Systems and methods for three-dimensional printing of structures and three-dimensional printing of structures

Abstract

The 3D printed structure comprises a structure having multiple sides each constructed using a 3D printing process, where the 3D printing process additively deposits material in successive beads to generate the multiple sides by 1) initially depositing material to form a monolithic and continuous back end surface, and thereafter 2) the 3D printing process additively deposits material in successive beads to grow the initially deposited material and further build a 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 a monolithic and continuous front end surface associated with each of the bottom, top, left wall, and right wall, and the 3D printed structure is rotated to rest on the bottom upon completion of the 3D printing process.

Description

[Technical field]

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 325,488, filed March 30, 2022, and entitled “SYSTEM AND METHOD FOR THE 3-DIMENSIONAL PRINTING OF STRUCTURES.” [Background technology]

[0002] The present disclosure and the exemplary embodiments described herein describe methods and systems for three-dimensional printing techniques, and more particularly, the three-dimensional printing of structures, although 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 be applied to a variety of processes in which material is deposited, bonded, or solidified under computer control to generate a 3D object. Generally, a 3D printable model is generated using a CAD program, via a 3D scanner, or using photogrammetry software. Once a suitable file type (such as an STL file) is generated, the file is processed slice by slice, which transforms the model into a series of thin layers. These layers become the individual steps in the additive manufacturing printing process.

[0004] Traditionally, 3D printing has used polymers for printing. However, methods have been developed that allow the use of metals, ceramics, and other materials. The main differences between the various known processes lie in 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 [Means for solving the problem]

[0005] This Summary is provided to introduce various concepts in a simplified form that are further disclosed in the Detailed Description of the Embodiments. This Summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended to delineate the scope of the claimed subject matter.

[0006] The embodiments described herein relate to 3D printed structures including structures with multiple sides including a bottom, a top, a left side, and a right side, each constructed using a 3D printing process. According to an exemplary embodiment of the present disclosure, the structure is monolithically 3D printed by an additive process that results in a structure placed on a platform and oriented such that the top is the uppermost surface. The completed structure is then rotated onto the bottom exterior surface to provide a properly oriented structure. A front side / wall and a back side / wall that are not 3D printed are constructed and / or added using various construction techniques that attach the front and back sides to the 3D printed structure. Some of the features associated with the front and back sides may include, but are not limited to, windows, doors, electrical fixtures, etc.

[0007] The disclosed embodiments and variations thereof, in some embodiments, provide an efficient and cost-effective means of producing habitable structures using recycled polymers, i.e., recycled plastics. Structures can be 3D printed at remote locations and shipped to consumers with reduced amounts of on-site processing, preparation, and labor.

[0008] According to one exemplary embodiment of the present disclosure, a 3D printed structure is disclosed, the 3D printed structure comprising a structure having a plurality of sides including a bottom, a top, a left wall, and a right wall, each constructed using a 3D printing process, the 3D printing process additively depositing material in successive beads to generate the plurality of sides by 1) initially depositing material to form a monolithic and continuous back end surface associated with each of the bottom, top, left wall, and right wall, thereafter 2) the 3D printing process additively depositing material in successive beads to grow the initially deposited material to further build 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 a monolithic and continuous front end surface associated with each of the bottom, top, left wall, and right wall, and the 3D printed structure is rotated to rest on the bottom upon completion of the 3D printing process.

[0009] According to another exemplary embodiment of the present disclosure, a method of constructing a 3D printed structure including a plurality of sides including a bottom, a top, a left wall, and a right wall is disclosed, the method including a 3D printing process additively depositing material in successive beads to generate a plurality of sides by 1) initially depositing material to form a monolithic and continuous back end surface associated with each of the bottom, top, left wall, and right wall, and thereafter 2) the 3D printing process additively depositing material in successive beads to grow the initially deposited material to further build 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 a monolithic and continuous front end surface associated with each of the bottom, top, left wall, and right wall, and the 3D printing structure is rotated to rest on the bottom upon completion of the 3D printing process.

[0010] In accordance with another exemplary embodiment of the present disclosure, a six-sided encapsulated habitable structure is disclosed, the six-sided encapsulated habitable structure being a 3D printed structure including a plurality of sides including a bottom, a top, a left wall, and a right wall, each of which is constructed using a 3D printing process, the 3D printing process comprising: 1) initially depositing material to form a monolithic and continuous back edge associated with each of the bottom, top, left wall, and right wall; and thereafter, 2) the 3D printing process additively deposits material in successive beads to grow the initially deposited material and further construct the bottom, top, left wall, and right wall. and completing 3D printing of the structure, the 3D printing process additively depositing material in successive beads to generate a plurality of faces by final deposition of material to form monolithic and continuous front end faces associated with each of the bottom, top, left wall, and right wall, the 3D printed structure comprising a 3D printed structure that is rotated to rest on top of the bottom upon completion of the 3D printing process, and a front wall and a back wall that are added to the 3D printed structure after completion of the 3D printing process, the front wall and the back wall being operatively attached to the 3D printed structure to encapsulate 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 descriptions taken in conjunction with the accompanying drawings, in which:

[0012] [Figure 1] FIG. 1 illustrates a perspective view of an encapsulated habitable structure including a 3D printed structure according to an exemplary embodiment of the present disclosure (3D printed structure).

[0013] [Diagram 2] FIG. 2 illustrates a perspective view of another encapsulated habitable structure including two 3D printed structures according to an exemplary embodiment of the present disclosure, the structure including two 3D printed modules attached to increase the overall size of the encapsulated habitable structure.

[0014] [Diagram 3]FIG. 3 illustrates a perspective view of a completed 3D printed structure during a 3D printing process according to an exemplary embodiment of the present disclosure.

[0015] [Figure 4] FIG. 4 illustrates a cross-section of a sidewall of a 3D printed structure according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] The present disclosure and exemplary embodiments described herein provide a method and system for generating a 3D printed structure, the structure comprising multiple sides including a bottom, a top, a left side, and a right side, each constructed using a 3D printing process. According to an exemplary embodiment of the present disclosure, the structure is monolithically 3D printed by an additive process, which results in a four-sided structure, which is placed on a platform and oriented such that the top side is the uppermost surface. The completed structure is then rotated onto the bottom exterior surface to provide a properly oriented structure. A front side / wall and a back side / wall (not 3D printed) are constructed and / or added using various construction techniques that attach the front and back sides to the 3D printed structure. Some of the features associated with the front and back sides may include, but are not limited to, windows, doors, electrical fixtures, etc.

[0017] Specific details of a single embodiment or various embodiments described herein are described in this application. Any specific details of the embodiments are used for illustrative purposes only, and no unnecessary limitations or inferences should be understood therefrom.

[0018] Before describing the exemplary embodiments in detail, it should be noted that the embodiments are primarily given in combination with system-related components, and thus, device components are represented in the drawings, where appropriate, by conventional symbols showing only those specific details relevant for understanding the embodiments of the present disclosure, so as not to obscure the present disclosure with details that would be readily apparent to those skilled in the art having the benefit of the description herein.

[0019] In general, the embodiments described herein relate to a process for three-dimensional (3D) printing of structures. The structures are designed to be occupiable and / or inhabitable by at least one person and may include insulation and capacity for inclusion of building services while creating a means for interior and exterior customization. The structures are constructed from 3D printable materials, such as polymers and / or recycled polymers, and printed on the faces of the structures, whereby the structures are printed in a single monolithic print, thus reducing the time required for production and simplifying the manufacturing process.

[0020] In some embodiments, the deposition material is made of recycled plastic or glycol modified polyethylene terephthalate (PETG) and is fiberglass filled.

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

[0022] Referring to FIG. 2, FIG. 2 illustrates another second exemplary embodiment of an encapsulated habitable structure including a 3D printed structure, where the habitable structure 100 in FIG. 2 is larger than the habitable structure 100 in FIG. 1. This relatively enlarged encapsulated habitable structure includes two modular encapsulated habitable structures 100 that are joined together. 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 front habitable structure 100B includes a back side / wall / window 111, which are added after completion of 3D printing of the bottom 101, top 103, left wall 105, and right wall 107, as described herein. Each surface of the bottom 101, top 103, left wall 105, and right wall 107 can receive a decorative finish, such as drywall, siding, etc., to allow a 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 back wall 111 may be constructed of a transparent material and are not 3D printed. Alternatively, the front wall 109 and the back wall 111 may be constructed from a combination of materials including, but not limited to, cement board, wood framing, drywall, siding, windows, doors, etc.

[0024] The 3D printing process is performed such that the structure 100 is 3D printed on that face. In that case, the back wall 111 or the front wall 109 is positioned as the base (see FIG. 3). Once the 3D printing process is completed, 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 completed, the structure 100 undergoes various pre-fabrication and other processes. These pre-fabrication processes may include installing doors, windows, interior MEP, insulation, flooring, wall finishes, ceiling cladding, and applying protective exterior finishes.

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

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

[0027] Referring to Figure 3, another perspective view of a completed 3D printed structure during a 3D printing process according to an exemplary embodiment of the present disclosure is illustrated, and Figure 4 illustrates a cross section of the top / bottom / sidewall 400 of the structure. The cross section specifically shown shows details of the top portion of the 3D printed structure, however, cross section details are associated with all sides (top / bottom / left / right) of the 3D printed structure.

[0028] As shown, during the 3D printing process, continuous exterior printed beads 421 and continuous interior printed beads 422 are deposited to form a structure. Additionally, the continuous interior printed beads 422 are printed to generate a plurality of channels extending between the continuous exterior printed beads 421 and the continuous interior printed beads 422. The cavities 403 resulting from these channels provide space for insulation, electrical wiring, plumbing, etc. Additionally, as shown, the interior surface of the continuous interior beads 422 is relatively linear / flat to provide a fastening surface for wall / ceiling / floor substrate attachment and other interior wall / ceiling / floor covering materials.

[0029] When completed, face 400 includes interior surface 113 and exterior surface 115. The interior 401 space between interior surface 113 and exterior surface 115 includes insulation 403. One or more lighting assemblies 405 and electrical wiring 407 are positioned such that the lighting assemblies 405 protrude through interior surface 113 and its substrate 409. Exterior 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 provided herein.

[0031] According to an exemplary embodiment of the present disclosure, a 3D printed structure and associated printing system and method includes a structure having multiple sides including a bottom, a top, a left wall, and a right wall, each of which is constructed using a 3D printing process. 1) first depositing material to form a monolithic and continuous back edge associated with each of the bottom, top, left wall, and right wall; and thereafter; 2) the 3D printing process additively deposits material in successive beads, growing the initially deposited material to further build up the bottom, top, left wall, and right wall, completing the 3D printing of the structure, and the 3D printing process finally deposits material to form a monolithic and continuous front end surface associated with each of the bottom, top, left wall, and right wall. additively depositing material in successive beads to generate a plurality of surfaces by The 3D printed structure is rotated so that it rests on top of the base upon completion of the 3D printing process.

[0032] According to an exemplary embodiment, the material being deposited is recycled plastic, and the 3D printing process includes the use of a three-axis robotic arm operatively associated with positioning an extruder to additively deposit the material.

[0033] According to another exemplary embodiment, the 3D printing process includes the use of a fixed three-axis robotic arm operatively associated with positioning an extruder for additively depositing material, and a rotating platform for positioning the 3D printed structure for additively depositing material.

[0034] According to another exemplary embodiment, a 3D printed structure includes continuous exterior printed beads and continuous interior printed beads, the continuous interior printed beads being printed to generate a plurality of channels extending between the continuous exterior printed beads and the continuous interior printed beads.

[0035] According to another exemplary embodiment, the front and back walls are added independently to the 3D printed structure after the 3D printing process is completed, and the front and back walls are operably attached to the 3D printed structure, such that the front and back walls encapsulate the 3D printed structure.

[0036] According to another exemplary embodiment, multiple surfaces are 3D printed as a complete monolithic structure.

[0037] According to another exemplary embodiment, each of the plurality of sides includes an interior surface and an exterior surface, the interior surface and the exterior surface being separated by insulation.

[0038] According to another exemplary embodiment, the interior surface includes at least one of the following: a wall covering, a flooring, a wall finish, and a ceiling cladding.

[0039] According to another exemplary embodiment, the exterior surface includes a UV protective layer.

[0040] It should be understood, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, and as will be apparent from the discussion herein, discussions throughout the description utilizing terms such as "processing" or "computing" or "calculating" or "determining" or "displaying" should be understood to refer to the actions and processes of a computer system or similar electronic computing device that manipulates and transforms data represented as physical (electronic) quantities in the computer system's registers and memories into other data that are similarly represented as physical quantities in the computer system's memory or registers or other such information storage, transmission or display device.

[0041] It will 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 presently unforeseen or unanticipated alternatives, modifications, variations, or improvements thereon may subsequently be made by those skilled in the art, which are also intended to be encompassed by the following claims.

[0042] Exemplary embodiments have been described with reference to preferred embodiments. Obviously, modifications and alterations will occur to those skilled in the art upon reading and understanding the foregoing detailed description. It is intended that the exemplary embodiments be construed as including all such modifications and alterations insofar as they fall within the scope of the appended claims or their equivalents.

Claims

1. 1. A 3D printed structure, the 3D printed structure comprising a structure having a plurality of sides, the plurality of sides including a bottom, a top, a left wall, and a right wall, each of which is constructed using a 3D printing process; The 3D printing process comprises: 1) first depositing a material to form a monolithic and continuous back edge associated with each of said bottom, said top, said left wall, and said right wall; and thereafter; 2) the 3D printing process additively deposits material in successive beads, growing the initially deposited material to further build up the bottom, top, left wall, and right wall, completing the 3D printing of the structure, and the 3D printing process finally deposits material to form a monolithic and continuous front edge associated with each of the bottom, top, left wall, and right wall. additively depositing material in successive beads to generate said plurality of surfaces by The 3D printed structure is rotated to rest on the bottom upon completion of the 3D printing process.

2. 10. The 3D printed structure of claim 1 , wherein the deposited material is recycled plastic and the 3D printing process includes use of a three axis robotic arm operatively associated with positioning an extruder to additively deposit the material.

3. 2. The 3D printed structure of claim 1 , wherein the 3D printing process includes the use of a fixed three-axis robotic arm operatively associated with positioning the extruder for additively depositing the material and a rotating platform for positioning the 3D printed structure for additively depositing the material.

4. 2. The 3D printed structure of claim 1, wherein the 3D printed structure includes continuous exterior printed beads and continuous interior printed beads, the continuous interior printed beads being printed to generate a plurality of channels extending between the continuous exterior printed beads and the continuous interior printed beads.

5. 2. The 3D printed structure of claim 1 , wherein a front wall and a back wall are independently added to the 3D printed structure after the 3D printing process is completed, the front wall and the back wall are operatively attached to the 3D printed structure, and the front wall and the back wall encapsulate the 3D printed structure.

6. 10. The 3D printed structure of claim 1 , wherein the multiple surfaces are 3D printed as a complete monolithic structure.

7. 10. The 3D printed structure of claim 1 , wherein each of the plurality of sides includes an interior surface and an exterior surface, the interior and exterior surfaces being separated by insulation.

8. 10. The 3D printed structure of claim 1, wherein the interior surface comprises at least one of the following: a wall covering, a flooring, a wall finish, and a ceiling cladding.

9. The 3D printed structure of claim 1 , wherein the exterior surface includes a UV protective layer.

10. 1. A method of constructing a 3D printed structure including a plurality of faces including a bottom, a top, a left wall, and a right wall, the method comprising: The 3D printing process 1) first depositing a material to form a monolithic and continuous back edge associated with each of said bottom, said top, said left wall, and said right wall; and thereafter; 2) the 3D printing process additively deposits material in successive beads, growing the initially deposited material to further build up the bottom, top, left wall, and right wall, completing the 3D printing of the structure, and the 3D printing process finally deposits material to form a monolithic and continuous front edge associated with each of the bottom, top, left wall, and right wall. additively depositing material in successive beads to generate said plurality of surfaces by The method of claim 1, wherein the 3D printed structure is rotated to rest on top of the base upon completion of the 3D printing process.

11. 11. The method of constructing a 3D printed structure of claim 10, wherein the material deposited is recycled plastic and the 3D printing process includes use of the three-axis robotic arm operatively associated with positioning the extruder to additively deposit the material.

12. 11. The method of constructing a 3D printed structure of claim 10, wherein the 3D printing process includes the use of a fixed three-axis robotic arm operatively associated with positioning the extruder for additively depositing the material and a rotating platform for positioning the 3D printed structure for additively depositing the material.

13. 11. The method of constructing a 3D printed structure of claim 10, wherein the 3D printed structure includes continuous exterior printed beads and continuous interior printed beads, the continuous interior printed beads being printed to generate a plurality of channels extending between the continuous exterior printed beads and the continuous interior printed beads.

14. 11. The method of constructing a 3D printed structure of claim 10, wherein a front wall and a back wall are added independently to the 3D printed structure after the 3D printing process is completed, the front wall and the back wall are operably attached to the 3D printed structure, and the front wall and the back wall encapsulate the 3D printed structure.

15. The method of constructing a 3D printed structure of claim 10 , wherein the multiple surfaces are 3D printed as a complete monolithic structure.

16. The method of constructing a 3D printed structure of claim 10 , wherein each of the plurality of sides includes an interior surface and an exterior surface, the interior surface and the exterior surface being separated by insulation.

17. 11. The method of constructing a 3D printed structure of claim 10, wherein the interior surface comprises at least one of the following: a wall covering, a flooring, a wall finish, and a ceiling cladding.

18. The method of constructing a 3D printed structure of claim 10 , wherein the exterior surface includes a UV protective layer.

19. 1. A six-sided enclosed habitable structure, comprising: a 3D printed structure including a plurality of sides including a bottom, a top, a left wall, and a right wall, each of which is constructed using a 3D printing process, the 3D printing process additively depositing material in successive beads to generate the plurality of sides by: 1) initially depositing material to form a monolithic and continuous back edge associated with each of the bottom, the top, the left wall, and the right wall; thereafter, the 3D printing process additively depositing material in successive beads to grow the initially deposited material to further construct the bottom, the top, the left wall, and the right wall, completing the 3D printing of the structure; and finally, the 3D printing process depositing material to form a monolithic and continuous front edge associated with each of the bottom, the top, the left wall, and the right wall, and the 3D printed structure is rotated to rest on top of the bottom upon completion of the 3D printing process; a front wall and a back wall that are added to the 3D printed structure after the 3D printing process is completed; Equipped with A six-sided encapsulated habitable structure, wherein the front and back walls are operably attached to the 3D printed structure, the front and back walls encapsulating the 3D printed structure.

20. 20. The six sided encapsulated habitable structure of claim 19, wherein the deposited material is recycled plastic and the 3D printing process includes use of the three axis robotic arm operatively associated with positioning the extruder to additively deposit the material.

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