Miljković, T., Jovanović, M. and Bajšanski, I., 2026. Zero Waste Manufacturing Design Approach of Doubly Curved EPS Fenestration Facades Using Robotic Hotwire Cutting. Nexus Network Journal, pp.1-14.

Abstract: The use of expanded polystyrene (EPS) in architectural facades offers versatility and efficiency, particularly for curved designs. However, integrating openings like windows poses challenges in material use and waste management. Previous research introduced a zero-waste manufacturing (ZWM) workflow utilizing robotic hot wire cutting to create doubly curved EPS facades without fenestration, avoiding waste. This study extends the ZWM approach by incorporating openings through segmented facade patches and advanced cutting strategies, maintaining residue below 2% of the total volume on average. The refined process balances material efficiency and design flexibility, contributing to sustainable practices in complex architectural forms.

Keywords: integrated design approach, digital fabrication, ZWM, expanded
polystyrene

Online version of the article: https://link.springer.com/article/10.1007/s00004-026-00869-9