Device for 3D printing from construction materials

Abstract

An automatic device for 3D printing from construction materials comprising an application head with construction material inlets from a mixing and pumping device, a crane, or a robotic arm for lifting the construction material inlets on one chassis and a crane or robotic arm on the other chassis for carrying up and placing a rail for the movable application head on opposite racks of folding cross members, where a vertical support structure is erected from each chassis, to which two opposite horizontal arms are connected, which are telescopically extendable for adjusting the width of the automatic device for 3D printing from construction materials, wherein the outer ends of the opposite horizontal arms are fitted with vertical telescopic brackets, where the vertical telescopic brackets on one chassis are terminated by folding toothed cross members, the end of which, in the unfolded state, abuts the vertical telescopic brackets on the other chassis, wherein the rail is arranged across the unfolded opposite cross members, which is movable along the cross members, and this rail is fitted with the movable application head.

Description

[0001] Device for 3D Printing from Construction Materials

[0002] Technical Field

[0003] The present invention relates to a construction device for 3D printing buildings and other structures using construction materials.

[0004] Background of the Invention

[0005] Today, 3D printing or additive manufacturing technology is increasingly being used in the construction industry. As in other fields, in the construction industry the work of 3D printers consists in extruding a certain compound layer by layer based on a three- dimensional computer model. 3D printers can be used either to produce parts of a construction project that are later assembled at the target site, or directly on the construction site to 3D print essential parts of buildings, especially vertical support and completing structures.

[0006] 3D printing in the construction industry can comprise either the use of 3D printers that actively build the project on site, or the use of printers in a factory producing parts of a construction project that are later assembled. 3D printing brings a number of benefits to the construction industry. These mainly include increased safety and easier dealing with labor shortages, as it requires less human labor. Construction projects printed using 3D printing allow the use of exactly the right amount of material needed, thus the technology is more environmentally friendly. It is also much faster than conventional construction and brings high flexibility, as it allows the creation of even atypical structures. In addition, a wide range of materials can be used in 3D printers developed for the field of the construction industry. 3D printers are composed of an application head, also called a printing head, with a built-in nozzle, which is carried by the structure of the printer, and which is composed of moving members and drive units. A material mixing and pumping device is also a part of the machine printing system. The structural arrangement of the 3D printer determines the geometry of the printing space and thus the maximum dimensions of the part printable from one position of the printer. In the construction industry, two basic kinds of 3D printer structural solutions can be encountered.

[0007] The first type is a modular frame printer, where the movement of the application head is ensured by a structure in the form of a frame bench (portal) or a so-called delta structure. The advantages of the frame structural arrangement include the high load capacity of the structure and therefore the ability to bear a heavier application head. The printing accuracy of frame printers is determined by the production setup (the size of the smallest stepper motor displacement) and the fact that the entire element can be printed in one position of the machine. The size of the printing space of the frame structure is determined by the production dimensions of the printer. Frame printers are less suitable for use in uneven terrain, they are used more for stationary use for foundations, vertical support structures, and partitions of less extensive premises, they are particularly suitable for production of prefabricated components in production halls.

[0008] The second type is 3D printers with multi-axis industrial robotic arms. The movement of the application head is implemented in the form of a robotic arm with usually six degrees of freedom (rotation axes). It is preferred for use in buildings where printing space is limited, as this type of printers allows printing from only one side. The field of application can be seen in the printing of in situ vertical support structures, prefabricated components, furnishings, completing structures, and finishing work. More degrees of freedom compared to the frame solution allow greater variability in the printing method and allow a different method of dividing the model into layers with the possibility to print vertically or in spatial curves. A disadvantage is a smaller printing space compared to frame printers, as this is determined by the length of the arm links and the angle of rotation at the joints.

[0009] Thus, both above basic structural solutions of 3D printers are suitable for different applications, and both are limited especially in terms of the size of the printing space. Therefore, it would be desirable to come up with a solution for a construction device for 3D printing that would allow to expand the size of the printing space directly in situ. At the same time, it would be advantageous if this solution offered better mobility than that offered by the modular frame solutions described above.

[0010] Summary of the Invention

[0011] The above shortcomings are to a certain extent eliminated by a device for 3D printing from construction materials comprising an application head with construction material inlets from a mixing and pumping device, the essence of which lies in the fact that it comprises two chassis, where a vertical support structure is erected from each chassis to which two opposite horizontal arms are connected, which are telescopically extendable for adjusting the width of the device for 3D printing from construction materials, wherein the outer ends of the opposite horizontal arms are fitted with vertical telescopic brackets, wherein the vertical telescopic brackets belonging to one chassis are terminated by folding toothed cross members, the end of which, in the unfolded state, abuts the vertical telescopic brackets belonging to the other chassis, wherein a rail is arranged across the unfolded opposite cross members, which is movable along the cross members, and this rail is fitted with a movable application head, wherein the device for 3D printing from construction materials further comprises a crane or a robotic arm for lifting the construction materials inlets on one chassis, and a crane or robotic arm on the other chassis for carrying up and placing the rail for the movable application head on the opposite folding toothed cross members.

[0012] The device for 3D printing from construction materials of the invention allows, thanks to the structure thereof, to easily change the height and width of the printing space.

[0013] The chassis will enable the transportation of the support structures to the construction site, most often they will be made with wheels. The vertical support structures, the opposite horizontal arms, and the vertical telescopic brackets may preferably be connected to each other by joint mechanisms such that the parts can be stacked on the chassis when each chassis is transported, preferably in such a way that they do not extend beyond the chassis outline when the chassis is transported when viewed from above. After the chassis are transported to the construction site and prior to the actual 3D printing, the vertical support structures, the opposite horizontal arms, and the vertical telescopic brackets are erected.

[0014] The device for 3D printing from construction materials further comprises two cranes or robotic arms -a crane or robotic arm for lifting the construction material inlets, e.g. pipes, hoses, and cables, to the application head on one chassis, and on the other chassis, a crane or robotic arm for placing the rail on the unfolded opposite cross members along which the application head will move, and which will ensure during the 3D printing the placement of fillings of construction openings, in particular door cases and window frames, or other construction prefabricated components. For the purposes of the 3D printing from construction materials, the window frames and door cases will preferably be provided with lightweight lintels that will allow the application of the next printed layer of construction materials to proceed immediately after placement. The window frames and door cases may preferably be provided with projections that fit into grooves formed by the 3D printing on the sides of the construction openings. The fillings of the construction openings will thus be placed so tightly that there will be no thermal bridges. Typically, the basic construction compound will be prepared on the ground and transported from the mixing and pumping device to the application head using the construction material inlets using the crane or robotic arm to the application site. The construction material inlets will be held on the robotic arm or crane arm by cables.

[0015] The cranes or robotic arms will be preferably fixed in the region of contact of both opposite horizontal arms, i.e. above the vertical support structure. In one embodiment, they may emerge from a support platform, where the construction opening fillings, trays with components added to the construction compound, etc. may be arranged on the support platform. In such a case, the cranes and construction components stored on the support platform may be arranged at opposite ends of the support platform, the center of which is above the vertical support structure. Alternatively, when robotic arm is used, a main handling feed arm may emerge from the region of contact between both opposite horizontal arms, which is fitted at its end with a support platform for carrying construction opening fillings or other construction prefabricated components, and a robotic arm for quick placement of these fillings and prefabricated components. Both chassis with the downstream components of the device for 3D printing from construction materials of the present invention will be facing each other during the construction and will be independently moving, which will allow their quick preparation for printing at the new construction site or easy operational rearrangement. The chassis will be able to be equipped with their own drive, e.g. hydrogen, electric, or diesel, or means for connecting to towing or other devices of means of transport. In the case of the own drive, the chassis will be implemented either with a driver cab and / or as remotely controlled. The size of the chassis must ensure the basic stability of the support structures during the transport and the 3D printing itself, typical dimensions will be approximately 2.5 m x 6 m. The load capacity of the chassis should be high, e.g. approximately 3 t in practice, as they will be loaded not only with the downstream components of the device for 3D printing from construction materials but also with the platform with trays for construction compounds or construction opening fillings.

[0016] The support structure is attached to the chassis by a joint connection that allows it to be erected from the transport horizontal position to the working vertical or inclined position. It may be telescopically extendable for adjustment of the height of the horizontal arms. The telescopic mechanisms will be provided with a hydraulic or other drive. Typically, the support structure will be used to provide a greater vertical displacement of the downstream components of the device for 3D printing from construction materials, e.g. by a whole floor, wherein the height range of the support structure will be adapted to the height of the typical intended building. E.g. for a two-floor family house, a support structure height of approximately 7 m will be sufficient, for larger apartment houses up to 20 m will be needed.

[0017] Two opposite horizontal arms are arranged at the end of each support structure. The horizontal arms are telescopically extendable and their span determines the width of the entire device for 3D printing from construction materials, and thus the width of the printing region of this device. Even these telescopic mechanisms will be provided with a hydraulic or other drive and will provide a width of the device for 3D printing from construction materials typically in the range of approximately 10 m to 30 m. The horizontal arms will be loaded only by the downstream printing parts of the device for 3D printing from construction materials. For stability reasons, the horizontal arms will be preferably fixed into the facade when 3D printing larger dimensions, or the entire structure may be reinforced. The vertical telescopic brackets are fitted on the outer ends of the opposite horizontal arms. These vertical telescopic brackets will be provided with a hydraulic or other drive, will most often take the form of hydraulic cylinders, and will provide for the gentle lifting of downstream printing parts within a single floor by just the height of one layer of the printed construction material. The vertical telescopic brackets should be able to handle very precise height displacements in steps of 1 cm to 5 cm, within a range of 1 floor of the building, i.e. approximately 2 m to 5 m. These displacements will be mutually corrected in all 4 corners to maintain the water-balanced state.

[0018] Both support structures can preferably be provided with the joint mechanism that allows them to be bent downwards and thus the construction device for 3D printing from construction materials to be used for the construction of underground parts of buildings. In such case, it is sufficient to lay the base slab and the underground walls can be built without any molds. The 3D printing of underground walls at the greatest depth on the base slab will be carried out with the support structure bent downwards and the vertical telescopic brackets extended, wherein the vertical telescopic brackets will be progressively shortened by the height of one layer of the printed construction material. For 3D printing of the higher parts of the underground walls, the vertical telescopic brackets are turned upwards and will be progressively lengthened by the height of one layer of the printed construction material. For 3D printing aboveground walls, the bent support structures are also turned upwards, wherein for 3D printing the lowest parts of the aboveground walls, the vertical telescopic brackets can be turned downwards and for 3D printing the higher parts of the aboveground walls, the vertical telescopic brackets are turned upwards. Thus, all the elements of the device for 3D printing from construction materials allow for seamless interaction such that the 3D printing can proceed continuously without any long delays. During the 3D printing of the underground wall, waterproofing can be applied to the wall in the excavated pit using the application head, and then the free space can be backfilled with gravel.

[0019] The toothed cross members are used for the movement of the rail that is placed between them. Their length determines the length of the entire device for 3D printing from construction materials and thus the length of the printing space. They are placed on the vertical telescopic brackets of the support structures. For ease of transport, the cross members are implemented as foldable, e.g. from several-meter-long sections connected by joints in the manner of a folding tape measure. The cross members can be unfolded by means of hydraulic pistons fixed on the sides of the cross members, where they connect the individual adjacent sections. Alternatively, to simplify handling, such that each joint does not have to be provided with a piston drive and to reduce effort, it will be sufficient if only every other joint between the sections is provided with these hydraulic pistons, e.g. the connection between section 1 and section 2, between section 3 and section 4, between section 5 and section 6, etc., wherein in such a case the telescopic brackets will be provided with a downstream last section, e.g. 1 m long, to the free end of which cables will be attached for lowering the foldable cross members into the working position. The cables will lift the individual joints of the foldable cross members, wherein they will be automatically held in a tense state. The cross member can be rotationally attached to one vertical telescopic bracket and may abut the other one when completing the construction device for 3D printing from construction materials and may be removably attached and provided with a lock against disconnection. The length of the foldable cross members, as well as the length of the construction material inlets, is limited both by the length of the building and by the requirement for sufficient stability of the entire structure, which could be reduced if the cross members are too long. In practice, this implies a limitation of the length of the cross members to a maximum of 30 m, e.g. 5 m for each section. The last section will be easily removable if necessary and of variable length, thus adapting to the size of the premises being built, or it will be able to extend beyond the vertical telescopic bracket which it abuts. The unfolded cross members are in the form of a rack - they are toothed and allow the movement of pinions (toothed wheels) attached to the rail with a movement mechanism.

[0020] The rail fitted with the movable application head is arranged across between the opposite cross members. This rail is movable, moving on toothed wheels (pinions driven by linear motors) and thus ensures the first horizontal movement of the application head between the individual support structures. In practice, the rail will normally be supplied in lengths corresponding to the dimensions of the building for each construction project. The movement of the application head in the second horizontal direction perpendicular to the first horizontal direction is ensured by the movement of the application head along the rail, preferably using a fast linear drive. The application head will be connected to the construction material inlets prior to the actual 3D printing. The outlet of the spout of the application head with the laid printed material will be at such a height to allow the 3D printing of the next printed layer at the appropriate height. The spout for the application of the concrete compound, and possibly the insulator, will have individual height and width adjustment above the previous layer.

[0021] In order to ensure better stability of the device for 3D printing from construction materials, and thus the accuracy thereof, this device can be fastened to the wall of a reconstructed I newly built building during the printing. The fixation will take place on the higher floors, from the 2nd aboveground floor upwards. For this purpose, the opposite horizontal arms can be, e.g. near their outer ends, equipped with handles, the fixation of which to the wall or disconnection from the wall can be controlled remotely and take place as required.

[0022] The device for 3D printing from construction materials of the present invention offers several advantages over existing devices known as frame printers: a) Significantly easier and faster handling with delivery to the construction site b) Short time for preparation of the device for 3D printing from construction materials after arrival at the construction site c) The device for 3D printing from construction materials does not need to be specially prepared for the specific building, it is sufficient to supply an appropriate length of the cross members and the rail along which the application head will move, wherein the length of the cross members and the rail does not need to be precisely measured unless the building is limited by the space for the construction - e.g. in-building in the gap of terraced housing d) The device for 3D printing from construction materials allows higher heights to be achieved, e.g. 5 or 6 floors, without compromising stability, as the support structure can be fixed on both sides to the facade of the house

[0023] Compared to printers with multi-axis industrial robotic arms, the device for 3D printing from construction materials will have the following advantages: a) Higher complexity and reach / range of work of the application head of the device for 3D printing from construction materials in the horizontal plane and high variability of the obtained compound in a given time will be achieved by a crane that will lift the construction compound inlets with the components. The crane will actively adapt in height according to the distance to the application head and passively move to the sides such that the inlets to the application head are not unnecessarily twisted. b) The support part of the device for 3D printing from construction materials is cheaper and easier to produce, wherein the resulting product will allow for great variability both qualitatively and quantitatively according to the type of the building. c) The device for 3D printing from construction materials also has the advantage of simpler handling of the application head, as it does not need to laboriously change the diagonal length of the arm and at the same time displace the application head over the already made wall. While this would be technically possible, it would be both technology and software intensive.

[0024] Description of Drawings

[0025] A summary of the invention is further clarified using exemplary embodiments thereof, which are described with reference to the accompanying drawings, in which:

[0026] Fig. 1 shows schematically a chassis of the device for 3D printing from construction materials of the present invention with a support structure including downstream printing parts, a crane, and construction material inlets, except for a rail with a movable application head,

[0027] Fig. 2 show schematically a telescopic bracket, on which a cross member is stored by means of a cable system, in the construction of underground parts of buildings, where the support structure is bent downwards by means of its joint mechanism. When the cable is released and the telescopic pistons are simultaneously expanded (only the piston between sections 1 and 2 of the cross member is shown), the originally folded cross member is straightened and together with the second, parallel opposite rack prepared to place the rail and the application head. Fig. 3 shows schematically the device for 3D printing from construction materials including the rail with the movable application head when printing one inner wall of the building

[0028] Fig. 4 shows schematically a top view of the device for 3D printing from construction materials

[0029] Fig. 5 shows schematically a floor plan of an aboveground atypical building of small dimensions for 3D printing from building materials

[0030] Exemplary Embodiments of the Invention

[0031] The invention will be further clarified using exemplary embodiments with reference to the respective drawings.

[0032] 3D printing of an aboveground two-floor building with a floor plan of 8 m x 20 m will be performed using the device for 3D printing from construction materials according to the invention of the following parameters. The device for 3D printing consists of two wheeled chassis 1, which are equipped with means for connecting to the towing devices of means of transport. In this case, the chassis 1 have dimensions of 2.5 x 6 m) and a load capacity of approximately 3-10 tons. For larger buildings, the parameters can be higher.

[0033] On each chassis 1, as shown in fig. 1 , a vertical steel telescopic support structure 2 is erected and two opposite telescopically extendable horizontal arms 3 are arranged thereon that together with the support structure 2 form the shape of the letter T. The telescopic mechanisms of the horizontal arms 3 are provided with a hydraulic drive and provide a width of the device for 3D printing from construction materials in a range of up to 10 m, where the individual horizontal arms 3 achieve a length of up to 5 m. The horizontal arms 3 are provided with a remotely controlled drilling device that allows their fixing into the facade for greater stability of the device for 3D printing from construction materials during the printing.

[0034] The outer ends of the opposite horizontal arms 3 are fitted with steel vertical telescopic brackets 4, which have a total maximum height of 8 m on the first chassis 1, wherein the last section of the telescopic brackets 4 of a length of 1 m is provided with a cable to lower the foldable cross members 5 into the working position, and a total maximum height of 7 m on the second chassis 1.

[0035] The vertical telescopic brackets 4 are on the first chassis 1 provided with folding toothed cross members 5 before the last meter section, the end of which, in the unfolded state, abuts the vertical telescopic brackets on the second chassis 1. The cross members 5 are made of four five-meter sections connected by joints in the manner of a folding tape measure and are unfolded by means of hydraulic pistons fixed to the sides of the cross members 5.

[0036] The rail 9 is arranged across the unfolded opposite cross members 5, which is movable along the cross members 5, and this rail 9 is fitted with the movable application head 10. The application head 10 is connected to the construction material inlets 7 from the mixing and pumping device, which are located both on the ground (basic compound) and on the support platform arranged in the region of contact between the two opposite horizontal arms 3 on the first chassis 1. The construction material inlets 7 are secured and lifted by the crane 6 also located on the support platform on the first chassis 1. The second crane 6 is located on the second chassis 1, which is designed to place the rail 9, on which the application head 10 will move, on the cross members 5.

[0037] The actual 3D printing is then performed in layers, where each layer is printed using the application head 10, which moves along the rail 9, where the rail 9 moves on the toothed cross wheels of the cross members 5. Before printing the next layer, the assembly of the application head 10, the rail 9 and the cross members 5 is lifted by the height of the printed layer by extending the telescopic brackets 4.

[0038] The actual 3D printing must be preceded by laying the base slab, which can also be performed by 3D printing, but then the slab must be allowed to harden.

[0039] The preparation of the device for 3D printing from construction materials of the invention prior to printing a two-floor building is performed as follows: The beginning of the construction with the device for 3D printing from construction materials of the invention consists in placing two chassis 1 against each other at a distance corresponding to the length of the building. The support structure 2 and the opposite telescopically extendable horizontal arms 3_in the shape of the letter T, as well as the vertical telescopic brackets 4 on both chassis 1 are adjusted as required. Subsequently the cross members 5 are unfolded from the telescopic brackets 4 from the first chassis 1, and subsequently, using the crane 6 from the second chassis 1, the rail 9 will be laid thereon, and the application head 10 with the construction material inlets 7 from the first chassis 1 is placed thereon. Before the 3D printing begins, all mechanisms are calibrated, including height levelling at all corners. The resulting arrangement of the device for 3D printing from construction materials of the invention is shown in fig. 3 and a top view thereof is shown in fig. 4.

[0040] In another exemplary embodiment, the 3D printing of an aboveground atypical building of small dimensions, e.g. a gazebo with a floor plan in the shape of a hexagon with a side length of 5 m shown in fig. 5, may be demonstrated, which will be performed using the device for 3D printing from construction materials, where the exact same procedure as for the above-mentioned building is used, the only difference being that smaller dimensions of the cross members 5 and the rail 9 carrying the application head 10 are used.

[0041] In the third exemplary embodiment, the device for 3D printing from construction materials may be used to print underground parts of buildings. In such a case, the vertical telescopic support structure 2 is provided in its bottom part with a joint mechanism for folding it below the level of the chassis 1. The arrangement of the telescopic brackets 4 and the foldable cross members 5 is shown in this case in fig. 2. The last section of the telescopic brackets 4 of a length of 1 m is rotated upwards, the first cable lifting the cross member 5 is also shown extended from the free end of the telescopic bracket 4 to the first joint of the cross member 5 and the first hydraulic piston 8 between sections 1 and 2 of the cross member 5. Industrial Applicability

[0042] The above-described device for 3D printing from construction materials can be used in practice especially in the construction of various types of buildings such as residential and office buildings, schools, and production and sports halls. In addition, various works of art can also be made using the device for 3D printing from construction materials. This technology should also bring a great advantage in shipbuilding, where the low need for maintenance, as construction materials for 3D printing do not rust, and inner insulation, which will prevent condensation on the inner walls, will be especially appreciated.

[0043] List of Reference Signs

[0044] 1 - Chassis

[0045] 2 - Support structure

[0046] 3 - Horizontal arm

[0047] 4 - Telescopic bracket

[0048] 5 - Cross member

[0049] 6 - Crane

[0050] 7 - Construction material inlets

[0051] 8 - Hydraulic piston 9 - Rail

[0052] 10 - Application head

Claims

CLAIMS1. A device for 3D printing from construction materials comprising an application head with construction material inlets from a mixing and pumping device characterized in that it comprises two chassis (1), where a vertical support structure (2) is erected from each chassis (1), to which two opposite horizontal arms (3) are connected, which are telescopically extendable for adjusting the width of the automatic device for 3D printing from construction materials, wherein the outer ends of the opposite horizontal arms (3) are fitted with vertical telescopic brackets (4), where the vertical telescopic brackets (4) belonging to one chassis (1 ) are terminated by folding toothed cross members (5), the end of which, in the unfolded state, abuts the vertical telescopic brackets (4) belonging to the other chassis (1), wherein a rail (6) is arranged across the unfolded opposite cross members (5), which is movable along the cross members (5), and this rail (6) is fitted with a movable application head (7), wherein the device for 3D printing from construction materials further comprises a crane for lifting the construction materials inlets on one chassis (1 ), and a crane on the other chassis (1 ) for carrying up and placing the rail (6) for the movable application head on the opposite folding toothed cross members (5).

2. The device for 3D printing from construction materials according to claim 1 , characterized in that the chassis (1) thereof are equipped with their own drive and / or means for connecting to the towing devices of the means of transport.

3. The device for 3D printing from construction materials according to any one of claims 1 to 2, characterized in that the support structure (2) is telescopically extendable.

4. The device for 3D printing from construction materials according to any one of claims 1 to 3, characterized in that the support structure (2) is provided with a joint mechanism for the downward bending thereof.

5. The device for 3D printing from construction materials of any one of claims 1 to 4, characterized in that the telescopic mechanisms of the horizontal arms (3) and / or of the vertical telescopic brackets (4) are provided with a hydraulic drive.

6. The device for 3D printing from construction materials according to any one of claims 1 to 5, characterized in that hydraulic pistons for folding and unfolding the cross members (5) are fixed on the sides of the cross members (5).

7. The device for 3D printing from construction materials according to any one of claims 1 to 6, characterized in that the opposite horizontal arms (3) are equipped with handles for fixation to a wall for greater stability when printing.

8. The device for 3D printing from construction materials of any one of claims 1 to 7, characterized in that the vertical support structures (2), the opposite horizontal arms (3), and the vertical telescopic brackets (4) are connected to each other by joint mechanisms.

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