A transformative approach to construction is on the horizon, as a new paper published in Science Robotics on 23 April 2025, unveils the potential of aerial robots to revolutionise building practices. This comprehensive review, titled Aerial Additive Manufacturing: Towards On-site Building Construction with Aerial Robots, examines the emerging field of Aerial Additive Manufacturing (Aerial AM) and its capacity to address pressing global housing and infrastructure challenges through sustainable and scalable solutions.
Authored by researchers from leading institutions, including EPFL, EMPA, Imperial College London and University College London, the study highlights how aerial robots equipped with advanced manipulators can overcome the limitations of traditional construction methods and ground based robotic systems. These innovations promise enhanced productivity, environmental sustainability and access.
Key findings
Unlike conventional construction techniques or ground-based robotic systems, aerial robots operate within an unrestricted work envelope. This flexibility allows them to build at greater heights and in challenging terrains that are otherwise inaccessible.
Aerial AM encompasses three distinct approaches – Discrete (placing individual units like bricks), Tensile (constructing tension-based structures with cables) and Continuous (extruding materials in layers). Each method offers unique advantages for different construction scenarios.
The paper introduces a five-level autonomy framework tailored for Aerial AM, addressing critical challenges such as flight coordination, material deposition precision, and scalability in large-scale manufacturing tasks.
By leveraging lightweight materials and reducing reliance on labour-intensive processes, aerial robots contribute to safer construction practices while minimising environmental impact.
Challenges ahead
Despite promising advancements, the deployment of aerial robots for large scale autonomous construction remains in its infancy. The study identifies key obstacles such as material durability, localisation systems for outdoor environments, and coordination among multiple aerial units. Addressing these challenges is essential to unlocking the full potential of Aerial AM in real world applications.
Implications for the future
With global demand for housing and infrastructure rising due to urbanisation and population growth, innovative construction methods are urgently needed. The authors argue that Aerial AM could play a pivotal role in meeting these demands while advancing sustainability goals. Early stage demonstrations have already showcased capabilities such as rapid on demand repairs and modular assembly techniques, paving the way for broader adoption across industries.
“Construction drones can be tested here under real conditions, further developed and brought to market maturity."
Box: DroneHub | Empa – UCL Partnership
The new multi-environment robotic testbed, the “DroneHub”, in Empa's NEST research and innovation building plays a key role for Aerial AM. This test infrastructure was designed as a bridge between the laboratory and industrial applications. “Construction drones can be tested here under real conditions, further developed and brought to market maturity,” says Mirko Kovač, who heads the NEST unit developed in collaboration with University College London. This infrastructure, which is unique in Europe, provides Empa and UCL with a platform on which flying construction machines can be tested outside the laboratory for the first time. The first field trials are planned for this year.
Legend infographic Autonomy framework:
Five steps to autonomous construction drones: The full potential of aerial AM will only unfold when drones are increasingly able to act autonomously. The autonomy framework presented in the study ranges from simple flight route tracking to the highest level, in which drones analyse the construction environment, detect errors and continuously adapt the design.
Infographic state of the art:
The state-of-the-art Aerial Additive Manufacturing applications fall into three main categories: Discrete Aerial AM (constructing structures with modular units), Tensile Aerial AM (constructing tensile structures with linear elements), and Continuous Aerial AM ( constructing structures with continuous material deposition).
About the Authors
The study was led by Yusuf Furkan Kaya and Professor Mirko Kovač from EPFL and Empa's Laboratory of Sustainability Robotics and Imperial College London's Aerial Robotics Laboratory. Collaborators include experts from University College London, University of Bristol, and the University of Pennsylvania.
For further inquiries or interview requests with the authors, please contact Yusuf Furkan Kaya, Professor Mirko Kovač or Dr Vijay Pawar below.
Doctoral Assistant, Laboratory of Sustainability Robotics, EPFL
Click to email. yusuf.kaya@epfl.ch
Head of Unit, Laboratory of Sustainability Robotics, EPFL
Click to email. mirko.kovac@epfl.ch
Science Robotics Publication
Aerial additive manufacturing: Toward on-site building construction with aerial robots
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