Systems and methods of producing components for use in the construction of modular building units

A system for assembling a wall structure for a modular construction unit, the system comprising:

• a framing sub-assembly station configured to form one or more framing sub-assemblies, each of which define one or more openings through the wall structure after the wall structure is assembled;
• a wall stud station configured to form and provide a plurality of wall studs for forming a wall frame of the wall structure;
• a main framing assembly station configured to form the wall frame of the wall structure by attaching each of the wall studs between top and bottom plates that define top and bottom edges of the wall structure, wherein the one or more framing sub-assemblies are installed within the wall frame of the wall structure according to a set of assembly instructions in a controller for the wall structure being assembled;
• a sheathing system configured to position a plurality of sheathing panels over an outer surface of the wall frame of the wall structure, wherein the plurality of sheathing panels are placed over the wall frame of the wall structure in a predetermined pattern specified in the set of assembly instructions, and wherein the sheathing system is configured to apply a plurality of first fasteners to at least temporarily secure each of the plurality of sheathing panels onto the outer surface of the wall frame of the wall structure;
• a sheathing fastening station configured to apply a plurality of second fasteners at a plurality of predetermined positions to secure the plurality of sheathing panels over the outer surface of the wall frame of the wall structure, wherein the plurality of predetermined positions correspond to locations of the plurality of wall studs and/or the one or more framing sub-assemblies within the wall frame, wherein none of the plurality of second fasteners is installed in a position within cavities defined by the one or more framing sub-assemblies or an area between studs of the wall structure;
• a pre-drilling station configured to form one or more through-holes in designated positions of one or more of the wall studs of the wall frame of the wall structure, the one or more through-holes being configured for a third fastener to be at least partially threadably engaged therein for connection of the wall structure to a floor or ceiling structure;
• a sawing/routing station comprising a plurality of cutting devices configured to form openings through one or more of the sheathing panels at positions corresponding to the openings defined by the one or more framing sub-assemblies, wherein locations of each of the cavities is stored within the set of assembly instructions;
• a utility installation system configured to allow installation of at least one of a plurality of utilities within the wall structure, the plurality of utilities comprising plumbing and/or electrical facilities;
• at least one flip table station at which the wall frame is rotated from a first horizontal position, in which the sheathing panels are facing up, in a direction away from a transport frame supporting and/or transporting the wall frame, to a vertical position, in which the wall frame is in a substantially similar orientation to a position in which the wall structure will be in when assembled as part of the modular construction unit, and to a second horizontal position, in which the sheathing panels are facing down, in a direction towards the transport frame supporting and/or transporting the wall frame, the first and second horizontal positions being rotated by approximately 180° relative to each other;
• an insulation installation system configured to apply an insulation material within one or more of the cavities defined between adjacent wall studs of the wall frame;
• a drywall installation station configured to arrange and attach a plurality of drywall panels over an opposite surface of the wall frame from the outer surface on which the sheathing panels are attached, wherein the plurality of drywall panels are arranged over the wall frame of the wall structure in a predetermined pattern specified in the set of assembly instructions, and wherein the drywall installation station is configured to apply a plurality of drywall fasteners to secure each of the plurality of drywall panels onto the opposite surface;
• and
• a wall covering station configured to adhesively apply a plurality of wall covering strips from a roll of wall covering material in a substantially continuous single layer without adjacent wall covering strips overlapping each other.