CORA Installation: Sustainable Digital Fabrication in Architecture at IAAC

A Fusion of Tradition and Technology

The CORA Installation, developed by the Institute for Advanced Architecture of Catalonia (IAAC) at the Valldaura Labs Campus, represents a groundbreaking approach to sustainable digital fabrication in architecture. Situated in the Collserola Natural Park near Barcelona, the project merges 19th-century brick architecture with cutting-edge robotic construction techniques. Designed to house and operate a KUKA industrial milling robot, the structure serves as a functional laboratory and a symbol of the synergy between craftsmanship and automation.

Context and Site Integration

Located within a 135-hectare research campus, the installation repurposes an old brick stable while introducing a contemporary wooden framework. This balance between historical preservation and modern intervention ensures that the structure remains contextually relevant while embracing sustainable design. The existing brick walls were carefully restored, while a new timber volume was inserted to support robotic operations and human interaction.

Architectural Concept: The Cathedral of Robotic Artisans

The design concept pays homage to traditional woodworking and digital fabrication, leading to its name—CORA, an acronym for the "Cathedral of Robotic Artisans." The building’s interior evokes the grandeur of a cathedral, with towering wooden columns and a geometric roof structure. Seven tree-like columns, constructed from solid wood and cross-laminated timber (CLT), rise to support an intricate Voronoi-patterned ceiling. This organic structural system highlights the project’s biomimetic inspiration while demonstrating the potential of computational design in sustainable construction.

Digital Fabrication and Construction Methods

The construction process relied heavily on digital fabrication techniques, including computer numerical control (CNC) machining. Due to the depth limitations of CNC milling, complex joints were fabricated using multiple layers of precisely cut wood, which were then assembled to form seamless structural elements. The prefabricated wooden components were transported to the site and assembled within the existing brick walls, emphasizing efficiency and sustainability in material use.

To support the high precision required for robotic milling, a reinforced concrete pedestal was integrated into the design, providing a stable base for the KUKA industrial robot. The façade, made of CLT panels, was parametric-milled to create a textured surface that visually connects the modern intervention with the historical character of the site.

Sustainability and Biophilic Design

A key aspect of the project is its commitment to environmental sustainability. The wooden structure minimizes carbon emissions compared to conventional construction materials, while the integration of a Mediterranean green roof enhances energy efficiency. The roof system consists of multiple layers, including a waterproof membrane, geotextile fabric, drainage board, and humus to support native plant species.

Selected vegetation includes common honeysuckle, sweet clematis, creeping sedum, and French lavender, chosen for their resilience and ecological benefits. An integrated irrigation system ensures the sustainability of the roof, contributing to thermal insulation and biodiversity while reinforcing the project's alignment with ecological principles.

Lighting and Spatial Experience

The architectural composition prioritizes natural light to create an inspiring workspace for both humans and machines. A strategically placed skylight above the robot floods the interior with daylight, reducing reliance on artificial lighting while enhancing the immersive quality of the space. The combination of warm wooden surfaces and diffused natural light fosters an environment that merges technology with a sense of artisanal craftsmanship.

CORA as a Prototype for Future Sustainable Architecture

Beyond its immediate function as a robotic fabrication lab, CORA serves as a prototype for future sustainable architecture. The integration of historical materials, digital fabrication, and ecological design principles demonstrates how adaptive reuse can coexist with advanced manufacturing. This project exemplifies how computational design and traditional craftsmanship can work in harmony, paving the way for more sustainable and innovative construction methods.

As an active part of the Valldaura Labs research initiatives, the installation continues to evolve as a testing ground for new architectural and technological advancements. By blending sustainable digital fabrication with natural materials and biophilic strategies, CORA stands as a forward-thinking model for architectural innovation.

All Photographs are works of  Adrià Goula