Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

Design of a 6-DOF robot manipulator for 3D printed construction

Md. Hazrat Ali a,⇑, Yernar Kuralbay a, Aidos Aitmaganbet a, M.A.S. Kamal b
a
Department of Mechanical and Aerospace Engineering, SEDS, Nazarbayev University, Nur-Sultan 010000, Kazakhstan
b
Graduate School of Science and Technology, Gunma University, Gunma 376-8515, Japan

a r t i c l e i n f o a b s t r a c t

Article history: Robotics and their application in industrial automation are increasing over the decades. There are a vari-
Received 5 May 2021 ety of conventional and non-conventional applications of robotic manipulators. One example of the non-
Received in revised form 9 June 2021 traditional application of robot manipulators is the 3D printing-based construction of houses and build-
Accepted 9 July 2021
ings. Up to date, different ambitious solutions and methods are proposed, and they are expanding fast. In
Available online xxxx
large-scale production, 6 DOF robotic arms, designed by common manufacturers such as KUKA, DENSO
are widely used in 3D construction. The main objective of this work is to model a 6 DOF robot manipu-
Keywords:
lator for 3D printing-based construction technology. This paper presents two new designs of robot
Automation
Construction
manipulators for construction purposes; one is to transport the building materials, and the other is to
Modeling help print with the concrete mixtures. The simulation results are obtained applying fundamental theories
Robot manipulator of robotics through Roboanalyzer software. The simulation parameters are chosen for the designed speci-
Robotics fic model.
3D printing Ó 2021 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of the scientific committee of the Global Conference on
Recent Advances in Sustainable Materials 2021.

1. Introduction for construction engineering, as presented in [2]. The 6-DOF

Industrial robotic arms have been improved in a practically
complete manner over the past decades. Robotic manipulators
can easily maintain remote control for operators in various areas
where human abilities are limited. A robot arm is a mechanical tool
that imitates a human arm but with programmable performance.
Robots can be an element or total system mechanism of a more
complex robot. Robotic arms are crucial tools that can operate in
the immense diversity of tasks and are implemented in essential
engineering industries. For instance, robotic manipulators can be
managed in manufacturing processes like welding, drilling, casting,
etc., in many industrial factories. Cartesian robots (Fig. 1) are
widely used in CNC machine applications and 3D printers [1].
However, these kinds of manipulators are performed in medium-
scale workspaces. The primary aim of this paper is to build a model
and do the simulation of a robotic arm capable of making 3D
printing-based constructions of houses, walls, and so on. Fig. 1
shows a design of a cartesian robot aimed to use in assisting 3D
printed construction work. This a cartesian robot, helpful in trans-
porting construction raw materials. The cartesian robot is flexible
⇑ Corresponding author.
E-mail address: md.ali@nu.edu.kz (M.H. Ali).
robotic arm with 6 links is modeled to cooperate with 3D construc-
tion engineering.
New designs and prototypes are needed to validate the applica-
tion in various areas of construction engineering. Thus, new
designs are proposed to be implemented in 3D building construc-
tion. The current challenges in implementing 3D printing technol-
ogy include the lack of new machines, methodologies, materials,
and low acceptance by the conventional industries. This can be
solved with new ideas, inventions, introducing suitable materials
and novel technologies. The key focus of this research is to intro-
duce new technologies to construction engineering as well as to
automate the construction sectors.
2. Literature review
There is a large variety of literature worldwide regarding
robotics, industrial automation, and 3D printing-based construc-
tion. In this section, key sources such as journal articles, books,
and relevant open sources are studied and highlighted the main
aspects that provided sufficient insight into the topic of the paper.
Bock [3] reviewed the history of 3D construction by broadcast-
ing its evolution and development over the decades. Moreover, the
author analyzed the reference sources that appeared in his

https://doi.org/10.1016/j.matpr.2021.07.228
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of the scientific committee of the Global Conference on Recent Advances in Sustainable Materials 2021.

Please cite this article as: Md. Hazrat Ali, Y. Kuralbay, A. Aitmaganbet et al., Design of a 6-DOF robot manipulator for 3D printed construction, Materials
Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.07.228
Md. Hazrat Ali, Y. Kuralbay, A. Aitmaganbet et al.
Fig 1. Cartesian robot.
publication to discuss the industry’s future aspects. Kangari [1]
addressed the term ’integration’ of 3D construction into industrial
automation. The author indicated that with innovative solutions
such as 3D construction, new problems would be solved. The paper
aims to adopt new technologies into conventional construction
systems with cost-effectiveness and productivity. This work’s crit-
ical statement is that robotic systems should be integrated into
construction engineering and technology.
Kumar et al., [4] performed an extremely crucial comparative
analysis between 3D automotive construction and labor construc-
tion in cities of India in the engineering economy way. The main
objective was to demonstrate the capability and effectiveness of
automated construction over manual management. The findings
show that automatic construction outperforms by 50–60% in cost,
printing time, and printed work quality. Izard et al., [5] introduced
new types of cable-driven parallel robots (CDPR), an innovative
Cartesian robot (Fig. 2). Such a robot’s main applications are instal-
Fig 2. Cable-driven parallel robots (CDPR).
2
Materials Today: Proceedings xxx (xxxx) xxx
ling windows, beams, lintels, curtain wall modules, bricklaying,
etc. See (Fig. 3.).
Zhang et al., [6] proposed a large-scale solution for 3D construc-
tion using multiple robots’ systems. The authors stated that it was
the first practical implementation of multi-robots on such a scale.
Their primary objectives are to develop a multi-agent robot for col-
laborative printing, improvement of scalability, and time effi-
ciency. They demonstrated on-site printing capability and large
structures printed with the proposed system safely, efficiently,
and scalably. This was the first multi-robot simultaneous printing
on a single concrete structure.
Kazemian et al., [7] conducted experimentation with cementi-
tious materials to be applied to 3D printing constructions. Criteria
for sustainability were chosen among printing quality, shape sta-
bility, and printability window. Their tests resulted that silica fume
and nano-clay are the best options with significantly enhanced
shape stability.
There are several challenges with respect to the implementa-
tion of robotics in construction engineering. Authors in [8] have
shown that the main obstacles are cost, technology adaptation in
the workplace, various construction works, and limited resources.
In addition, the implementation of robotics in construction needs
support by the construction management to get expected results
[9]. This is another big challenge in the adaptation of new technol-
ogy in construction industries. A similar study [10] presents an
investigation into the industry-specific factors that limit the adop-
tion in the construction industry.
From the available resources, it can be summarized that the
applications of 3D printing in construction engineering have sev-
eral challenges. First, the lack of new technologies, appropriate
materials, and acceptance by the conventional industries. Second,
the building time needs to be reduced through optimization. Third,
lack of new development in this area.
3. Methodology
A 6 DOF robot manipulator will be represented in this section in
Denavit-Hartenberg’s (DH) convention, forward, and inverse kine-
matics. This robotic arm has 6 degrees of freedom, often referred to
as joints, and 6 links. 1st link will serve as a fixed base of the robot,
while the 6th link will be an extruder hand for the material.
3.1. Denavit-hartenberg (DH) selection
This representation shows the relationship between two
attached joints and corresponding links. This convention is shown
Fig 3. Denavit-Hartenberg convention.
Md. Hazrat Ali, Y. Kuralbay, A. Aitmaganbet et al. Materials Today: Proceedings xxx (xxxx) xxx

in terms of a 4x4 transformation matrix with elements corre- wherenx = C6C12C345-S6S12; ny = C6C12C345 + C12S6; nz = C6S345ox = -
sponded with joint angle variables (Z) and positions (X) of links. C12S6C345-S12C6; oy = -S6S12C345 + C12C6; oz = -S6S345ax = -C12S345;
The equation for transformation for each frame is presented as ay = -S12S345; az = C345Px = a4C12C3C4-a4C12S3S4 + S12d5 + a3C12C3Py =-
follows: a4S12C3C4-a4S12S3S4-C12d5 + a3S12C3Pz = a4S3C4 + a4C3S4 + a3S3 +
i
1
Ti = RzTzTxRx d1Ci = cos(Hi); Si = sin(Hi); Cijk or Sijk = cos(Hi+ Hj +Hk) or sin
Table 1 shows the DH configuration for 6 DOF manipulators. (Hi+ Hj +Hk).
Fig. 4 shows the free-body diagram of DH frames in each joint.
Another industrial robot based-on vision system is introduced in 3.3. Inverse kinematics
[10]. The authors have explained how an industrial manipulator
could efficiently use a camera system. The robot can do the tasks Inverse kinematic analysis is often challenging in contrast with
efficiently with the developed algorithm. direct kinematics. This is due to the complexity and variety of pos-
sible solutions of joint angles. Inverse kinematics is the opposite of
3.2. Forward kinematics forward kinematics, and the goal is to determine joint angle solu-
tions, whereas the end-effector’s position coordinates are given.
Forward kinematics analysis is the procedure where position Inverse kinematics can be solved either geometrically or analyti-
and orientation of end-effector are determined with given joint cally. An analytical approach will be performed in this subsection
angles (Hi). This process is implemented by applying 4x4 homoge- to obtain possible solutions.
neous matrices with given values from each frame to the previous Firstly, each homogeneous frame matrix can be inverted and
one. Generally, the matrix representation of each frame is shown multiplied to 0Tn, and then by equating the corresponding ele-
as: ment, calculate the required parameters.
2 3 2 3
C Hi
SHiC ai SHiSai ai C Hi nx ox ax Px
6 SHi C HiC ai
C HiSai ai SHi 7 6 ny oy ay Py 7
6 7 6 7 1 2 3 4 5
Ai ¼ 6 7 ð1Þ A
1
1 6 7 ¼ A2 A3 A4 A5 A6 ð4Þ
4 0 Sai C ai di 5 4 nz oz az Pz 5
0 0 0 1 0 0 0 1
where Chi = coshi and Shi = sinhi. By applying matrix manipulations, we obtain:
2 3
Matrices below demonstrate homogeneous transformations of .. ..
6 . . C 1 ax þ S1 ay C 1 P x þ S 1 P y 7
each frame: 6 .. . . 7
2 3 2 3 6.
C 1
S1 0 0 C 2 0 S2 0 6 .
S1 ax þ C 1 ay
S1 Px þ C 1 P y 77 =
6 S1 C 1 0 0 7 1 6 7 6. .. 7
0
A1 = 6 7, A2 = 6 S2 0
C 2 0 7, 4 .. . a P
d 5
4 0 0 1 d1 5 4 0 1 0 05 z z 1
0 0 0 1
0 0 0 1 0 0 0 1 2 3
2 3 .. ..
C 3
S3 0 a3 C 3 6. .
C 2 S345 a4 C 2 C 34 þ a3 C 2 C 3 þ S2 d5 7
6 S3 C 3 0 a3 S3 7 6. . 7
2
A3= 6 7, 6 .. . .
S S a4 S2 C 34 þ a3 S2 C 3
C 2 d5 7
4 0 0 1 0 5 6 2 345 7
6 .. .. 7
0 0 0 1 4. . C 345 a4 S34 þ a3 S3 5
2 3 2 3 2 3 0 0 0 1
C 4
S4 0 a4 C 4 C5 0
S5 0 C 6
S6 0 0
6S C 0 a S 7 6S By equating corresponding elements, we get
6 4 4 4 47 4 6 5 0 C5 0 775
6 S C 0 07
6 6 6 7
3
A4 ¼ 6 7; A ¼ 6 7; A6 ¼ 6 7
40 0 1 0 5 5 40
1 0 d5 5 4 0 0 1 05 C 1 Px þ S1 Py ¼ a4 C 2 C 34 þ a3 C 2 C 3 þ S2 d5 ð5Þ
0 0 0 1 0 0 0 1 0 0 0 1
ð2Þ
S1 P x þ C 1 Py ¼ a4 S2 C 34 þ a3 S2 C 3
C 2 d5 ð6Þ

Multiplicating these transformation matrices implied from the By performing algebraic manipulations, we obtain:
end-effector to the base frame gives the robotic arm’s endpoint’s qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2
final position and orientation matrix. Px 2 þ Py 2
d5
a4 C 34
C3 ¼ ð7Þ
2 3 2 3 a3
R6    P6 nx ox ax Px
6 . 6 ny oy ay Py 7 0qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 1
.. . 7
7 6 7
0
T 6 ¼ 0 A11 A22 A33 A44 A55 A6 ¼ 6
4 .. . .. 5 ¼ 6 7 Px 2 þ Py 2
d5
a4 C 34
2
4 nz oz az Pz 5 h3 ¼ arccos@ A ð8Þ
0  1 0 0 0 1
a3

ð3Þ
Pz
d1 ¼ a4 S34 þ a3 S3 ð9Þ

Table 1
DH configuration for 6 DOF manipulator.

Joint Joint angle Hi (variable) Joint Offset di (m) Link length ai (m) Twist angle ai
1 H1 d1 a1 a1
2 H2 0 a2 a2
3 H3 0 a3 a3
4 H4 0 a4 a4
5 H5 d5 a5 a5
6 H6 0 a6 a6
Hi – the angle between Xi and Xi-1 around Zi-1.
di – joint offset distance between Xi and Xi-1 around Zi-1.
ai – link distance between Zi and Zi-1 starting from Zi-1.
ai – the angle of twist between Zi and Zi-1 around Xi-1.

3
Md. Hazrat Ali, Y. Kuralbay, A. Aitmaganbet et al. Materials Today: Proceedings xxx (xxxx) xxx

Fig 4. The free-body diagram of DH frames in terms of each joint.

Table 2
DH parameters for 6 DOF 6R robotic arm.

Joint Joint type
1 Revolute
2 Revolute
3 Revolute
4 Revolute
5 Revolute
6 Revolute
Joint angle Hi (variable) Joint Offset di (m) Link length ai (m) Twist angle ai The initial value of H
H1 0.1 0 0 60
H2 0 0 90
10
H3 0 0.25 0 10
H4 0 0.25 0
10
H5 0 0.25 0
50
H6 0 0.05 0
60

a3 S3
Pz þ d1 S2 Px
C 2 Py
d1 ¼ d5 ¼> S2 P x
C 2 Py ¼ d1 þ d5 ð18Þ
S34 ¼ ð10Þ
a4

  qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
a3 S3
Pz þ d1 2
h34 ¼ arcsinð Þ ð11Þ h2 ¼ arctan2 P x ;
Py  arctan2ð P x 2 þ P y 2
ðd1 þ d5 Þ ; d1 þ d5
a4
ð19Þ
h4 ¼ h34
h3 ð12Þ
From ax = -C12S345 and ay = -S12S345
The next step is shown below.
S12 ay
2 3 ¼ ð20Þ
nx ox ax Px C 12 ax
6 ny oy ay Py 7
6 7 2 3 4 5 Hence H12 = arctan2ðay ; ax ) and H1= H12 - H2.
A
1
1
1 A2  6 7 ¼ A3 A4 A5 A6 ð13Þ
4 nz oz az Pz 5
0 0 0 1
2 3
.. .. .. 4. Simulation results and analysis
6 . . . C 1 C 2 Px þ C 1 S2 Py þ S1 Pz 7
6 .. .. .. 7
6 . . .
S1 C 2 Px
S1 S2 Py þ C 1 Pz 7
6 7 LHS A mathematical model developed in methodology will be thor-
6 7
4 S n
C n S o
C o ... S2 Px
C 2 P y
d1 5 oughly examined via Roboanalyzer software in this section.
2 x 2 y 2 x 2 y
0 0 0 1
2 3
C 6 C 345
S6 C 345
S345 a4 C 34 þ a3 C 3
6 C 6 S345
S6 S345 C 345 a4 S34 þ a3 S3 7
6 7 RHS
4
S6
C 6 0 d5 5
0 0 0 1

S6 ¼ S2 nx
C 2 ny ð14Þ

S6 ¼ C 2 ny
S2 nx ð15Þ

C 6 ¼ C 2 oy
S2 ox ð16Þ
   
h6 ¼ arctan2 C 2 ny ; C 2 Oy
S2 ox ð17Þ
Fig 5. 3D Roboanalyzer model.

4
Md. Hazrat Ali, Y. Kuralbay, A. Aitmaganbet et al. Materials Today: Proceedings xxx (xxxx) xxx

Table 3
6 different inputs of direct kinematic analysis.

Joint angle Hi and position vector P input 1 input 2 input 3 input 4 input 5 input 6
H1 90 75 50 40 30
45
H2 20 10 15 0 10 25
H3 40 30 45 55 50
20
H4 20 5 20 25 40
30
H5
20
15
25
10
5
25
H6
30
20
40
35
15 10
Px
0.1906 0.0616 0.2214 0.2400 0.1529 0.4524
Py 0.5237 0.7036 0.4749 0.2014 0.1283
0.1647
Pz 0.6466 0.4539 0.6640 0.8146 0.8375
0.4638

Fig 6. The graph of links from forward-kinematic analysis done by input 6.

Fig. 5 shows a 3D model of a robotic arm in Roboanalyzer by

parameters from the table above:
Direct kinematic analysis is performed by choosing each frame’s
final joint angle values. Table 3 demonstrates 6 different final value
inputs that have been selected for each joint and final position vec-
tor (Px, Py, and Pz) of link 6 for each input:
Fig. 6. shows a graphical representation of links from FKin anal-
ysis done by input 6 in 4.00secs with 100 steps. The path of manip-
ulation is shown in Fig. 7.

4.2. Inverse kinematics analysis

In this section, inverse kinematic analysis is performed on the

Fig 7. Path of manipulator from forward-kinematics when t = 4.00 s and N = 100.
4.1. Forward kinematics analysis
3D model of 6 DOF robotic arm was developed in Roboanalyzer
software to solve a manipulator’s direct kinematics. DH parameters
were chosen such that it has an approximately similar pattern as
KUKA KR 5 manipulator since the inverse kinematics in this soft-
ware will be observed for this model further. Table 2 shows DH
parameters for 6 DOF 6R robotic arms.
5
KUKA KR5 Arc manipulator via Roboanalyzer Software. DH param-
eters of the manipulator are shown in Table 4.
As mentioned, inverse kinematics aims to obtain possible joint
angle variables suitable for desired final positions of the robotic
arm. Table 5 demonstrates joint angle solutions for 3 different
positions of the manipulator. Fig. 8 shows FKin simulation of KUKA
KR5 links in t = 1.00 s and N = 100. Compared to the modeled
manipulator’s end-effector position, KUKA KR 5 has a similar pat-
tern in link3, link4, and link 5.
4.3. Application of 6-DOF robot manipulator in 3D printed
construction
The implementation of a 6 DOF robot manipulator in 3D print-
ing has been discussed in several research works. Authors in [11]
have presented an overall 3D printing pipeline, robots position
optimization to localization and mapping, path planning, trajectory
Md. Hazrat Ali, Y. Kuralbay, A. Aitmaganbet et al. Materials Today: Proceedings xxx (xxxx) xxx

Table 4
DH parameters of the manipulator.

Joint Joint type Joint angle Hi (variable) Joint Offset di (m) Link length ai (m) Twist angle ai
1 Revolute H1 0.4 0.18 90
2 Revolute H2 0.135 0.6 180
3 Revolute H3 0.135 0.12
90
4 Revolute H4 0.62 0 90
5 Revolute H5 0 0
90
6 Revolute H6 0.115 0 0

Table 5
Joint angle solutions for 3 different positions of manipulator.

Position vector P and joint angle solutions (theta) input 1 input 2 input 3
initial final initial final initial final
Px 0.08 0,085 0,1
Py 0.1 0,15 0,3
Pz 1.2 1,25 1,5
H1 82,962 82,962 83,404 83,404 83,846 83,846
H2 50,389 50,389 50,519 50,519 70,67 70,67
H3
165,649
165,649
159,1
159,1
105,366
105,366
H4 234,438
305,562 239,773
300,22 281,481
258,519
H5 134,13
134,13 137,438
137,43 143,354
143,354
H6 125,562
54,438 133,514
46,486
173,389 6,611

Fig 8. The graph of forward-kinematics simulation of KUKA KR5 links at t = 1.00 s and N = 100.

control, and execution. They have also discussed the difficulties in
material delivery for building construction. Another work [12] pro-
posed to automate the printing process by collecting material
properties through a feedforward control system. A six-axis indus-
trial robot was used to print geopolymer concrete. A study [13]
suggested that the building construction industry and research
organizations could benefit through innovative construction mate-
rials, improved robotics technology, and advanced engineering
design to enhance construction workflows to achieve a complete
on-site robotic construction system. Another research [14] dis-
cussed several cases and highlighted the prospects of 3D printing
in construction engineering from the perspective of New Zealand.
Fig. 9 shows a prototype of a 3D printing robot manipulator. The
3D printed construction with a robot manipulator is deemed nec-
essary in modern construction engineering. The end effector can
be adjusted based on the specific construction model. Usually,
robot manipulators can carry heavier loads than a human being
with less time and higher efficiency. The materials should be fed
through the end effector, which is pre-mixed in conventional
machines. The aim is to control the material feed through the
end effector to the printing wall.
The technical dimensions of Figs. 1 and 9 are flexible. Therefore,
it can be adjusted to any extent required to print any specific
object.

6
Md. Hazrat Ali, Y. Kuralbay, A. Aitmaganbet et al.
Fig 9. A small-scale robot manipulator design for construction engineering.
5. Conclusions
Two models of robot manipulators were designed to solve the
existing problem of expanding 3D printing in construction engi-
neering. The simulation result is presented in this paper for the
proposed models. One of the robots is to transport the construction
materials, and the other is to print building blocks, walls using the
end effector with concrete mixtures. In addition, the robot manip-
ulator’s mathematical model was driven by the principles of for-
ward and inverse kinematics for the proposed designs. Finally,
Roboanalyzer software was used to validate the theoretical data.
The input parameters verified the angular positions and position
vectors. The current challenges are also discussed in this work.
To solve the current problem, new methods and mechanisms are
the critical requirements for this industry.
Materials Today: Proceedings xxx (xxxx) xxx
CRediT authorship contribution statement
Md. Hazrat Ali: Supervision. Yernar Kuralbay: Conceptualiza-
tion, Methodology. Aidos Aitmaganbet: Methodology, Validation.
M.A.S. Kamal: Supervision.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Acknowledgements
This work was supported by the Faculty Development Compet-
itive Research Grants, Ref. No. 021220FD1551, Nazarbayev
University.
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