On-site drywall fabrication systems and related methods

An on-site drywall fabrication robot comprising:

• a robot chassis comprising one or more wheels configured to support the on-site drywall fabrication robot adjacent a support surface and enable rolling movement of the on-site drywall fabrication robot across the support surface;
• a first wall material spool support disposed adjacent the robot chassis, the first wall material spool support being substantially vertically oriented relative to the support surface and configured to support a first wall material spool comprising a backer layer material;
• a second wall material spool support disposed adjacent the robot chassis, the second wall material spool support being substantially vertically oriented relative to the support surface, substantially parallel to and spaced apart from the first wall material spool support, and configured to support a second wall material spool comprising a face layer material;
• one or more sprayers disposed between the first wall material spool support and the second wall material spool support;
• one or more first rollers that correspond to the first wall material spool support;
• one or more second rollers that correspond to the second wall material spool support;
• and
• a computer controller configured, wherein the computer controller is configured to:
• cause the one or more sprayers to spray a fill material between the backer layer material and the face layer material as the first wall material spool and the second wall material spool unwind along the studded wall while the on-site drywall fabrication robot traverses the studded wall.

A method of fabricating drywall substantially directly on a studded wall, the method comprising:

• providing a drywall installation robot comprising:
• a robot chassis comprising one or more wheels configured to support the on-site drywall fabrication robot adjacent a support surface and enable rolling movement of the on-site drywall fabrication robot across the support surface;
• one or more wall material spool supports;
• one or more rollers that correspond to each of the one or more wall material spool supports;
• a vertical motion platform;
• and
• one or more sprayers disposed on the vertical motion platform;
• selecting one or more suitable layer materials for use in the fabrication of the drywall;
• placing a wall material spool comprising each selected one or more suitable layer materials on a corresponding wall material spool support on the drywall installation robot;
• unspooling at least a portion of each wall material spool and running the spool along one or more corresponding rollers;
• affixing an end of one or more of the wall material spools to an anchor stud on the studded wall causing the drywall installation robot to traverse the studded wall such that each of the wall material spools unspools along the wall as the drywall installation robot traverses the studded wall;
• using the one or more sprayers on the drywall installation robot to spray a fill material between the wall material spools;
• optionally using a fastener applicator on the drywall installation robot to at least partially insert one or more fasteners into each stud of the wall such that the fill material is sprayed around the fastener and the fastener is fully disposed within the outer drywall layer;
• and
• allowing the fill material to dry until to produce finished drywall.