A method for manufacturing a foam wall structure, comprising: (a) placing a wall structure proximate to a robot comprising a robotic arm, by conveying the wall structure, in either a continuous or a discontinuous manner, using any suitable conveyor, the wall structure comprising: a frame comprising a first member, a second member that is spaced apart from the first member, and connecting members (16, 17) extending between the first member and the second member, wherein a front surface of the first member, a front surface of the second member, and a front surface of the connecting members (16, 17) form a front frame surface; and a panel attached to the front frame surface so that the panel, the first member, the second member, and the connecting members (16,17) define an open cavity (18, 26), wherein the robotic arm comprises: a spray nozzle, and an imaging device; (b) orienting the imaging device so that the imaging device faces the open cavity (18, 26); (c) surveying the open cavity (18, 26) using the imaging device; (d) determining, based on data received from surveying the cavity using the imaging device, which open cavities in the wall structure are those containing a visual marking or other indicia to indicate that no foam layer is desired wherein a computing device containing a software code instructs the robot not to spray foam-forming composition into any such cavities, and which open cavities in the wall structure are those for which a foam layer is desired, wherein a computing device receiving data from the imaging device determines, using software code, whether a foam layer is present, the amount of foam-forming composition components to add to achieve a required thickness for the foam layer and a spray pattern to minimize variations in the depth of the foam layer in the open cavity, (e) in case a foam layer is desired, orienting the spray nozzle so that the spray nozzle faces the open cavity; and (f) spray-applying a foam-forming composition into the open cavity according to the spray foaming pattern by passing the foam-forming composition through the spray nozzle to form the foam layer. (a) placing a wall structure proximate to a robot comprising a robotic arm, by conveying the wall structure, in either a continuous or a discontinuous manner, using any suitable conveyor, the wall structure comprising: a frame comprising a first member, a second member that is spaced apart from the first member, and connecting members (16, 17) extending between the first member and the second member, wherein a front surface of the first member, a front surface of the second member, and a front surface of the connecting members (16, 17) form a front frame surface; and a panel attached to the front frame surface so that the panel, the first member, the second member, and the connecting members (16,17) define an open cavity (18, 26), wherein the robotic arm comprises: a spray nozzle, and an imaging device; a frame comprising a first member, a second member that is spaced apart from the first member, and connecting members (16, 17) extending between the first member and the second member, wherein a front surface of the first member, a front surface of the second member, and a front surface of the connecting members (16, 17) form a front frame surface; and a panel attached to the front frame surface so that the panel, the first member, the second member, and the connecting members (16,17) define an open cavity (18, 26), a spray nozzle, and an imaging device; (b) orienting the imaging device so that the imaging device faces the open cavity (18, 26); (c) surveying the open cavity (18, 26) using the imaging device; (d) determining, based on data received from surveying the cavity using the imaging device, which open cavities in the wall structure are those containing a visual marking or other indicia to indicate that no foam layer is desired wherein a computing device containing a software code instructs the robot not to spray foam-forming composition into any such cavities, and which open cavities in the wall structure are those for which a foam layer is desired, wherein a computing device receiving data from the imaging device determines, using software code, whether a foam layer is present, the amount of foam-forming composition components to add to achieve a required thickness for the foam layer and a spray pattern to minimize variations in the depth of the foam layer in the open cavity, which open cavities in the wall structure are those containing a visual marking or other indicia to indicate that no foam layer is desired wherein a computing device containing a software code instructs the robot not to spray foam-forming composition into any such cavities, and which open cavities in the wall structure are those for which a foam layer is desired, wherein a computing device receiving data from the imaging device determines, using software code, whether a foam layer is present, the amount of foam-forming composition components to add to achieve a required thickness for the foam layer and a spray pattern to minimize variations in the depth of the foam layer in the open cavity, (e) in case a foam layer is desired, orienting the spray nozzle so that the spray nozzle faces the open cavity; and (f) spray-applying a foam-forming composition into the open cavity according to the spray foaming pattern by passing the foam-forming composition through the spray nozzle to form the foam layer.