3D printing forming method for large-area special-shaped formwork

Abstract

Disclosed is a 3D printing forming method for a large-area special-shaped formwork, comprising: establishing a digital model of a large-area special-shaped formwork (S1); determining a 3D printing scheme on the basis of the digital model, wherein the 3D printing scheme comprises a formwork segmentation scheme and a formwork assembly scheme of the large-area special-shaped formwork (S2); splitting the large-area special-shaped formwork into a plurality of formwork segments on the basis of the formwork segmentation scheme, and performing a slicing process to generate a printing program for each formwork segment (S3); printing a plurality of formwork segments on the basis of the printing program (S4); and assembling the plurality of formwork segments on the basis of the formwork assembly scheme (S5).

Description

3D printing method for large-format special-shaped templates

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on December 12, 2023, with application number 202311699274.X, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the field of building construction technology, for example, to a 3D printing method for large-format special-shaped templates. Background Art

[0003] In construction, special-shaped casting formwork is usually used. In related technologies, the following two manufacturing methods are often used for special-shaped formwork: one is to use wooden formwork to discretely lay out and splice to form special-shaped formwork, and the other is to use steel formwork to form special-shaped formwork.

[0004] The discrete layout and splicing method of wooden formwork usually requires manual production on the construction site. Wooden boards are discretely laid out in sections according to arcs and then spliced ​​together. For irregular-shaped special-shaped formwork, the above method is difficult to control the splicing accuracy of the formwork and cannot meet the design requirements. In addition, there will be many joints after the pouring is completed, and the workload of subsequent polishing is heavy.

[0005] Although the method of opening steel formwork can ensure the accuracy of the formwork, the cost of manufacturing the formwork is high. For irregular and special-shaped formwork, most of them are used once. If the method of opening steel membrane is used, the construction cost will be very high and the economy will be poor.

[0006] Therefore, there is an urgent need for a 3D printing method for large-format special-shaped templates to improve the above situation.

[0007] Summary of the Invention

[0008] The embodiment of the present application provides a 3D printing method for large-format special-shaped templates, which can simplify the manufacturing process of large-format special-shaped templates, reduce construction costs, and ensure construction quality.

[0009] This application adopts the following technical solutions:

[0010] A 3D printing method for a large-format special-shaped template is provided, comprising the following steps:

[0011] Establish digital models of large-format special-shaped templates;

[0012] Determine the 3D printing plan for large-format special-shaped templates based on the digital model. The 3D printing plan includes the template segmentation plan and template splicing plan for large-format special-shaped templates;

[0013] Split the large-format special-shaped template into multiple template segments according to the template segmentation plan, and perform a slicing process to generate a printing program for each template segment;

[0014] Print out multiple template segments according to the printing program;

[0015] According to the template splicing plan, multiple printed templates are segmented and spliced ​​together to form large-format special-shaped templates.

[0016] Create digital models of large-format special-shaped formwork, including:

[0017] Design the template structure of the large-format special-shaped template according to the application scenario, and the template structure includes at least one of the template back rib form and the template lattice form;

[0018] A digital model of the large-scale special-shaped template is established according to the template structure, and a mechanical performance simulation is performed to test whether the large-scale special-shaped template meets the use requirements.

[0019] Splitting the large-format special-shaped template into a plurality of template segments according to the template segmentation scheme, including: splitting each template segment of the large-format special-shaped template into a first template and a second template that can be spliced ​​according to the template segmentation scheme;

[0020] A casting cavity is formed between the first template and the second template. The first template and the second template are respectively provided with back ribs on the sides facing away from each other, and the back ribs extend along the length direction of the first template and the second template.

[0021] Each template segment of the large-format special-shaped template is divided into a first template and a second template that can be spliced ​​according to the template segmentation scheme, including: dividing the first template and the second template into a first curved plate, a first connecting plate, a second curved plate, and a second connecting plate that are sequentially connected end to end according to the template segmentation scheme; wherein the second curved plate is provided with a plurality of back ribs on a side facing away from the first curved plate, and the plurality of back ribs are spaced apart along the circumference of the second curved plate;

[0022] Printing out multiple template segments according to a printing program includes: printing out a first template and a second template along a printing trajectory according to the printing program; wherein the printing trajectory of the first template is a cross-sectional contour line of a figure formed by the first curved plate, the first connecting plate, the second curved plate and the second connecting plate of the first template, and the printing trajectory of the second template is a cross-sectional contour line of a figure formed by the first curved plate, the first connecting plate, the second curved plate and the second connecting plate of the second template.

[0023] According to the template splicing plan, multiple printed and formed templates are segmented and spliced ​​together to form a large-format special-shaped template, including: according to the template splicing plan, the first connecting plate of the printed and formed first template is adhered and connected to the first connecting plate of the second template, and the second connecting plate of the printed and formed first template is adhered and connected to the second connecting plate of the second template; wherein a casting cavity is defined between the first curved plate of the spliced ​​first template and the first curved plate of the second template.

[0024] According to the template splicing plan, the first connecting plate of the printed first template is adhered and connected to the first connecting plate of the second template, and the second connecting plate of the printed first template is adhered and connected to the second connecting plate of the second template, including: connecting and fixing the first connecting plate of the printed first template and the first connecting plate of the printed second template through a first fastener, and connecting and fixing the second connecting plate of the printed first template and the second connecting plate of the printed second template through a first fastener, so that the printed first template and the printed second template are spliced ​​and fixed.

[0025] Printing out a plurality of template segments according to a printing program includes: printing out a first template and a second template according to the printing program;

[0026] After the first template and the second template are printed out according to the printing program, the method further includes:

[0027] Milling the upper and lower end surfaces of the first template into planes, and milling the upper and lower end surfaces of the second template into planes, so that the two adjacent template segments can fit together;

[0028] The contact surface of the first connecting plate and the contact surface of the second connecting plate are respectively milled into planes, and first connecting holes are drilled on the planes of the first connecting plate and the second connecting plate.

[0029] Printing out multiple template segments according to a printing program includes: printing splicing tables on the first template and the second template respectively according to the printing program, so that the splicing tables of the two adjacent spliced ​​template segments can be connected and fixed by a second fastener after printing.

[0030] A plurality of template segments are printed out according to a printing program, including: printing connecting bosses on the sides of a first template and a second template facing away from each other according to the printing program, and printing a connecting rod on the connecting bosses; wherein the connecting bosses are located between two adjacent back ribs, and an end of the connecting rod away from the connecting bosses is configured to be connected to an external support.

[0031] According to the template splicing plan, multiple printed templates are segmented and spliced ​​together to form large-format special-shaped templates, including:

[0032] Pre-join the multiple template segments after printing and perform precision check on the dimensions of the multiple template segments;

[0033] Multiple templates that meet the precision requirements are divided into sections and fixed to form large-scale special-shaped templates. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG1 is a flow chart of a 3D printing method for a large-format special-shaped template provided by an exemplary embodiment of the present application;

[0035] FIG2 is a first structural diagram of a first template provided in an exemplary embodiment of the present application;

[0036] FIG3 is a top view of FIG2;

[0037] FIG4 is a second structural diagram of the first template provided in an exemplary embodiment of the present application;

[0038] FIG5 is a third structural diagram of the first template provided in an exemplary embodiment of the present application;

[0039] FIG6 is a fourth structural diagram of the first template provided in an exemplary embodiment of the present application;

[0040] FIG7 is a schematic diagram of splicing two adjacent template segments provided in an exemplary embodiment of the present application;

[0041] FIG8 is a schematic diagram of the fixing of two adjacent templates after segmented splicing provided by an exemplary embodiment of the present application;

[0042] FIG. 9 is a top view of FIG. 8 .

[0043] In the picture:

[0044] 1-template segment; 2-first fastener; 3-second fastener;

[0045] 11-first template; 12-second template; 13-casting cavity;

[0046] 111-first curved plate; 112-first connecting plate; 113-second curved plate; 114-second connecting plate;

[0047] 1121-first connecting hole;

[0048] 1131-back rib; 1132-joining platform; 1133-connecting boss; 1134-connecting rod;

[0049] 11321-Fixed portion; 11322-Connecting portion;

[0050] 100-support truss;

[0051] 101-supporting vertical rod; 102-supporting horizontal rod; 103-top rod. DETAILED DESCRIPTION

[0052] In the description of this application, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, they cannot be understood as limitations on this application. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance. Among them, the terms "first position" and "second position" are two different positions.

[0053] In the description of this application, it should be noted that, unless otherwise specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they can refer to fixed or detachable connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application in specific contexts.

[0054] As shown in FIG1 , this embodiment provides a 3D printing method for a large-format special-shaped template, comprising the following steps:

[0055] S1. Establish a digital model of large-scale special-shaped templates;

[0056] S2. Determine a 3D printing solution for the large-format special-shaped template based on the digital model. The 3D printing solution includes a template segmentation solution and a template splicing solution for the large-format special-shaped template.

[0057] S3, splitting the large-format special-shaped template into multiple template segments 1 according to the template segmentation scheme, and performing a slicing process to generate a printing program for each template segment 1;

[0058] S4, printing out multiple template segments 1 according to the printing program;

[0059] S5. According to the template splicing scheme, the multiple printed template segments 1 are spliced ​​together to form a large-format special-shaped template.

[0060] The 3D printing method for large-format, special-shaped templates provided in this embodiment first uses digital modeling software to model the large-format, special-shaped template to be printed to obtain a corresponding digital model. A 3D printing plan is then determined based on the digital model, including a plan for segmenting and splicing the large-format, special-shaped template. The large-format, special-shaped template is then split into multiple template segments 1 according to the template segmentation plan. Each template segment 1 is sliced ​​using slicing software to obtain a printing program for each template segment 1. The printing program is input into a 3D printing device, and multiple template segments 1 are sequentially printed and formed. Finally, the multiple printed template segments 1 are transported to the construction site for splicing to obtain the large-format, special-shaped template.

[0061] Due to the irregular and large formwork, splitting the large-scale, special-shaped formwork into multiple template segments 1 facilitates individual printing of each template segment 1, making it easier to implement. Furthermore, the printed, multiple template segments 1 are easier to transport and transfer to the construction site, allowing for on-site splicing, reducing construction difficulty and significantly saving construction costs. By 3D printing each template segment 1, the molding accuracy of each template segment 1 can be precisely controlled, ensuring that the spliced ​​large-scale, special-shaped formwork meets design requirements, thereby ensuring the quality of the cast components and improving construction efficiency and quality.

[0062] In this embodiment, step S1 includes the following steps:

[0063] S11. Designing a template structure for a large-format special-shaped template according to the application scenario, wherein the template structure includes a template back rib form and / or a template lattice form;

[0064] S12. Establish a digital model of the large-scale special-shaped template according to the template structure, and perform mechanical performance simulation to test whether the large-scale special-shaped template meets the use requirements.

[0065] In step S11, the template structure of the large-format special-shaped template mainly considers the template back rib form and the template lattice form. The design of the template back rib form is considered to enhance the structural strength of the template itself, so that the large-format special-shaped template has sufficient load-bearing capacity and prevents the template from deformation. On the other hand, considering the actual application scenario, the template back rib can be easily connected to the external support, which plays a role in facilitating the installation and fixing of the template. At the same time, the template back rib design also needs to consider saving printing materials and reducing construction costs. The design of the template lattice form is considered to enhance the structural strength of the template while saving printing materials.

[0066] In step S12, a digital model is established and mechanical performance simulation is performed to detect whether the current template structure meets the use requirements. If not, the template structure can be adjusted in time until the large-scale special-shaped template meets the use requirements in the current application scenario.

[0067] Step S3 includes: splitting each template segment 1 of the large-format special-shaped template into a first template 11 and a second template 12 that can be spliced ​​according to the template segmentation scheme. A casting cavity 13 is formed between the first template 11 and the second template 12. Back ribs 1131 are provided on the sides of the first template 11 and the second template 12 facing away from each other. The back ribs 1131 extend along the length of the first template 11 and the second template 12.

[0068] Referring to Figures 2 to 7, each formwork segment 1 of the large-format, special-shaped formwork comprises a first formwork 11 and a second formwork 12 that can be spliced ​​together. A casting cavity 13 is formed between the first formwork 11 and the second formwork 12. A back rib 1131 is provided on the side of the first formwork 11 and the second formwork 12 facing away from each other. The back rib 1131 extends along the length of the first formwork 11 and the second formwork 12. Assembling the large-format, special-shaped formwork by splicing facilitates construction at the construction site and reduces construction difficulty. The provision of the back rib 1131 effectively increases the bearing capacity and rigidity of the first formwork 11 and the second formwork 12, enabling them to better withstand the pressure and weight of concrete. Furthermore, the back rib 1131 serves as support during the installation and fixation of the first formwork 11 and the second formwork 12, improving the installation stability of the first formwork 11 and the second formwork 12.

[0069] In this embodiment, as shown in FIG. 2 and FIG. 3 , the cross section of the back rib 1131 is triangular, which makes the structure more stable and can effectively improve the structural strength of the first template 11 and the second template 12 .

[0070] In step S3, each template segment 1 of the large-format special-shaped template is split into a first template 11 and a second template 12 that can be spliced ​​according to the template segmentation scheme, including: according to the template segmentation scheme, the first template 11 and the second template 12 are respectively split into a first curved plate 111, a first connecting plate 112, a second curved plate 113 and a second connecting plate 114 that are connected end to end; wherein, the second curved plate 113 is provided with a plurality of back ribs 1131 on the side facing away from the first curved plate 111, and the plurality of back ribs 1131 are distributed at intervals along the circumferential direction of the second curved plate 113.

[0071] Step S4 includes: printing out the first template 11 and the second template 12 along the printing trajectory according to the printing program, wherein the printing trajectory of the first template 11 is the cross-sectional contour line of the figure formed by the first curved plate 111, the first connecting plate 112, the second curved plate 113 and the second connecting plate 114 of the first template 11, and the printing trajectory of the second template 12 is the cross-sectional contour line of the figure formed by the first curved plate 111, the first connecting plate 112, the second curved plate 113 and the second connecting plate 114 of the second template 12.

[0072] Referring to Figures 2 and 3 , the first and second templates 11 and 12 each include a first curved plate 111, a first connecting plate 112, a second curved plate 113, and a second connecting plate 114, which are connected end to end. The second curved plate 113 has a plurality of back ribs 1131 projecting from the side facing away from the first curved plate 111. These back ribs 1131 are spaced apart along the circumference of the second curved plate 113. The cross-sectional contour of the pattern formed by the first curved plate 111, the first connecting plate 112, the second curved plate 113, and the second connecting plate 114 represents the printing trajectory of the first and second templates 11 and 12. In other words, the cross-sectional contours of the first and second templates 11 and 12 are both continuous closed loops, facilitating molding via 3D printing. In this embodiment, the first curved plate 111 and the second curved plate 113 are arranged at intervals, and the second curved plate 113 is bent in the direction away from the first curved plate 111 to form a raised back ridge 1131. The existence of the back ridge 1131 does not affect the continuity of the cross-sectional contour lines of the first template 11 and the second template 12, so as to ensure the continuity of the printing track.

[0073] As shown in Figure 3, the second curved plate 113 is concentric with the first curved plate 111 and spaced apart. Two back ribs 1131 are symmetrically protruded from the middle of the second curved plate 113. The two ends of the second curved plate 113 are bent outward and connected to the first connecting plate 112 and the second connecting plate 114, respectively, to form back ribs 1131. In other words, four back ribs 1131 are spaced apart on the second curved plate 113. Except for the back ribs 1131, the rest of the second curved plate 113 forms a double-plate structure with the first curved plate 111. This arrangement enhances the mechanical properties of the first and second templates 111 and 12, and improves the load-bearing capacity of the usable surfaces of the first and second templates 111 and 12 (the side of the first curved plate 111 facing away from the second curved plate 113). Furthermore, the triangular back ribs 1131 provide a foundation for connection to external supports, facilitating the securement of the first and second templates 111 and 12.

[0074] Step S5 includes: according to the template splicing plan, the first connecting plate 112 of the printed first template 11 is adhered and connected to the first connecting plate 112 of the second template 12, and the second connecting plate 114 of the printed first template 11 is adhered and connected to the second connecting plate 114 of the second template 12; wherein, a casting cavity 13 is defined between the first curved plate 111 of the spliced ​​first template 11 and the first curved plate 111 of the second template 12.

[0075] 5 , 7 , and 8 , after the first formwork 11 and the second formwork 12 are spliced ​​together, the first connecting plate 112 of the first formwork 11 and the first connecting plate 112 of the second formwork 12 are affixed and connected, and the second connecting plate 114 of the first formwork 11 and the second connecting plate 114 of the second formwork 12 are affixed and connected, defining the aforementioned casting cavity 13 between the first curved plate 111 of the first formwork 11 and the first curved plate 111 of the second formwork 12. Because the two first connecting plates 112 and the two second connecting plates 114 can be directly affixed, the joint between the first curved plate 111 of the first formwork 11 and the first curved plate 111 of the second formwork 12 can be minimized after the first formwork 11 and the second formwork 12 are spliced ​​and fixed, preventing grout leakage during the casting process and thereby improving casting quality.

[0076] In step S5, according to the template splicing scheme, the first connecting plate 112 of the printed first template 11 is attached and connected to the first connecting plate 112 of the second template 12, and the second connecting plate 114 of the printed first template 11 is attached and connected to the second connecting plate 114 of the second template 12, including:

[0077] The first connecting plate 112 of the printed first template 11 and the first connecting plate 112 of the printed second template 12 are connected and fixed by the first fastener 2, and the second connecting plate 114 of the printed first template 11 and the second connecting plate 114 of the printed second template 12 are connected and fixed by the first fastener 2, so that the printed first template 11 and the printed second template 12 are spliced ​​and fixed.

[0078] As shown in FIG9 , the first connecting plate 112 of the first form 11 and the first connecting plate 112 of the second form 12, as well as the second connecting plate 114 of the first form 11 and the second connecting plate 114 of the second form 12, are connected and fixed by first fasteners 2, so that the first form 11 and the second form 12 are spliced ​​and fixed. In this embodiment, since the two first connecting plates 112 (second connecting plates 114) are not in the same plane as the use surfaces of the first curved plate 111 and the second curved plate 113 after being affixed, the first fasteners 2 are inserted and fixed to the first connecting plates 112 and the second connecting plates 114 without damaging the casting cavity 13, thus avoiding slurry leakage and not affecting the surface quality of the concrete member after casting. Referring to FIG9 , both ends of the first fastener 2 are located in the space between the first curved plate 111 and the second curved plate 113. For example, the first fastener 2 is a threaded bolt and nut.

[0079] Step S4 includes: printing out the first template 11 and the second template 12 according to a printing program.

[0080] In step S4, after the first template 11 and the second template 12 are printed and formed, the following steps are also included:

[0081] S41, milling the upper end surface and the lower end surface of the first template 11 and the second template 12 into planes so that the two adjacent template segments 1 can fit together;

[0082] S42 , milling the contact surface of the first connecting plate 112 and the contact surface of the second connecting plate 114 into planes, and drilling first connecting holes 1121 on the planes of the first connecting plate 112 and the second connecting plate 114 .

[0083] In step S41, the first and second templates 11, 12, after being printed and formed, are subjected to processes such as putty spraying and polishing to ensure that the first and second templates 11, 12 meet the precision requirements. By milling the upper and lower end surfaces of the first and second templates 11, 12 into flat surfaces, the first and second templates 11, 12 of the two adjacent template segments 1 can be tightly fitted together, further preventing grout leakage during pouring, avoiding excessive joints in the formed components, and reducing the workload of post-processing.

[0084] In step S42, by milling the contact surface of the first connecting plate 112 and the contact surface of the second connecting plate 114 into a plane, the corresponding two first connecting plates 112 and the two second connecting plates 114 can be tightly fitted together, preventing leakage, improving the surface quality of the component after casting, and reducing the workload of post-processing. By drilling the first connecting hole 1121 in the first connecting plate 112 and the second connecting plate 114, when fixing the first template 11 and the second template 12, the first fastener 2 can be used to penetrate the first connecting hole 1121 to complete the fastening operation. For example, three first connecting holes 1121 are arranged at intervals on the first connecting plate 112 and the second connecting plate 114 to ensure that the first template 11 and the second template 12 can be spliced ​​and fixed securely.

[0085] Step S4 includes: printing the splicing platform 1132 on the first template 11 and the second template 12 respectively according to the printing program, so that the splicing platform 1132 of the two adjacent template segments 1 can be connected and fixed by the second fastener 3 after printing.

[0086] Referring to Figures 6 and 7 , both the first and second templates 11, 12 are provided with splicing platforms 1132. The splicing platforms 1132 of two adjacent template segments 1 are connected and fixed via second fasteners 3. After the first and second templates 11, 12 are spliced ​​and fixed, the two template segments 1 are spliced ​​vertically using lifting equipment, so that the splicing platforms 1132 on the upper and lower template segments 1 are aligned. The two splicing platforms 1132 are then fastened using second fasteners 3, thereby firmly fixing the two template segments 1 in the vertical direction and preventing grout leakage between the adjacent spliced ​​template segments 1.

[0087] In this embodiment, referring to FIG6 , the splicing platform 1132 includes a fixed portion 11321 and a connecting portion 11322, which are connected and arranged at an angle. The fixed portion 11321 is provided on the back rib 1131, and the second fastener 3 is passed through and connected to the connecting portion 11322. For example, the second fastener 3 is a bolt and nut with threaded engagement, and the connecting portion 11322 is perpendicular to the fixed portion 11321.

[0088] In step S4, after the first template 11 and the second template 12 are printed and formed, the following steps are also included:

[0089] S43 , milling out a fixing portion 11321 and a connecting portion 11322 arranged at an angle on the splicing platform 1132 , and drilling a second connecting hole on the connecting portion 11322 .

[0090] That is, during the 3D printing process, a solid rectangular splicing platform 1132 is integrally printed on the back rib 1131, and then a portion of the rectangular splicing platform 1132 is milled off later to form the above-mentioned angled fixing portion 11321 and connecting portion 11322, providing a mechanical connection basis for the subsequent splicing of adjacent template segments 1.

[0091] In related technologies, in order to prevent the mold from expanding, bolts are usually used to penetrate the formwork and fix it directly. However, during the pouring process, the bolt holes on the formwork are prone to leakage, and the bolt heads will affect the surface of the internally formed components, increasing the workload of post-processing.

[0092] Step S4 includes: printing a connecting boss 1133 on the side of the first template 11 and the second template 12 facing away from each other according to the printing program, and printing a connecting rod 1134 on the connecting boss 1133; wherein the connecting boss 1133 is located between two adjacent back ribs 1131, and the end of the connecting rod 1134 away from the connecting boss 1133 is set to be connected to an external support.

[0093] As shown in Figures 4 and 6, the first and second templates 11 and 12 are each provided with a connecting boss 1133 on the side facing away from each other. This boss 1133 is located between two adjacent back ribs 1131. A connecting rod 1134 is provided on the connecting boss 1133, with the end of the connecting rod 1134, facing away from the connecting boss 1133, being used to connect to an external support. In this embodiment, the connecting boss 1133 is located on the side of the second curved plate 113 facing away from the first curved plate 111. That is, the connecting boss 1133 is located on the non-use surface of the first and second templates 11 and 12, thus not affecting the surface quality of the cast component. The provision of the connecting boss 1133 and connecting rod 1134 allows the first and second templates 11 and 12 to be securely connected to the external support, thereby effectively securing the positions of the first and second templates 11 and 12, preventing mold popping and further improving the quality of the cast component. Furthermore, the provision of the connecting boss 1133 and connecting rod 1134 simplifies the securing operation of the first and second templates 11 and 12, reducing the difficulty of on-site construction.

[0094] Referring to Figure 4 , the cross-section of the connecting boss 1133 is an isosceles trapezoid, which increases the stability of the connection between the connecting boss 1133 and the second curved plate 113. For example, multiple connecting bosses 1133 are provided at intervals on both the first template 11 and the second template 12, with a connecting boss 1133 disposed between each two adjacent back ribs 1131 to ensure that the first template 11 and the second template 12 are securely fixed and evenly stressed.

[0095] In step S4, after the first template 11 and the second template 12 are printed and formed, the following steps are also included:

[0096] S44. Mill a third connecting hole on the connecting boss 1133 so that the connecting rod 1134 is connected to the connecting boss 1133 through the third connecting hole.

[0097] Specifically, during the 3D printing process, the connecting boss 1133 is integrally printed on the second curved plate 113. Later, a hole is drilled on the side of the connecting boss 1133 facing away from the second curved plate 113 to form the third connecting hole. For example, the third connecting hole is a threaded hole, and the connecting rod 1134 is a screw. Connecting rod 1134 is screwed into the third connecting hole. By screwing connecting rod 1134, its length can be adjusted to allow for secure connection to various external supports.

[0098] 8 and 9 , the external support comprises a support truss 100, which comprises a plurality of cross-connected support vertical bars 101 and support horizontal bars 102. The support horizontal bars 102 are provided with top bars 103, the ends of which, away from the support horizontal bars 102, can abut against back ribs 1131. The support truss 100 can be erected at the construction site to support and secure the plurality of formwork segments 1. By abutting the top bars 103 against the back ribs 1131 and connecting the connecting bars 1134 on the connecting bosses 1133 to the support vertical bars 101 or the support horizontal bars 102, the first and second formwork segments 11 and 12 can be stably supported.

[0099] There are multiple push rods 103, and the two opposite sides of the back rib 1131 are supported by push rods 103 to ensure firm fixation.

[0100] In this embodiment, step S5 includes the following steps:

[0101] S51, pre-joining the multiple printed template segments 1 (for example, pre-joining can be performed in a factory) to perform precision calibration on the dimensions of the multiple template segments 1;

[0102] S52: Assemble and fix multiple template segments 1 that meet the precision requirements to form a large-scale special-shaped template. For example, the multiple template segments 1 that meet the precision requirements can be transported to the construction site for on-site assembly and fixing.

[0103] By pre-assembling and checking the first template 11 and the second template 12 of multiple template segments 1 in the factory, it is conducive to the smooth assembly of large-scale special-shaped templates at the construction site, avoiding rework, and ensuring that the large-scale special-shaped templates meet the design requirements after assembly, thereby ensuring that the components after casting meet the preset requirements.

[0104] The 3D printing molding method of the large-format special-shaped template is used to make the template, which avoids the situation that the large-format special-shaped template is difficult to splice and the splicing accuracy is difficult to control due to the irregular shape and large size. It can also ensure the template accuracy, reduce the difficulty and cost of on-site construction, and improve the construction quality.

[0105] The following table compares the manufacturing cost, construction period, and template performance required to manufacture and install the same special-shaped template in this embodiment and related technologies, including wooden templates and steel templates.

[0106] 100m 2 Taking the special-shaped formwork as an example, the traditional wooden formwork requires 3 to 5 workers and the construction period is more than 10 days, while this embodiment only requires 2 workers and the construction period can be controlled within 7 days, thus saving more than 33% of labor and shortening the construction period by more than 30%; the cost of the steel membrane is 2,000 yuan / m2 Above, this embodiment only needs 800 to 1200 yuan / m 2 , so the construction cost can be saved by 40% to 60%.

[0107] The 3D printing method for large-format, special-shaped templates provided in this embodiment leverages the characteristics of 3D printing technology, integrating the back rib 1131, splicing platform 1132, and connecting boss 1133 of the large-format, special-shaped template into the digital model of the large-format, special-shaped template. This ensures the overall accuracy of the large-format, special-shaped template while also improving the mechanical properties of the template itself. By later milling, drilling, and processing the connecting portion 11322, a tight fit is achieved between the first template 11 and the second template 12, as well as between adjacent template segments 1. This effectively prevents grout leakage during the pouring process, ensuring pouring quality while simplifying the splicing process, improving construction efficiency, and reducing construction costs.

[0108] This application also proposes a 3D printing device for large-format special-shaped templates, including a memory, a processor, a 3D printing device, and an assembly device;

[0109] The memory stores a computer program, and when the processor executes the computer program, the following steps are implemented:

[0110] Establish digital models of large-format special-shaped templates;

[0111] Determine a 3D printing solution for the large-format special-shaped template based on the digital model, wherein the 3D printing solution includes a template segmentation solution and a template splicing solution for the large-format special-shaped template;

[0112] Split the large-format special-shaped template into multiple template segments according to the template segmentation plan, and perform a slicing process to generate a printing program for each template segment;

[0113] The 3D printing device is configured to print out a plurality of template segments according to a printing program;

[0114] The assembly equipment is configured to splice multiple printed templates in sections according to a template splicing plan to form a large-format special-shaped template.

[0115] The assembly equipment may include virtual reality (VR) and augmented reality (AR) equipment, laser measuring instruments, jigs and fixtures, or robots.

Claims

1. 3D printing method for large-format special-shaped templates, including: Establish digital models of large-format special-shaped templates; Determine a 3D printing scheme for the large-format special-shaped template according to the digital model, wherein the 3D printing scheme includes a template segmentation scheme and a template splicing scheme for the large-format special-shaped template; Splitting the large-format special-shaped template into a plurality of template segments according to the template segmentation scheme, and performing a slicing process to generate a printing program for each of the template segments; Printing out a plurality of the template segments according to the printing program; According to the template splicing scheme, the plurality of printed templates are segmented and spliced ​​together to form the large-format special-shaped template.

2. The 3D printing method for large-format special-shaped templates according to claim 1, wherein: The digital model of the large-format special-shaped template is established, including: The template structure form of the large-format special-shaped template is designed according to the application scenario, and the template structure form includes at least one of a template back rib form and a template lattice form; A digital model of the large-format special-shaped template is established according to the template structure, and a mechanical property simulation is performed to test whether the large-format special-shaped template meets the use requirements.

3. The 3D printing method for large-format special-shaped templates according to claim 1, wherein: The step of splitting the large-format special-shaped template into a plurality of template segments according to the template segmentation scheme comprises: splitting each template segment of the large-format special-shaped template into a first template and a second template that can be spliced ​​according to the template segmentation scheme; A casting cavity is formed between the first template and the second template, and the first template and the second template are respectively provided with back ribs on the sides facing away from each other, and the back ribs extend along the length direction of the first template and the second template.

4. The 3D printing method for large-format special-shaped templates according to claim 3, wherein: The method of dividing each template segment of the large-format special-shaped template into a first template and a second template that can be spliced ​​according to the template segmentation scheme includes: According to the template segmentation scheme, the first template and the second template are respectively divided into a first arc-shaped plate, a first connecting plate, a second arc-shaped plate and a second connecting plate which are sequentially connected end to end; Wherein, the second arc-shaped plate is provided with a plurality of back ridges on a side facing away from the first arc-shaped plate, and the plurality of back ridges are distributed at intervals along the circumferential direction of the second arc-shaped plate; Printing out a plurality of template segments according to the printing program comprises: Printing the first template and the second template along a printing track according to the printing program; Among them, the printing trajectory of the first template is the cross-sectional contour line of the figure formed by the first curved plate, the first connecting plate, the second curved plate and the second connecting plate of the first template, and the printing trajectory of the second template is the cross-sectional contour line of the figure formed by the first curved plate, the first connecting plate, the second curved plate and the second connecting plate of the second template.

5. The 3D printing method for large-format special-shaped templates according to claim 4, wherein: The method of splicing the multiple printed templates in sections to form the large-format special-shaped template according to the template splicing scheme includes: sticking and connecting the first connecting plate of the first template after printing and the first connecting plate of the second template after printing according to the template splicing scheme, and sticking and connecting the second connecting plate of the first template after printing and the second connecting plate of the second template; wherein the casting cavity is defined between the first curved plate of the spliced ​​first template and the first curved plate of the second template.

6. The 3D printing method for large-format special-shaped templates according to claim 5, wherein: The method of attaching and connecting the first connecting plate of the first template after printing and forming and the first connecting plate of the second template after printing and forming according to the template splicing scheme includes: The first connecting plate of the first template after printing and the first connecting plate of the second template after printing are connected and fixed by a first fastener, and the second connecting plate of the first template after printing and the second connecting plate of the second template after printing are connected and fixed by the first fastener, so that the first template after printing and the second template after printing are spliced ​​and fixed.

7. The 3D printing method for large-format special-shaped templates according to claim 4, wherein the step of printing a plurality of template segments according to the printing program comprises: Printing out the first template and the second template according to the printing program; After printing out the first template and the second template according to the printing program, the method further includes: Milling the upper end surface and the lower end surface of the first template into planes, and milling the upper end surface and the lower end surface of the second template into planes, so that the two adjacent template segments can fit together; The contact surface of the first connecting plate and the contact surface of the second connecting plate are respectively milled into planes, and first connecting holes are drilled on the planes of the first connecting plate and the second connecting plate.

8. The 3D printing method for large-format special-shaped templates according to claim 3, wherein: Printing out a plurality of template segments according to the printing program comprises: The splicing tables are printed on the first template and the second template respectively according to the printing program, so that after printing and forming, the splicing tables of the two adjacent template segments can be connected and fixed by the second fastener.

9. The 3D printing method for large-format special-shaped templates according to claim 3, wherein: Printing out a plurality of template segments according to the printing program comprises: According to the printing program, connecting bosses are printed on the first template and the second template on the side facing away from each other, and connecting rods are printed on the connecting bosses; wherein, the connecting bosses are located between two adjacent back ribs, and one end of the connecting rod away from the connecting bosses is configured to be connected to an external support.

10. The 3D printing method for large-format special-shaped templates according to any one of claims 1 to 9, wherein: The step of splicing the printed templates in sections to form the large-format special-shaped template according to the template splicing scheme includes: Pre-joining the plurality of template segments after printing and checking the accuracy of the sizes of the plurality of template segments; A plurality of template segments meeting the precision requirements are assembled and fixed to form the large-format special-shaped template.

Images