Three-dimensional printed structures and systems and methods for three-dimensional printing of structures

Abstract

A 3D printed structure comprising: a structure comprising a plurality of sides, each side constructed using a 3D printing process wherein the 3D printing process deposits material superimposed in the form of a continuous bead to produce the plurality of sides by: 1) first depositing material to form a monolithic and continuous rear end surface, and then 2) a 3D printing process deposits material in a superimposed manner in the form of continuous beads to build the initially deposited material, thereby further building the bottom, top, left and right walls to complete 3D printing of the structure, the 3D printing process ultimately deposits material to form an integral and continuous leading end surface associated with each of the bottom, top, left and right walls, where the 3D printed structure is rotated to be placed on the bottom after completion of the 3D printing process.

Description

[0001] This application claims priority to U.S. Provisional Application No. 63 / 325,488, filed on March 30, 2022, entitled Systems and Methods for Three-Dimensional Printing of Structures. Background Art

[0002] The present disclosure and the exemplary embodiments described herein describe methods and systems for three-dimensional printing technology, and more particularly, describe three-dimensional printing of structures. However, it should be understood that the scope of the present disclosure is not limited to such applications.

[0003] Three-dimensional (3D) printing or additive manufacturing is the construction of a 3D object from a computer-aided design (CAD) or another 3D model. 3D printing can apply a variety of processes that deposit, join, or solidify materials under computer control to create a 3D object. Typically, 3D printable models are created using a CAD program, via a 3D scanner, or using photogrammetry software. Once a suitable file type is generated (such as an STL file), it is processed by slicing software, which converts the model into a series of thin layers. These layers become the individual steps in the additive manufacturing printing process.

[0004] Traditionally, 3D printing uses polymers for printing. However, methods have been developed that allow the utilization of metals, ceramics and other materials. The main differences between the various known processes are the way the layers are deposited and the materials used. 3D printing has many applications in the manufacturing and medical industries. Summary of the invention

[0005] This description is provided to introduce various concepts that are further disclosed in the detailed description of the embodiments in a simplified form. This description is not intended to identify key or fundamental inventive concepts of the claimed subject matter, nor is it intended to determine the scope of the claimed subject matter.

[0006] The embodiments described herein relate to a 3D printed structure, including a structure, the structure including multiple sides, the multiple sides including: a bottom, a top, a left side and a right side, each side being constructed using a 3D printing process. According to an exemplary embodiment of the present disclosure, the structure is 3D printed as a whole by an additive process, which produces a structure placed on a platform and oriented with the top as the uppermost surface. The completed structure is then rotated onto the bottom outer surface to provide a structure that is appropriately oriented. The front side / wall and the rear side / wall are not 3D printed, but are constructed and / or added using various construction techniques that connect the front side and the rear side to the 3D printed structure. Some features associated with the front side and the rear side may include, but are not limited to, windows, doors, electrical devices, etc.

[0007] The disclosed embodiments and variations thereof provide an efficient and cost-effective method, in some embodiments, of producing habitable structures using recyclable polymers (i.e., recyclable plastics) that can be 3D printed at a remote location and shipped to a consumer, while reducing the amount of on-site manufacturing, preparation, and labor.

[0008] According to an exemplary embodiment of the present disclosure, a 3D printed structure is disclosed, comprising: a structure comprising multiple sides, the multiple sides comprising a bottom, a top, a left wall and a right wall, each side being constructed using a 3D printing process, wherein the 3D printing process deposits material in an additive manner in the form of continuous beads to produce the multiple sides by: 1) first depositing material to form an integral and continuous rear end surface associated with each of the bottom, the top, the left wall and the right wall, and then 2) the 3D printing process deposits material in an additive manner in the form of continuous beads to build up the initially deposited material, thereby further building up the bottom, the top, the left wall and the right wall to complete the 3D printing of the structure, the 3D printing process finally deposits material to form an integral and continuous front end surface associated with each of the bottom, the top, the left wall and the right wall, wherein, after the 3D printing process is completed, the 3D printed structure is rotated to be placed on the bottom.

[0009] According to another exemplary embodiment of the present disclosure, a method for constructing a 3D-printed structure including multiple sides is disclosed, the multiple sides including a bottom, a top, a left wall and a right wall, the method comprising: a 3D printing process deposits material in a superimposed manner in the form of continuous beads to produce the multiple sides by: 1) first depositing material to form an integral and continuous rear end surface associated with each of the bottom, top, left wall and right wall, and then 2) the 3D printing process deposits material in a superimposed manner in continuous beads to build up the initially deposited material, thereby further building up the bottom, top, left wall and right wall to complete the 3D printing of the structure, the 3D printing process finally deposits material to form an integral and continuous front end surface associated with each of the bottom, top, left wall and right wall, wherein, after the 3D printing process is completed, the 3D printed structure is rotated to be placed on the bottom.

[0010] According to another exemplary embodiment of the present disclosure, a six-sided enclosed habitable structure is disclosed, including: a 3D printed structure including multiple sides, the multiple sides including a bottom, a top, a left wall and a right wall, each side being constructed using a 3D printing process, wherein the 3D printing process deposits material in a continuous bead-like manner to produce the multiple sides by: 1) first depositing material to form an integral and continuous rear end surface associated with each of the bottom, the top, the left wall and the right wall, and then 2) the 3D printing process deposits material in a continuous bead-like manner to build up the initially deposited material, thereby further building up the bottom, the top, the left wall and the right wall to complete the 3D printing of the structure, the 3D printing process finally deposits material to form an integral and continuous front end surface associated with each of the bottom, the top, the left wall and the right wall, wherein, after the 3D printing process is completed, the 3D printed structure is rotated to be placed on the bottom; and after the 3D printing process is completed, a front wall and a rear wall are added to the 3D printed structure, the front wall and the rear wall are operably attached to the 3D printed structure, and the front wall and the rear wall enclose the 3D printed structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a more complete understanding of the present disclosure, reference is now made to the following description taken in conjunction with the accompanying drawings.

[0012] Figure 1 A perspective view of an enclosed habitable structure including a 3D printed structure, ie, a 3D printed structure, is shown according to an exemplary embodiment of the present disclosure.

[0013] Figure 2 A perspective view of another enclosed habitable structure comprising two 3D printed structures according to an exemplary embodiment of the present disclosure is shown, the structure comprising two 3D printed modules, and the two 3D printed modules are attached together to expand the overall size of the enclosed habitable structure.

[0014] Figure 3 A perspective view of a 3D printed structure completed during a 3D printing process according to an exemplary embodiment of the present disclosure is shown.

[0015] Figure 4 A cross-section of a side wall of a 3D printed structure according to an exemplary embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0016] The present disclosure and exemplary embodiments described herein provide methods and systems for generating a 3D printed structure, the structure comprising multiple sides, the multiple sides comprising: a bottom, a top, a left side, and a right side, each side being constructed using a 3D printing process. According to an exemplary embodiment of the present disclosure, the structure is integrally 3D printed by an additive process, thereby producing a 4-sided structure placed on a platform, with the top side as the uppermost surface orientation. The completed structure is then rotated to provide a structure with the appropriate orientation on the bottom outer surface. The front side / wall and the rear side / wall are not 3D printed, but are constructed and / or added using various construction techniques that connect the front side and the rear side to the 3D printed structure. Some features associated with the front side and the rear side may include, but are not limited to, windows, doors, electrical devices, etc.

[0017] The specific details of a single embodiment or various embodiments described herein are set forth in the present application. Any specific details of the embodiments are only for exemplary purposes and should not be interpreted as unnecessary limitations or inferences.

[0018] Before describing the exemplary embodiments in detail, it should be noted that the embodiments reside primarily in the combination of components related to the system. Therefore, in the drawings, the device components are represented by conventional symbols where appropriate, and only those specific details relevant to understanding the embodiments of the present disclosure are shown to avoid obscuring the present disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0019] In general, embodiments described herein relate to processes for three-dimensional (3D) printing of structures. The structures are designed to be occupied or inhabited by at least one person and may include thermal isolation, as well as the ability to include building utilities, while creating methods for interior and exterior customization. The structures are constructed of 3D printable materials (such as polymers and / or recyclable polymers) and printed on their sides so that the structure is printed as a single monolithic print, thereby reducing the time required for production and simplifying the manufacturing process.

[0020] In some embodiments, the deposited material consists of recycled plastic or polyethylene terephthalate glycol (PETG) and is filled with glass fibers.

[0021] refer to Figure 1, an enclosed habitable structure, i.e., a 3D printed structure, is shown according to an exemplary embodiment of the present disclosure including a 3D printed structure. The enclosed habitable structure 100 includes a bottom 101, a top 103, a left wall 105, and a right wall 107. As described herein, after the 3D printing of the bottom 101, the top 103, the left wall 105, and the right wall 107 is completed, the front side / wall / window 109 and the back side / wall / window 111 are added. In the illustrated embodiment, the bottom 101, the top 103, the left wall 105, and the right wall 107 are 3D printed and form a self-supporting structure. Each surface of the bottom 101, the top 103, the left wall 105, and the right wall 107 (collectively referred to as the side walls) can receive a decorative finish, such as drywall, paneling, etc., to allow the consumer to customize the appearance of the interior surface 113 or the exterior surface 115 of the structure 100.

[0022] refer to Figure 2 , showing another second exemplary embodiment of an enclosed habitable structure comprising a 3D printed structure, wherein Figure 2 The habitable structures in 100 are greater than Figure 1 1. The relatively enlarged and enclosed habitable structure includes two connected modular enclosed habitable structures 100. Each habitable structure 100 includes a bottom 101, a top 103, a left wall 105, and a right wall 107. The front habitable structure 100A includes a front side / wall / window 109, and the rear habitable structure 100B includes a rear side / wall / window 111, which are added after the 3D printing of the bottom 101, top 103, left wall 105, and right wall 107 described herein is completed. Each surface of the bottom 101, top 103, left wall 105, and right wall 107 can receive a decorative finish, such as drywall, paneling, etc., to allow the consumer to customize the appearance of the interior surface 113 or exterior surface 115 of the structure 100.

[0023] In some embodiments, the front wall 109 and the rear wall 111 can be made of transparent materials and are not 3D printed. Alternatively, the front wall 109 and the rear wall 111 can be made of a combination of materials, including but not limited to cement board, wood frame, dry wall, paneling, windows, doors, etc.

[0024] The 3D printing process is performed so that the structure 100 is 3D printed on its side. In this way, the rear wall 111 or the front wall 109 is positioned as the base (see Figure 3 ). Once the 3D printing process is complete, the 3D printed structure 100 is rotated so that the bottom 101 becomes the base of the structure 100. Additionally, once the 3D printing process is complete, the structure 100 undergoes various pre-machining and other processes. These pre-machining processes may include the installation of doors, windows, internal mechanical and electrical plumbing (MEP), insulation, flooring, wall finishes, ceiling cladding, and the application of protective exterior finishes.

[0025] Prior to delivery, the structural foundation and utilities may be completed. The foundation ensures that the structure has a suitable base to sit on, while the utilities ensure that the structure is habitable.

[0026] Those skilled in the art will readily appreciate that the size, dimensions, shape, and features of the structures may be modified without obstructing the embodiments described herein.

[0027] refer to Figure 3 , showing another perspective view of a 3D printed structure completed in a 3D printing process according to an exemplary embodiment of the present disclosure, and Figure 4 A cross section of the structure's top / bottom / sidewall 400 is shown. While the cross section shown specifically shows details of the top portion of the 3D printed structure, the cross section details are associated with all sides (top / bottom / left / right) of the 3D printed structure.

[0028] As shown, in the 3D printing process, a continuous outer print bead 421 and a continuous inner print bead 422 are deposited to form a structure. In addition, the continuous inner print bead 422 is printed to create a plurality of extended channels between the continuous outer print bead 421 and the continuous inner print bead 422. The cavity 403 created by these channels provides space for insulation materials, wiring, pipes, etc. In addition, as shown, the inner surface of the continuous inner bead 422 is relatively linear / flat, thereby providing a surface for anchoring wall / ceiling / floor substrate attachment and other internal wall / ceiling / floor covering materials.

[0029] When completed, the side 400 includes an inner surface 113 and an outer surface 115. The interior 401 space between the inner surface 113 and the outer surface 115 includes an insulating material 403. One or more light assemblies 405 and wires 407 are positioned so that the light assemblies 405 protrude through its inner surface 113 and base layer 409. The outer surface 115 may include an ultraviolet (UV) protective layer 411.

[0030] Various details of the disclosed three-dimensional printed structures and systems and methods for three-dimensional printing of structures are now provided.

[0031] According to an exemplary embodiment of the present disclosure, a 3D printed structure and associated printing system and method include a structure having multiple sides, the multiple sides including a bottom, a top, a left wall, and a right wall, each side being constructed using a 3D printing process. The 3D printing process deposits material in a continuous bead-like form to produce the multiple sides:

[0032] 1) first depositing material to form an integral and continuous rear end surface associated with each of the bottom, top, left wall, and right wall, and then

[0033] 2) The 3D printing process deposits material in an additive manner in the form of continuous beads to build the initially deposited material, thereby further building the bottom, top, left wall and right wall to complete the 3D printing of the structure, and the 3D printing process finally deposits material to form an integral and continuous front end surface associated with each of the bottom, top, left wall and right wall, wherein, after the 3D printing process is completed, the 3D printed structure is rotated to be placed on the bottom.

[0034] According to an exemplary embodiment, the deposited material is a recyclable plastic and the 3D printing process includes additively depositing the material using a 3-axis robotic arm operably associated with the positioning of the extruder.

[0035] According to another exemplary embodiment, a 3D printing process includes additively depositing material using an anchored 3-axis robotic arm operably associated with positioning of an extruder and additively depositing material using a rotating platform for positioning a 3D printed structure.

[0036] According to another exemplary embodiment, a 3D printed structure includes a continuous outer print bead and a continuous inner print bead, the continuous inner print bead being printed to create a plurality of channels extending between the continuous outer print bead and the continuous inner print bead.

[0037] According to another exemplary embodiment, after the 3D printing process is completed, the front wall and the rear wall are independently added to the 3D printed structure, the front wall and the rear wall are operably attached to the 3D printed structure, and the front wall and the rear wall enclose the 3D printed structure.

[0038] According to another exemplary embodiment, multiple sides are 3D printed as a complete unitary structure.

[0039] According to another exemplary embodiment, each of the plurality of side surfaces includes an inner surface and an outer surface, and the inner surface and the outer surface are separated by an insulating material.

[0040] According to another exemplary embodiment, the interior surface comprises at least one of: a wall covering, a floor, a wall finish, and a ceiling covering.

[0041] According to another exemplary embodiment, the outer surface includes a UV protective layer.

[0042] It should be understood, however, that all of these and similar terms are associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, it will be apparent from the discussion herein that discussions using terms such as "processing" or "computing" or "calculating" or "determining" or "displaying" and the like throughout the description should be understood to refer to the actions and processes of a computer system or similar electronic computing device that operates on and transforms data represented as physical (electronic) quantities in the computer system's registers and memories into other data similarly represented as physical quantities in the computer system's memories or registers or other such information storage, transmission or display devices.

[0043] It should be understood that variations of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various currently unforeseen or unanticipated substitutions, modifications, changes or improvements may be made thereto by those skilled in the art, and these substitutions, modifications, changes or improvements are also intended to be included in the following claims.

[0044] The exemplary embodiments have been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others after reading and understanding the preceding detailed description. It is intended that the exemplary embodiments be interpreted as including all such modifications and alterations as long as they are within the scope of the appended claims or their equivalents.

Claims

1. A 3D printed structure, comprising: A structure comprising a plurality of sides, the plurality of sides comprising a bottom, a top, a left wall and a right wall, each side being constructed using a 3D printing process, wherein the 3D printing process deposits material additively in the form of continuous beads to produce the plurality of sides by: 1) first depositing material to form an integral and continuous rear end surface associated with each of the bottom, top, left wall and right wall, and then 2) the 3D printing process additively deposits material in the form of continuous beads to build up the initially deposited material, thereby further building up the bottom, top, left wall and right wall to complete the 3D printing of the structure, the 3D printing process finally deposits material to form an integral and continuous front end surface associated with each of the bottom, top, left wall and right wall, wherein the 3D printed structure is rotated to be placed on the bottom after the 3D printing process is completed.

2. The 3D printed structure according to claim 1, wherein: The deposited material is a recyclable plastic and the 3D printing process includes depositing the material additively using a 3-axis robotic arm operably associated with the positioning of the extruder.

3. The 3D printed structure according to claim 1, wherein: The 3D printing process includes additively depositing material using an anchored 3-axis robotic arm operably associated with positioning of an extruder and additively depositing material using a rotating platform for positioning the 3D printed structure.

4. The 3D printed structure according to claim 1, wherein: The 3D printed structure includes a continuous outer print bead and a continuous inner print bead, the continuous inner print bead being printed to produce a plurality of channels extending between the continuous outer print bead and the continuous inner print bead.

5. The 3D printed structure according to claim 1, wherein: The front wall and the rear wall are independently added to the 3D printed structure after the 3D printing process is completed, the front wall and the rear wall are operably attached to the 3D printed structure, and the front wall and the rear wall enclose the 3D printed structure.

6. The 3D printed structure according to claim 1, wherein: The multiple side surfaces are 3D printed into a complete overall structure.

7. The 3D printed structure according to claim 1, wherein: Each of the plurality of side surfaces includes an inner surface and an outer surface, and the inner surface and the outer surface are separated by a heat insulating material.

8. The 3D printed structure according to claim 1, wherein: The interior surface includes at least one of: a wall covering, a floor, a wall finish, and a ceiling cladding.

9. The 3D printed structure according to claim 1, wherein: The outer surface includes a UV protective layer.

10. A method for constructing a 3D printed structure, the 3D printed structure comprising a plurality of sides, the plurality of sides comprising a bottom, a top, a left wall and a right wall, the method comprising: The 3D printing process deposits material additively in the form of continuous beads to produce the multiple sides by: 1) first depositing material to form an integral and continuous rear end surface associated with each of the bottom, top, left and right walls, and then 2) the 3D printing process deposits material additively in the form of continuous beads to build up the initially deposited material, thereby further building up the bottom, top, left wall and right wall to complete the 3D printing of the structure, the 3D printing process ultimately deposits material to form an integral and continuous front end surface associated with each of the bottom, top, left wall and right wall, Wherein, the 3D printed structure is rotated to be placed on the bottom after the 3D printing process is completed.

11. The method for constructing a 3D printed structure according to claim 10, wherein: The deposited material is a recyclable plastic and the 3D printing process includes using a 3-axis robot to deposit the material additively, the 3-axis robot being operably associated with the positioning of the extruder.

12. The method for constructing a 3D printed structure according to claim 10, wherein: The 3D printing process includes additively depositing material using an anchored 3-axis robotic arm operably associated with positioning of an extruder and additively depositing material using a rotating platform for positioning the 3D printed structure.

13. The method for constructing a 3D printed structure according to claim 10, wherein: The 3D printed structure includes a continuous outer print bead and a continuous inner print bead, and the continuous inner print bead is printed to produce a plurality of channels extending between the continuous outer print bead and the continuous inner print bead.

14. The method for constructing a 3D printed structure according to claim 10, wherein: The front wall and the rear wall are independently added to the 3D printed structure after the 3D printing process is completed, the front wall and the rear wall are operably attached to the 3D printed structure, and the front wall and the rear wall enclose the 3D printed structure.

15. The method for constructing a 3D printed structure according to claim 10, wherein: The multiple side surfaces are 3D printed into a complete overall structure.

16. The method for constructing a 3D printed structure according to claim 10, wherein: Each of the plurality of side surfaces includes an inner surface and an outer surface, and the inner surface and the outer surface are separated by a heat insulating material.

17. The method for constructing a 3D printed structure according to claim 10, wherein: The interior surface includes at least one of: a wall covering, a floor, a wall finish, and a ceiling cladding.

18. The method for constructing a 3D printed structure according to claim 10, wherein: The outer surface includes a UV protective layer.

19. A six-sided enclosed habitable structure comprising: A 3D printed structure comprising a plurality of sides, the plurality of sides comprising a bottom, a top, a left wall and a right wall, each side being constructed using a 3D printing process, wherein the 3D printing process additively deposits material in a continuous bead to produce the plurality of sides by: 1) first depositing material to form an integral and continuous rear end surface associated with each of the bottom, top, left wall and right wall, and then 2) the 3D printing process additively deposits material in a continuous bead to build up the initially deposited material, thereby further building up the bottom, top, left wall and right wall to complete the 3D printing of the structure, the 3D printing process finally depositing material to form an integral and continuous front end surface associated with each of the bottom, top, left wall and right wall, wherein the 3D printed structure is rotated to be placed on the bottom after completing the 3D printing process; and A front wall and a rear wall, wherein the front wall and the rear wall are added to the 3D printed structure after the 3D printing process is completed, the front wall and the rear wall are operably attached to the 3D printed structure, and the front wall and the rear wall enclose the 3D printed structure.

20. The six-sided habitable structure according to claim 19, wherein: The deposited material is a recyclable plastic and the 3D printing process includes depositing the material additively using a 3-axis robotic arm operably associated with the positioning of the extruder.

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