  While robotic spatial extrusion has demonstrated a new and efficient means to
fabricate 3D truss structures in architectural scale, a major challenge remains
in automatically planning extrusion sequence and robotic motion for trusses
with unconstrained topologies. This paper presents the first attempt in the
field to rigorously formulate the extrusion sequence and motion planning (SAMP)
problem, using a CSP encoding. Furthermore, this research proposes a new
hierarchical planning framework to solve the extrusion SAMP problems that
usually have a long planning horizon and 3D configuration complexity. By
decoupling sequence and motion planning, the planning framework is able to
efficiently solve the extrusion sequence, end-effector poses, joint
configurations, and transition trajectories for spatial trusses with
nonstandard topologies. This paper also presents the first detailed computation
data to reveal the runtime bottleneck on solving SAMP problems, which provides
insight and comparing baseline for future algorithmic development. Together
with the algorithmic results, this paper also presents an open-source and
modularized software implementation called Choreo that is machine-agnostic. To
demonstrate the power of this algorithmic framework, three case studies,
including real fabrication and simulation results, are presented.
