Repurposing Raw Edge Wood Offcuts Waste for Facade Covering with Minimal Cutting

Manufacturing standardized wood components typically generates 20–30% waste, predominantly as irregular raw edge offcuts. These offcuts are frequently discarded or incinerated, increasing carbon emissions. While the wood industry seeks recycling solutions, the highly variable dimensions and irregular bark edges of these offcuts challenge conventional manufacturing, often requiring secondary cutting that increases embodied carbon. To address this, we propose an integrated computational design and robotic fabrication methodology to upcycle raw edge offcuts into architectural facade coverings with minimal processing. First, a photogrammetry-based scanning method extracts physical dimensions to establish a 1:1 scale digital twin library. Subsequently, a bespoke packing algorithm evaluates library data to optimally position offcuts within a facade design, minimizing waste. Finally, coordinates are sent to a robotic cell that automates material picking, placement, and nailing onto a backing frame. Experimental testing demonstrates that 77% of the wood elements match the design without any post-processing after the initial calculation. For the remaining elements, a secondary algorithmic pass achieves a 100% success rate with minimal cutting. This approach offers a sustainable, automated workflow for timber waste mitigation in construction.