Affordable Fabrication of Polo-1 Connections For Slrss Using A Low-Tech Mechanical Joining System

Single-layer reticulated shells (SLRSs) are lightweight, curved structures made of connected linear bars, requiring precise fabrication of their connections. The POLO-1 connection involves a central tube with vertical splice plates welded. Although industrial robotic arms can weld the plates to the tubes, this technology is often unaffordable due to high-cost equipment, particularly in the Global South countries. In this paper, we present a low-tech mechanical joining system prototype that enables the assembly and welding of POLO-1 connections by a single worker. An algorithm generates a parametric model of the SLRS and its connections, providing essential measurements. A joining system, adapted with custom components, guides the precise assembly. The system's effectiveness was demonstrated using the proposed fabrication approach of an SLRS scale model instance. The results represent a step towards making these structures accessible to a broader audience.