An Industrial Application of Robotic Hot-Wire Cutting In Concrete Construction: Geometric, Technologic and Material Implications

In recent years, digitally driven concrete fabrication has focused on traditional mold-making with 3D milling and advancements in 3D Construction Printing (3DCP). Both methods face challenges in efficiency, sustainability, and practical application. In this context, Robotic Hot-Wire Cutting (RHWC) has emerged as a promising alternative for concrete formwork, offering potential cost and sustainability benefits, though its use remains limited. This paper presents an industrial application of RHWC in constructing a geometrically complex canopy—the port-cochère—at the W Algarve hotel in Portugal. It details the design-to-production workflow for Glass-Fiber Reinforced Concrete (GRC) molds, addressing construction challenges and showcasing RHWC's potential to support complex architectural designs. Developed by a team connected to the DFL (CEAU/FAUP), the project exemplifies successful technology transfer from academia to industry.