Flexible mold for the rapid deployment of structures

Abstract

Disclosed herein are systems and methods related to the construction of solid structures. In various implementations, the structures are formed by obtaining a flexible mold having a first membrane defining a first surface and a second surface, and a second membrane defining a third surface and a fourth surface. The first surface at least partially defines a first volume, and the second surface at least partially defines a second volume. The flexible mold further defines at least one inlet port in fluid communication with the first volume. A fluidic building material flows through the at least one inlet port into the first volume of the flexible mold, and an inflation fluid flows into the second volume of the flexible mold to expand the second volume of the flexible mold. The fluidic building material can then change from a fluid to a solid structure.

Description

BACKGROUND

[0001] Rapid and automated construction of concrete structures is highly desirable and has many applications including low-cost housing, disaster relief efforts, and military applications. In commercial real estate development, reducing labor costs and project time can readily create affordable housing, which is particularly advantageous in remote areas. In disaster relief efforts, the intent is to construct low-cost temporary housing very rapidly to provide shelter for civilians and rescue workers. In military applications, it is crucial to rapidly construct shelters to protect soldiers and house equipment. Furthermore, military applications benefit from quick, automated construction to remove soldiers from the line of fire during the construction.

[0002] Three-dimensional (3D) printing of concrete structures has recently gained significant attraction as a possible solution for the abovementioned needs. However, 3D printing technology faces many technological challenges, and despite 30 years of research in this area, these challenges limit its widespread use. For example, 3D structure printing often is limited by low speeds of production (i.e., printing speed), high cost of robotics and software development, stability of the mixture during extrusion and printing layers on top of each other, achieving and maintaining desirable mixture rheology, printed interface weakness and cracking, and perhaps most importantly, incompatibility of 3D printing of concrete with the mainstream concrete industry. Notably, the concrete mixtures that are produced daily at high volumes by the concrete industry cannot be used for 3D printing. This problem is compounded by the fact that different printing technologies and printers require different mixtures, none of which can currently be produced by the mainstream concrete industry.SUMMARY

[0003] Disclosed herein are methods for forming a solid structure including obtaining a flexible mold having a first membrane defining a first surface and a second surface, and a second membrane defining a third surface and a fourth surface, such that the first surface of the first membrane at least partially defines a first volume, and the second surface at least partially defines a second volume, the flexible mold defining at least one inlet port in fluid communication with the first volume; causing a fluidic building material to flow through the at least one inlet port into the first volume of the flexible mold; causing an inflation fluid to flow into the second volume of the flexible mold to expand the second volume of the flexible mold; and allowing the fluidic building material to transition from a fluid to a solid structure (e.g., by dying or curing). Also disclosed herein are systems for forming a solid structure including a flexible mold including a first membrane defining a first surface and a second surface, and a second membrane defining a third surface and a fourth surface, wherein the first surface of the first membrane at least partially defines a first volume and the second surface at least partially defines a second volume, wherein the flexible mold defines at least one inlet port in fluid communication with the first volume.

[0004] The present disclosure addresses many of the above-mentioned issues related to 3D printing of structures while remaining low cost and compatible with the current industry and, therefore, can be adopted very rapidly. The presently disclosed systems and methods provide several advantages over 3D printing. First, the systems and methods are compatible with the current practices of the concrete industry. That is, a variety of materials and concrete mixtures can be used. While a variety of building materials can be used, Self-Consolidating Concrete (SCC) is ideal for this application. SCC is a mature concrete technology and the majority of the ready mix producers in the US, and the developed parts of the world, can produce these mixtures with minimal effort. There are even standard codes for SCC published by ACI (American Concrete Institute). However, the disclosed technology is not limited to SCC, but can also employ portland cement-based or non-portland cement-based concrete mixtures, and / or other concrete materials including, but not limited to, geopolymers, alkali-activated concrete, and Calcium Sulfoaluminate (CAS) based concretes, or concretes made of a flowable cementitious slurry. Concrete materials with an epoxy binder can also be used provided the material can be easily pumped and have extended set time. Other types of cementitious materials that can be used include calcium hydroxide (Ca(OH)2) based slurries that solidify with carbon dioxide (CO2) as well as microbial-induced calcium carbonate precipitation mixtures. Further, the disclosed technology can be used to construct thin and ultrathin shell structures using concrete and / or Ultra High Performance Concrete (UHPC). A second benefit of the disclosed systems and methods is that construction using this technology is very rapid and low-cost. Some implementations use a concrete pump and concrete that comes out of ready-mix concrete trucks. The speed of the construction can be driven by the speed at which concrete can be produced and pumped. The process can also be fully automated resulting in cost savings by reducing or eliminating labor.

[0005] Third, the air pressure required for this technology can be relatively small and can be easily achieved using industrial air pumps. Lastly, the inflatable membrane materials can be made of industrially available rubbers (e.g., the kind used in tire and tube manufacturing), plastics, and even synthetic or natural woven or nonwoven fabrics.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Various objects, aspects, features, and advantages of the disclosure will become more apparent and better understood by referring to the detailed description taken in conjunction with the accompanying drawings, in which like reference characters identify corresponding elements throughout. In the drawings, like reference numbers generally indicate identical, functionally similar, and / or structurally similar elements.

[0007] FIG. 1 is a cross-sectional side view of a flexible mold for forming a solid structure using a concrete-based material. The flexible mold shows two inlet ports and an outlet port in fluid communication with a first volume.

[0008] FIG. 2 is a cross-sectional perspective view of a flexible mold having a first and second membrane.

[0009] FIG. 3 is a cross-sectional side view of a multilayer flexible mold having a first, second, and third membrane.

[0010] FIG. 4 is a perspective view of a solid structure having protrusion elements.

[0011] FIG. 5 is a perspective view of a truss structure formed according to one aspect of the present disclosure.

[0012] FIGS. 6A-6C are perspective views of solid structures formed according to the present method. The solid structure in FIG. 6A depicts a dome-shaped structure with a 2 ft. diameter and 1 ft. height. FIGS. 6B and 6C show 4 ft. diameter dome-shaped structures with a height of 2 ft.

[0013] The solid structures shown in FIGS. 6B and 6C additionally include integrated fabric mesh as reinforcement.

[0014] FIG. 7 is a cross-sectional side view of various shape configurations of a flexible mold.

[0015] FIG. 8 is a perspective view of a truss structure formed according to one aspect of the present disclosure.

[0016] FIG. 9 is a perspective view of a truss structure formed according to one aspect of the present disclosure.

[0017] FIG. 10 depicts the inflation of a dome-shaped truss structure with an inflation fluid and fluidic building material from a substantially flat configuration to an expanded state.

[0018] FIG. 11 is a cross-sectional perspective view of a truss structure formed in a dome-shape.DETAILED DESCRIPTIONDefinitions

[0019] In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:

[0020] Throughout the description and claims of this specification the word “comprise” and other forms of the word, such as “comprising” and “comprises,” means including but not limited to, and is not intended to exclude, for example, other additives, components, integers, or steps.

[0021] As used in the description and the appended claims, the singular forms “a,”“an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, a reference to “a composition” includes mixtures of two or more such compositions, a reference to “the compound” includes mixtures of two or more such compounds, reference to “an agent” includes a mixture of two or more such agents, and the like.

[0022] The term “substantially” means that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations, and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

[0023] “Exemplary” means “an example of” and is not intended to convey an indication of a preferred or ideal implementation. “Such as” is not used in a restrictive sense, but for explanatory purposes.

[0024] It is understood that throughout this specification the identifiers “first,”“second,” and the like are used solely to aid the reader in distinguishing the various components, features, or steps of the disclosed subject matter. The identifiers “first,”“second,” and the like are not intended to imply any particular order, amount, preference, or importance to the components or steps modified by these terms.

[0025] The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB.

[0026] Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

[0027] As used herein, the term “flexible mold” is intended to refer to an object having one or more flexible membranes configured for producing or shaping a material to a final structure. The molds can include flexible membranes made of only deformable materials or can include molds having both flexible and rigid / semi-rigid elements.System

[0028] Disclosed herein are systems for forming a solid structure, such as the one shown in FIGS. 1 and 2. The system includes a flexible mold 100 comprising a first membrane110 defining a first surface 112 and a second surface 114, and a second membrane 120 defining a third surface 122 and a fourth surface 124. The first surface 112 and third surface 122 at least partially define a first volume 140 and the second surface 114 at least partially defines a second volume 142. The flexible mold 100 further defines at least one inlet port 150 in fluid communication with the first volume 140.

[0029] Various aspects include an inflation pump in fluid communication with the second volume of the flexible mold. The inflation pump is configured to introduce an inflation fluid into the second volume, thereby increasing said volume. In some implementations, the system further includes a material injection component in fluid communication with one or more of the at least one inlet ports configured to direct a fluidic building material through the at least one inlet port to the first volume.Method

[0030] Disclosed herein are methods of forming a solid structure. Various implementations include obtaining a flexible mold having a first membrane defining a first surface and a second surface, and a second membrane defining a third surface and a fourth surface, such that the first surface and third surface at least partially define a first volume, and the second surface at least partially defines a second volume, the flexible mold defining at least one inlet port in fluid communication with the first volume; causing a fluidic building material to flow through the at least one inlet port into the first volume of the flexible mold; causing an inflation fluid to flow into the second volume of the flexible mold to expand the second volume of the flexible mold; and allowing the fluidic building material to transition from a fluid to a solid structure.

[0031] FIGS. 1-2 illustrate a flexible mold 100 according to one implementation of the present method. The flexible mold 100 has a first membrane 110 defining a first surface 112 and a second surface 114, and a second membrane 120 defining a third surface 122 and a fourth surface 124. The first surface 112 and third surface 122 at least partially define a first volume 140. The second surface 114 at least partially defines a second volume 142. As shown in FIG. 1, the flexible mold 100 further defines at least one inlet port 150 in fluid communication with the first volume 140. A fluidic building material 130 can flow through the at least one inlet port 150 into the first volume 140 of the flexible mold 100. The flexible mold 100 shown in FIG. 1 additionally shows an outlet port 160 in fluid communication with the first volume to provide a vent for air displaced by the fluidic building material 130. In some implementations, the flexible mold does not include an outlet port, such as where one or more membrane layers include a fabric material permeable to air.

[0032] As an example, a semi-permeable membrane can be used such that the fluidic building material is freely flowable within the first volume but is prevented or substantially restricted from escaping through the membrane. Any air or other trapped gases within the first volume, however, can still readily diffuse through the semi-permeable membrane, allowing the fluidic building material to fill its place in the first volume. Under this configuration, it is beneficial to use a semi-permeable membrane having pores that are resistant to saturation by the fluidic building material such that the diffusion of the air or trapped gases through the semi-permeable membrane is not substantially restricted as the fluidic building material is added to the volume.

[0033] Various implementations of the present method also include causing the fluidic building material to flow through the at least one inlet port into the first volume of the flexible mold before causing an inflation fluid to flow into the second volume of the flexible mold to expand the second volume of the flexible mold.

[0034] In some aspects, the flexible mold includes two or more membrane layers (e.g., 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, or more than 10 membrane layers), such as the trilayer mold depicted in FIG. 3. In FIG. 3, a flexible mold 200 having a first membrane 210 defining a first surface 212 and a second surface 214, a second membrane 220 defining a third surface 222 and a fourth surface 224, and a third membrane 260 defining a fifth surface 262. The first surface 212 and third surface 222 at least partially define a first volume 240. The second surface 214 at least partially defines a second volume 242. The fifth surface 262 of the third membrane 260 and the fourth surface 224 of the second membrane 220 at least partially define a third volume 244. In FIG. 3, a first fluidic building material 230 flows through an at least one first inlet port 250. In some aspects, the method includes causing a second fluidic building material to flow through the second inlet port into the third volume of the flexible mold. The flexible mold 200 depicted in FIG. 3 defines a second inlet port 252 in fluid communication with the third volume 244 and a second fluidic building material 232 is shown within the third volume 244. In various aspects, the first fluidic building material is a different material than the second fluidic building material. However, in some aspects, the first fluidic building material and the second fluidic building material are the same material.

[0035] In various implementations, the membranes can comprise one or more electrically conductive materials to provide electromagnetic shielding or sensory function of the structure (e.g., damage detection). In some implementations, membranes can include a blast-resistant material to add functionalities such as blast and projectile penetration resistance. The blast-resistant material can be formed from any suitable rigid or flexible material and may include an elastically deformable, shock absorbing material. For example, the blast-resistant material can include a flexible high polymer thermoplastic resin, including both crystalline and amorphous thermoplastic polymers. By way of example, said thermoplastic polymers can include acrylonitrile-butadiene-styrene (ABS) copolymers, styrene, cellulosic polymers, polycarbonates, nylons, polyethylene, polypropylene, polyurethane, or a combination thereof.

[0036] The flexible mold can also include various supporting components to increase the stability of the structure or to otherwise reinforce the structure. For example, various implementations include a flexible mold comprising one or more tensioning members extending through the first volume. In some aspects, the one or more tensioning members extend from the first surface to the third surface. The flexible mold can, in some examples, include one or more post-tensioning ducts extending through the first volume. In implementations having multiple layers, supporting components can be extended between adjacent surfaces, such as from the fourth surface to the fifth surface discussed above.

[0037] To increase the stability of the solid structure and provide reinforcement to the slurry after solidifying, various implementations can include a mesh layer disposed between adjacent membranes. As shown in FIG. 4, the solid structure 300 includes a mesh layer 320 disposed between a first and second membrane. In some aspects, the mesh layer is at least partially embedded within the fluidic building material after the fluidic building material flows through the at least one inlet port into the first volume of the flexible mold. The mesh can comprise, for example, a metal, fabric, basalt, glass, or a polymeric material. The structure 300 shown in FIG. 4 further includes protrusion elements 310, which can provide enhanced properties, such as blast resistance and thermal regulation.

[0038] One or more of the membranes can include a flexible membrane. The term “flexible membrane” as used herein refers to any sheet-like or otherwise relatively thin layer of deformable material which is mechanically deformed in response to an applied force. The flexible membrane can be elastic such that it provides a resistance to bending and / or stretching by an applied force, which resistance is proportional to an amount of the displacement / stretching of the membrane from an equilibrium configuration without such force applied. Examples of suitable materials for the flexible membranes include, for example, rubber, latex, flexible polymers, and / or textiles. In some implementations, each of the membrane layers includes a flexible membrane. However, in some implementations, the first membrane or the second membrane includes a rigid material. The term “rigid material” as used herein is intended to encompass any rigid materials, semi-rigid (partially flexible materials), and substantially any materials that are not or are partially flexible or elastic, i.e. that display no or very low elastic deformation (e.g. bending, stretching, twisting) under load. For instance, the rigid material can have a Young modulus of higher than 5, higher than 10, higher than 30, higher than 50, higher than 100 or higher than 200 GPa higher than or up to 1000 GPa. In some implementations, the flexible mold is removed following the transition of the fluidic building material from a fluid to a solid structure. However, in other aspects, the flexible mold is retained and is incorporated into the resulting solid structure.

[0039] In various implementations, the one or membranes can be permeable or semi-permeable to a specific gas (e.g., CO2) such that the gas can facilitate hardening or enhance structural properties of the fluidic building material. In various implementations, the inner membrane of the structure is supplied with an inflation fluid comprising a gas that can diffuse through the one or more membranes to harden the fluidic building material. For example, a calcium hydroxide-based cement can contact a carbon dioxide-containing gas to undergo a carbonation reaction. The carbonation of calcium hydroxide with carbon dioxide can produce calcium carbonate crystals in the cement, which can provide increased strength and durability.

[0040] The calcium carbonate further reduces the porosity of the cement, reducing the structure's permeability to water. In some examples, the inflation fluid includes a mixture of air and CO2. In various implementations, the inflation fluid includes a carbon dioxide-containing gas having a carbon dioxide concentration of at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 70%, at least 80%, or at least 85%.

[0041] FIGS. 6A-6C show several exemplary solid structures formed according to the present disclosure. Although the solid structures of FIGS. 6A-6C depict dome-shaped structures with a 2 ft. diameter and 1 ft. height, structures with larger dimensions can also be produced. For example, the solid structures can have a height from 1 ft. to 100 ft. (e.g., from 1 ft. to 50 ft., from 10 ft. to 50 ft., from 10 ft. to 40 ft., from 10 ft. to 30 ft., from 10 ft. to 20 ft., from 20 ft. to 50 ft., from 20 ft. to 40 ft., or from 20 ft. to 30 ft.) and can have widths (e.g. diameters) from 1 ft. to 100 ft. (e.g., from 1 ft. to 50 ft., from 10 ft. to 50 ft., from 10 ft. to 40 ft., from 10 ft. to 30 ft., from 10 ft. to 20 ft., from 20 ft. to 50 ft., from 20 ft. to 40 ft., or from 20 ft. to 30 ft.). The flexible mold, and therefore the solid structure, can be also arranged in various configurations and shapes, such as those shapes depicted in FIG. 7. In some aspects, the solid structure is substantially dome-shaped. In other aspects, the solid structure is substantially pyramid-shaped. In further instances, the solid structure is semi-cylindrical shaped. In some examples, the solid structure is substantially rectangular-shaped. The disclosed systems and methods can rapidly produce large structures with low energy requirements.

[0042] Various implementations include causing an inflation fluid to flow into the second volume of the flexible mold to expand the second volume of the flexible mold. Advantageously, the inflation of the second volume can utilize low-pressure to inflate the second volume and raise the structure. In some implementations, the inflation fluid is a gas that inflates the second volume to a pressure. For example, the pressure of the inflation fluid within the second volume can be less than or equal to 500 psi, such as less than or equal to 400 psi, less than or equal to 300 psi, less than or equal to 200 psi, less than or equal to 100 psi, or less than or equal to 50 psi. Various implementations additionally include modulating the pressure of the inflation fluid within the second volume between a first pressure and a second pressure. Modulating the pressure can facilitate the movement of the fluidic building material through the flexible mold.

[0043] In another implementation, a flexible mold for forming a solid truss structure is described. As shown in FIG. 5, the flexible mold 400 includes a first membrane 410 and a second membrane 420 defining a series of conduits in a truss-forming framework. The conduits of the second membrane 420 define a first volume therewithin for receiving a fluidic building material. The first membrane 410 is interiorly positioned with respect to the second membrane 420 and defines a second volume opposite the second membrane 420. As used herein, the term “truss-forming framework” refers to an arrangement of substantially flexible conduits configured to receive a fluidic building material that can harden to form a truss structure. Initially, the first membrane 410 and second membrane 420 of the flexible mold 400 are in a substantially unexpanded state. A fluidic building material is injected through a first inlet port 450 into the first volume of the second membrane 420. An inflation fluid flows through an inflation port 460 into the second volume to inflate the first membrane 410 into an expanded state such that the second membrane 420 is adjusted to the shape of a truss structure. After expanding the first membrane 410 to an expanded state and flowing a fluidic building material to substantially fill the second membrane 420, the fluidic building material can then harden to form a rigid / semi-rigid truss structure. FIG. 10 shows the inflation process Although the first membrane 410 and second membrane 420 of the flexible mold 400 in FIG. 5 are shown as a single connected piece, in some implementations, the first membrane and second membrane are not fixedly attached. Multiple inlet ports can also be used such that the fluidic building material is added at several locations in the first volume of the second membrane. The inclusion of multiple ports can provide uniform distribution of the fluidic building material within the second membrane and can further enhance the speed at which material is added. In various examples, it is advantageous to remove the first and / or second membrane after the fluidic building material is hardened. However, in some implementations, the first and / or second membranes are incorporated into the final truss structure.

[0044] FIG. 8 and FIG. 9 show several example truss-forming structures in an expanded state. For example, the truss-forming structure shown in FIG. 8 includes a pattern of distributed conduits (e.g., the first volume) which can receive a fluidic building material. The fluidic building material enters the first volume and extends substantially throughout the various conduit pathways to substantially fill an outer portion of the flexible mold. Before, during, or after the fluidic building material is disposed through the conduits, an inflation fluid (e.g., air) can be added to expand the flexible mold to an expanded state. An example of an expansion of of flexible mold for forming truss structures can be found in FIG. 10. In the left panel of FIG. 10, the flexible mold is in an unexpanded state where it is substantially flat. After the inflation fluid has been added, the flexible mold transitions to an expanded state (shown in the right panel of FIG. 10), positioning the conduits towards a truss-forming structure. Fluidic material can be disposed through the conduits, where it can subsequently transition to a solid truss structure. A cross section of an example solid truss-forming struction is shown in FIG. 11.

[0045] FIG. 10 shows Although each of the truss-forming structures shown in FIG. 5, FIG. 8, FIG. 9, FIG. 10, and FIG. 11 include a substantially-dome shape truss structure, other arrangements can also be formed. For example, various implementations include truss-structures that is substantially pyramid-shaped. In some implementations, the truss-structure is substantially semi-cylindrically shaped. In further instances, the solid truss-structure is substantially rectangular-shaped.Fluidic Building Material

[0046] Various fluidic building materials can be used to form a solid structure according to the present disclosure. Preferably, the fluidic building material includes a material capable of flowing into the flexible mold without large amounts of resistance. For example, the fluidic building material can include a slurry. As used herein, “slurry” refers to a flowable mixture of particles dispersed in a fluid carrier. Generally, the fluid carrier comprises water, however, other fluid carriers can also be used. In various aspects, the fluidic building material comprises a cementitious material, such as a cementitious composite. For example, the fluidic building material can include slurry comprising a Portland cement, concrete, mortar, or grout or a non-Portland cement, concrete, mortar, or grout, or a combination thereof. As used herein, the term “Portland cement” means cement compositions comprising calcium silicate compounds, such as those listed by the American Society for Testing and Materials (ASTM) Types I-V (“ordinary Portland cement”, or “OPC”), and White Portland cement (“WPC”)). Other types of cementitious materials can also be used, for example, calcium hydroxide-based slurries that solidify with carbon dioxide (CO2) as well as bioconcretes. The term “bioconcrete” generally refers to concrete that is formed by biological organisms. For example, bioconcretes include cementitious materials formed or reinforced by biomineralization. As used herein, the term “biomineralization” refers to the ability of a biological organism or biomolecule, i.e., a bioremediase enzyme, to produce or catalyze the formation of minerals from a biological process. Biologically produced minerals include, but are not limited to, silicates, carbonates, calcium phosphates, etc. In various implementations, the fluidic building material comprises a microbial induced calcium carbonate precipitation (MICP) mixture.

[0047] In some implementations, the fluidic building material includes a slurry comprising plain concrete, a fiber reinforced concrete, a lightweight concrete, a high early strength concrete, a heavy aggregate concrete, a radiation shielding concrete, a foam concrete, a limecrete, a high strength concrete, or a combination thereof. In some aspects, the fluidic building material comprises a high-performance or ultra-high-performance concrete.

[0048] Various implementations include a slurry comprising a fiber reinforced concrete. Examples of inorganic fibers include, for example, glass wool, rock wool, basalt fibers, slag wool, ceramic fibers containing melts of aluminum and / or silicon dioxide, metal oxides, pure silicon dioxide fibers, for example silica fibers. Organic fibers, for example, cellulose fibers, textile fibers and / or polymer fibers, may also be used as additives to the fiber reinforced concrete. In some aspects, the fiber reinforced concrete includes continuous and / or discontinuous short fiber glass, carbon, steel, basalt, a polymer, or combinations thereof. The length of the fibers will depend on the specific mechanical requirements of the structure. In various implementation, the average fiber length is from 1 mm to 100 mm (e.g., from 1 to 50 mm, from 1 to 25 mm, from 1 to 15 mm, or from 1 to 10 mm).

[0049] Other materials, such as polymeric materials, can also be used in the formation of structures. The term “polymeric materials” means a material, compound or composition that is defined by or includes at least one polymer or a derivative thereof. Polymeric compositions can also include additives, such as ultra-violet light stabilizers, fillers, plasticizers, tints, and other additives, such as glass or wood fiber. The polymeric material can, in some implementations, be an expandable polymeric foam that can be used to provide thermal insulation to the structure.

[0050] Examples of suitable polymeric materials include vinyl polymers, such as vinyl aromatic polymers including polystyrene, polypropylene; and polyurethanes. Blends of various polymers can also be used. The polymeric materials including those mentioned above can be present in the form of a foam either open-or closed-cell.

[0051] The fluidic building materials of the present disclosure can transition from a fluid to a solid structure by a solidification process. The solidification of the fluidic building material will depend on a number of factors including, the building material used, environmental factors, as well as the particular building conditions. By way of example, the solidification of the fluidic building material can be realized with chemical reactions, curing, heating / cooling, applied pressure, radiation (e.g., UV light), drying (e.g., passive or active drying), crosslinkage, crystallization, or any other mechanism known in the art.

[0052] The systems and methods of the appended claims are not limited in scope by the specific systems and methods described herein, which are intended as illustrations of a few aspects of the claims and any systems and methods that are equivalent are intended to fall within the scope of the claims. Various modifications of the systems and methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. Further, while only certain representative systems and method steps disclosed herein are specifically described, other combinations of the systems and method steps also are intended to fall within the scope of the appended claims, even if not specifically recited. Thus, a combination of steps, elements, components, or constituents may be explicitly mentioned herein; however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated.

Claims

1. A method of forming a solid structure, the method comprising:obtaining a flexible mold having a first membrane defining a first surface and a second surface, and a second membrane defining a third surface and a fourth surface, such that the first surface of the first membrane at least partially defines a first volume, and the second surface at least partially defines a second volume, the flexible mold defining at least one inlet port in fluid communication with the first volume;causing a fluidic building material to flow through the at least one inlet port into the first volume of the flexible mold;causing an inflation fluid to flow into the second volume of the flexible mold to expand the second volume of the flexible mold; andallowing the fluidic building material to transition from a fluid to a solid structure.

2. The method of claim 1, wherein causing the fluidic building material to flow through the at least one inlet port into the first volume of the flexible mold is performed before causing an inflation fluid to flow into the second volume of the flexible mold to expand the second volume of the flexible mold.

3. The method of claim 1, wherein the fluidic building material comprises a cementitious material.

4. (canceled)5. (canceled)6. (canceled)7. (canceled)8. The method of claim 3, wherein the cementitious material composite comprises a high-performance concrete.

9. The method of claim 1, wherein the solid structure comprises a polymeric material.

10. (canceled)11. (canceled)12. (canceled)13. The method of claim 1, wherein the flexible mold further comprises a third membrane defining a fifth surface such that the fifth surface of the third membrane and fourth surface of the second membrane at least partially define a third volume.

14. The method of claim 13, wherein the fluidic building material is a first fluidic building material and the at least one inlet port is at least one first inlet port, wherein the flexible mold defines at least one second inlet port in fluid communication with the third volume, further comprising causing a second fluidic building material to flow through the at least one second inlet port into the third volume of the flexible mold.

15. (canceled)16. The method of claim 1, wherein the flexible mold further comprises one or more tensioning members extending through the first volume.

17. (canceled)18. The method of claim 1, wherein the flexible mold further comprises one or more post-tensioning ducts extending through the first volume.

19. (canceled)20. The method of claim 1, further comprising modulating a pressure of the inflation fluid within the second volume between a first pressure and a second pressure.

21. The method of claim 1, wherein the second membrane defines one or more outlets ports in fluid communication with the first volume.

22. (canceled)23. The method of claim 1, wherein the flexible mold further includes a mesh layer disposed between the first and second membrane.

24. The method of claim 23, wherein after the fluidic building material flows through the at least one inlet port into the first volume of the flexible mold, the mesh layer is at least partially embedded within the fluidic building material.

25. (canceled)26. (canceled)27. The method of claim 1, wherein the first surface of the first membrane and the third surface of at least partially define the first volume.

28. The method of claim 1, wherein the first volume is defined by a conduit formed by the first surface of the first membrane.

29. A solid structure produced by the methods of claim 1.

30. (canceled)31. A system for forming a solid structure comprising:a flexible mold comprising:a first membrane defining a first surface and a second surface, anda second membrane defining a third surface and a fourth surface,wherein the first surface of the first membrane at least partially defines a first volume and the second surface at least partially defines a second volume, wherein the flexible mold defines at least one inlet port in fluid communication with the first volume.

32. The system of claim 31, further comprising a pneumatic pump in fluid communication with the second volume of the flexible mold.

33. The system of claim 31, further comprising a material injection component in fluid communication with one or more of the at least one inlet ports configured to direct a fluidic building material through the at least one inlet ports to the first volume.

34. The system of claim 31, wherein the flexible mold further comprises a third membrane defining a fifth surface such that the fifth surface of the third membrane and fourth surface of the second membrane at least partially define a third volume.

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