Structural Optimization for Robotic Concrete Construction: A Systematic Review

Abstract

Concrete construction is associated with high environmental impact and geometric limitations imposed by conventional formwork, which has led to growing interest in combining structural optimization with robotic fabrication. In this study, structural optimization refers to computational methods such as topology optimization, shape optimization, and form finding that aim to improve material efficiency and load-bearing performance by modifying the geometry of structural elements. This systematic review investigates how these optimization approaches are translated into fabrication-aware design workflows for robotic concrete construction. Following a PRISMA-based methodology, 90 peer-reviewed studies published between 2015 and 2025 were analyzed. The review focuses on fabrication routes including (i) 3D concrete printing, (ii) 3D-printed formwork, (iii) shotcrete-based additive manufacturing, and (iv) controlled casting systems, and examines how each route constrains geometry representation, design decisions, toolpath generation, and robotic execution. The review analyzes design-to-fabrication workflows that link optimized structural geometry to production logic and process control. Key findings indicate that incorporating fabrication constraints at early design stages can support buildability and potential material efficiency, while reinforcement integration and quality control remain critical challenges for structural reliability. The review also highlights the increasing role of in situ sensing and feedback-driven automation in improving process stability. Overall, the study clarifies current practices, limitations, and emerging directions for integrating structural optimization with robotic concrete fabrication.