprising:
• the mobile robotic coating system spraying the coating material onto the plurality of pieces of flexible multi-layer substrate via a coating end effector, the coating end effector comprising a sprayer to apply the coating material via a nozzle coupled with a mobile storage container storing the coating material, the coating material impregnating the voids of the second porous or mesh layer without permeating through the first layer that is coupled to the plurality of studs, and
• wherein the coating material impregnating the voids of the second porous or mesh layer and hardens to generate the wall or ceiling assembly.