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The integration of industrial robots into design practices has introduced a transition from automation to exploration, yielding diverse creative expressions. Robotic fabrication's advantages of precision and tool versatility drive their expanding role in design. Material-driven design values emergent expressions that incorporate imperfections. However, designs stemming from robotic fabrication often exhibit a digital aesthetic, constraining material expression. Thus, the research question emerges: How can formations resulting from concrete casting in cardboard formwork become more expressive? Employing an iterative 5-step design workflow, the experiments across six studies involve the robotic scoring of corrugated cardboard boards, which are subsequently stacked to create concrete formwork. The findings of our research include a set of factors relevant to the fabrication method of casting concrete with stacked cardboard formwork that is scored with a robot. Furthermore, they include knowledge on the approach separating the design workflow in steps and consequently, the roles the designer has in relation to these steps throughout the course of the design process. Recommendations considering balances between software, robot, material and designer agencies in design steps are provided, leading to an approach enabling the designer to robotically incorporate imperfections in design. Lastly, guidelines are provided in incorporating expressions caused by two materials and the unpredictability that comes with their involvement. By empowering designers with a deeper understanding of material combinations and their potential when manipulated robotically, this research paves the way for innovative and inspiring creations in the future.