Multifunctional volumetric and panelized construction elements fabricated using advanced manufacturing

Abstract

Performance-based designs follow building codes that specify the desired goals of a building, allowing more flexibility and innovation. Although the current modular and manufactured methods offer fewer manufacturing steps and reduced waste compared to traditional construction, production of modular components requires use of multiple materials and machines, and the processes are not highly precise or repeatable. The present disclosure incorporates performance- based designs and advanced manufacturing methods to fabricate construction components and / or sub-components that are intended to be utilized in building structures. The components and / or sub-components are manufactured by single machines or work cells in controlled environments and are subsequently transported to the site where minimal work is involved for assembly. The performance-based designs are applied in the initial design, throughout the life, and at the end-of- life reuse plan of the components. The current disclosure enables mass customization, precision and repeatability, and use of recyclable and biobased materials.

Description

MULTIFUNCTIONAL VOLUMETRIC AND PANELIZED CONSTRUCTIONELEMENTS FABRICATED USING ADVANCED MANUFACTURINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 572,109 filed March 29, 2024, the contents of which are incorporated by reference in its entirety.FIELD

[0002] The present embodiments described herein relate generally to construction components and / or subcomponents that are intended to be utilized in building structures, and in particular to 3D printed construction components using Large Scale Additive Manufacturing (LSAM).BACKGROUND

[0003] Prescriptive-based designs follow the building codes that specify the exact methods or materials to use in a building, rather than the desired outcomes or goals. Prescriptive codes limit innovation in design and construction and increase costs and waste due to the use of unnecessary or excessive materials or methods. Performance-based designs follow building codes that specify the desired outcomes or goals of a building, rather than the specific methods or materials to achieve them. Performance-based codes allow more flexibility and innovation in design and construction, as long as the performance criteria are met. Modem modular and manufactured methods which employ performance-based designs, offer fewer manufacturing steps and reduced waste compared to traditional construction. However, production of the modular components requires use of multiple materials and machines, and the processes are not highly precise or repeatable.SUMMARY

[0004] Described herein, are construction components and / or sub-components that are intended to be utilized in a building structure. The construction components and / or subcomponents are fabricated using two advanced manufacturing methods: volumetric and panelized. The components and / or sub-components are manufactured by single machines or work cells in controlled environments and are subsequently transported to the site where minimal work is involved for assembly. The present disclosure includes a performance-based design philosophy which is considered in the initial design, throughout the life, and the end-of-life reuse plan of the components. The performance-based design enables mass customization, precision and repeatability, elimination of traditional construction timelines, use of recyclable and biobased materials, and minimizing waste.

[0005] In one aspect, the present disclosure is directed to a construction element, including: a front surface, a rear surface positioned proximate to the front surface, the front surface and the rear surface defining an interior space that is at least partially hollow; and at least one internal structural member disposed within the interior space, wherein the front surface, the rear surface, and the at least one internal structural member form a single, unitary structure.

[0006] In some embodiments, wherein the front surface, the rear surface, and the at least one internal structural member are formed from a single, continuous build process.

[0007] In some embodiments, the unitary structure includes an integrated utility conduit disposed within the panel interior, and the integrated utility conduit includes at least one of an electrical conduit, an air vent, and a piping conduit.

[0008] In some embodiments, the integrated utility conduit is disposed through an aperture disposed within the at least one internal structural member.

[0009] In some embodiments, the aperture is double teardrop shaped.

[0010] In some embodiments, the at least one internal structural member forms continuous contacts with the front surface and the rear surface.

[0011] In some embodiments, the at least one internal structural member includes ridges on at least one side.

[0012] In some embodiments, the at least one internal structural member forms intermittent contact with the front surface.

[0013] In some embodiments, the at least one internal structural member includes ridges on both sides.

[0014] In some embodiments, the at least one internal structural member forms intermittent contacts with the front surface and the rear surface.

[0015] In some embodiments, the component includes one or more edge surfaces, the one or more edge surfaces defining the panel interior, in connection with the front surface and the rear surface.

[0016] In another aspect, the present disclosure is directed to a system including the construction element of claim 1 and an additive manufacturing machine used for manufacturing the construction element, the additive manufacturing machine including a build surface, wherein the build surface is configured to be rotated from about 30 degrees to about 50 degrees while the construction element is being manufactured.

[0017] In some embodiments, the construction element includes at least one of a wall panel, a floor panel, and a roof panel.

[0018] In some embodiments, the construction element is at least partially fabricated via additive manufacturing.

[0019] In some embodiments, the construction element is at least partially fabricated via subtractive manufacturing.

[0020] In some embodiments, the construction element is pre-fabricated at a first location and assembled with other construction elements into a building at a second location.

[0021] In some embodiments, each of the front surface and the rear surface includes a window opening disposed therein.

[0022] In some embodiments, the window opening includes an outward slope.

[0023] In some embodiments, the outward slope is oriented at an angle of about 5°.

[0024] In some embodiments, the floor panel includes a VVOOVVOOVV interior pattern.

[0025] In some embodiments, at least one of O space of the VVOOVVOOVV interior pattern includes at least one of an air vent and a piping conduit.

[0026] In some embodiments, the front surface, the rear surface, and the at least one internal structural member are composed of the same material.

[0027] In some embodiments, the material includes a composite material including a fdler and a matrix.

[0028] In some embodiments, the filler includes a biobased filler.

[0029] In some embodiments, the biobased filler is a member selected from the group consisting of wood flour, bamboo, corn husks, coconut fiber, hemp fiber, flax fiber, seaweed, kelp, and coffee grounds.

[0030] In some embodiments, the filler includes a non-biobased filler.

[0031] In some embodiments, the biobased filler is a member selected from the group consisting of glass fiber, carbon fiber, wood fiber, aramid fiber, basalt fiber, talc filler, and gypsum filler.

[0032] In some embodiments, the matrix includes a biobased matrix.

[0033] In some embodiments, the biobased matrix is a member selected from the group consisting of polycarbonate (PC), polypropylene (PP), polybutylene succinate (PBS), polyethylene (PE), chlorinated polyethylene (CPE), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), poly(lactic acid) (PLA), amorphous poly(lactic acid) (aPLA), and stereocomplex polylactide (scPLA).

[0034] In some embodiments, the matrix includes a non-biobased matrix.

[0035] In some embodiments, the non-biobased matrix is a member selected from the group consisting of acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), polyetherketoneketone (PEKK), hydroxyl carboxyl sulfonated aminophenol (AH), polyamide or nylon (PA), and polyoxymethylene (POM).

[0036] In another aspect, the present embodiments are directed to a method of creating a panelized building including : determining one or more performance criteria, using building codes and / or owner requirements; applying performance-based designs to meet the determined performance criteria; determining the number and type of panels and / or modules to be included in the panelized building; determining at least one advanced manufacturing method and / or machineto manufacture the panels and / or modules; manufacturing the panels and / or modules, by the at least one advanced manufacturing method and / or machine; transferring the manufactured panels and / or modules to building site; assembling the transferred panels and / or modules at the building site; and connecting utilities to the assembled panels and / or modules.

[0037] In some embodiments, the at least one advanced manufacturing method includes an additive manufacturing method.

[0038] In some embodiments, the additive manufacturing method includes automated fiber placement, fused granulate fabrication, and / or fused filament fabrication.

[0039] In some embodiments, the at least one advanced manufacturing method includes performing near net shape printing.

[0040] In some embodiments, the at least one advanced manufacturing method includes subtractive manufacturing.

[0041] In some embodiments, the at least one advanced manufacturing machine includes a commercial 3D printer.

[0042] In some embodiments, the method includes at least one method of preventing unsupported overhangs.

[0043] In some embodiments, the at least one method of preventing unsupported overhangs includes printing the panels and / or modules in a plane rotated about an X-axis of a printing surface.

[0044] In some embodiments, the rotated plane includes a 45° rotation about the X-axis of the printing surface.

[0045] In some embodiments, the at least one method of preventing unsupported overhangs include printing a structural support.

[0046] In some embodiments, the structural support is removeable.

[0047] In some embodiments, manufacturing the panels and / or modules further includes at least one step performed via a human-in-the-loop process.

[0048] In some embodiments, assembling the transferred panels and / or modules further includes installing at least one drop-in room.

[0049] In some embodiments, the drop-in room includes at least one appliance, wherein the at least one appliance includes at least one of a plumbing appliance, an electric appliance, and a gas appliance.

[0050] In another aspect, the present disclosure is directed to a drop-in room including a plurality of prefabricated components including: at least one appliance; and the structural element as previously described, wherein the at least one appliance is at least one of fluidly coupled and electrically coupled to the structural element.

[0051] In some embodiments, the plurality of prefabricated components are configured such that they may be shipped and / or delivered to a location of the drop-in room, and may form the drop-in room based on only a final assembly process.

[0052] In another aspect, the present disclosure is directed to a drop-in room including a plurality of prefabricated components including: at least one wall panel as described herein; and at least one of floor panel as described herein.

[0053] In some embodiments, once assembled, the drop-in room includes a continuous conduit extending from an interior of the at least one wall panel to the interior of the at least one floor panel, wherein the continuous conduit includes at least one of an electrical conduit and an air duct.

[0054] In another aspect, the present disclosure is directed to a method for providing a structure including: defining a design space that includes at least one interior volume; determining performance criteria based on building codes and / or owner requirements; applying performancebased design methodologies to meet the performance criteria, thereby producing an updated design space and an updated interior volume; determining at least one advanced manufacturing parameter to enable production of the updated design space; producing a continuous surface of the updated design space that borders the updated interior volume, wherein the continuous surface includes multiple attached elements that are configured such that they define the updated interior volume.

[0055] In some embodiments, producing a continuous surface of the updated design space includes using advanced manufacturing to produce the continuous surface at a site location.

[0056] In some embodiments, producing a continuous surface of the updated design space includes using advanced manufacturing to produce the continuous surface at a production facility.

[0057] In some embodiments, the method further includes shipping the continuous surface to a site location.

[0058] In some embodiments, the method further includes connecting at least one utility to the structure.

[0059] In some embodiments, producing a continuous surface of the updated design space includes using at least one additive manufacturing process.

[0060] In some embodiments, determining performance criteria based on building codes and / or owner requirements includes consideration of the multiple attached elements.

[0061] In some embodiments, determining performance criteria based on building codes and / or owner requirements includes consideration of the at least one detached element.

[0062] In some embodiments, determining performance criteria based on building codes and / or owner requirements includes defining a 2D footprint of the design space.

[0063] In some embodiments, determining at least one advanced manufacturing parameter includes defining vertical layers for each of the multiple attached elements.

[0064] In some embodiments, determining at least one advanced manufacturing parameter includes constructing a digital build file enabling 3D printing of the multiple attached elements.

[0065] In some embodiments, the multiple attached elements are composed at least partially of: glass fiber, carbon fiber, wood fiber, aramid fiber, basalt fiber, talc filler, and gypsum filler, polycarbonate (PC), polypropylene (PP), polybutylene succinate (PBS), polyethylene (PE), chlorinated polyethylene (CPE), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), poly(lactic acid) (PLA), amorphous poly(lactic acid) (aPLA), and stereocomplex polylactide (scPLA), acrylonitrile butadiene styrene (ABS), poly ether ether ketone (PEEK), polyetherketoneketone (PEKK), hydroxyl carboxyl sulfonated aminophenol (AH), polyamide or nylon (PA), and / or polyoxymethylene (POM).BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Fig. 1A shows an example of internal structure of a wall, according to aspects of the present disclosure.

[0067] Fig. IB shows an example of internal structure of a wall, according to aspects of the present disclosure.

[0068] Fig. 2A illustrates an exemplary thermal image of an interior surface of a wall, according to aspects of the present disclosure.

[0069] Fig. 2B illustrates an exemplary thermal image of an interior surface of a wall, according to aspects of the present disclosure.

[0070] Fig. 3A illustrates an example of a thermal simulation of a wall, according to aspects of the present disclosure.

[0071] Fig. 3B illustrates an example of a thermal simulation of a wall, according to aspects of the present disclosure.

[0072] Fig. 4A illustrates an example of a window trim and sealant in a wall, according to aspects of the present disclosure.

[0073] Fig. 4B illustrates an example of a cross section of a wall at a rough window opening, according to aspects of the present disclosure.

[0074] Fig. 5A illustrates an example of internal structure of a wall, according to aspects of the present disclosure.

[0075] Fig. 5B illustrates an example of a cross section of a wall, according to aspects of the present disclosure.

[0076] Fig. 6 illustrates an example of a desktop scale prototype of a wall, according to aspects of the present disclosure.

[0077] Fig. 7A illustrates an example of a wall geometry featuring insulation fill ports, according to aspects of the present disclosure.

[0078] Fig. 7B illustrates an example of a wall cross section at a modified rough window opening, featuring a modified rough window opening, according to aspects of the present disclosure.

[0079] Fig. 8A illustrates an example of a thermal simulation of an interior surface (i.e., inner skin) of a wall, according to aspects of the present disclosure.

[0080] Fig. 8B illustrates an example of a thermal simulation of an exterior surface (i.e., outer skin) of a wall, according to aspects of the present disclosure.

[0081] Fig. 9A illustrates an exemplary model of a wall to be printed on a commercial 3D printer, according to aspects of the present disclosure.

[0082] Fig. 9B illustrates an exemplary design of a structural member of a wall featuring a 35° rotation about X axis, according to aspects of the present disclosure.

[0083] Fig. 9C illustrates examples of test prints resulting in print failure, according to aspects of the present disclosure.

[0084] Fig. 9D illustrates an exemplary test print resulting in print failure, according to aspects of the present disclosure.

[0085] Fig. 10A illustrates an exemplary model of a wall to be printed on a commercial 3D printer, according to aspects of the present disclosure.

[0086] Fig. 10B illustrates an exemplary design of a structural member of a wall featuring a 45° rotation about X axis, according to aspects of the present disclosure.

[0087] Fig. 10C illustrates an example of a successful test print, according to aspects of the present disclosure.

[0088] Fig. 11A illustrates an exemplary model of an exemplary wall design for an interrupted print using a commercial 3D printer, according to aspects of the present disclosure.

[0089] Fig. 11B illustrates an example of a slice of the model to be printed on day one, according to aspects of the present disclosure.

[0090] Fig. 11C illustrates an example of a slice of the model being printed on day two, according to aspects of the present disclosure.

[0091] Fig. 12A illustrates an example of a final print of a wall, according to aspects of the present disclosure.

[0092] Fig. 12B illustrates an example of the back of a final print of a wall, according to aspects of the present disclosure.

[0093] Fig. 12C illustrates an example of a final print of a wall after removal of the support structure, according to aspects of the present disclosure.

[0094] Fig. 13A illustrates an example of a final print of a wall after positioning a window, according to aspects of the present disclosure.

[0095] Fig. 13B illustrates an example of a final print of a wall after sealing the window, according to aspects of the present disclosure.

[0096] Fig. 14A illustrates an example of internal structure of a wall, according to aspects of the present disclosure.

[0097] Fig. 14B illustrates an example of a cross section of a wall, according to aspects of the present disclosure.

[0098] Fig. 15A illustrates an example of a desktop scale prototype of a wall, according to aspects of the present disclosure.

[0099] Fig. 15B illustrates an example of desktop scale prototype of a wall with installed cables, according to aspects of the present disclosure.

[0100] Fig. 16A illustrates an example of a horizontal utility chase-way profile.

[0101] Fig. 16B illustrates an example of a horizontal utility chase-way profile, according to aspects of the present disclosure.

[0102] Fig. 17 illustrates an exemplary wall chase-way with an installed cable, according to aspects of the present disclosure.

[0103] Fig. 18A illustrates an example of a wall modular chase-way assembly, according to aspects of the present disclosure.

[0104] Fig. 18B illustrates exemplary completed prints of a wall modular chase-way assembly, according to aspects of the present disclosure.

[0105] Fig. 19A illustrates an exemplary model of a wall for an interrupted print using a commercial 3D printer, according to aspects of the present disclosure.

[0106] Fig. 19B illustrates an example of a slice of the model to be printed on day two, according to aspects of the present disclosure.

[0107] Fig. 19C illustrates an example of a slice of the model to be printed on day three, according to aspects of the present disclosure.

[0108] Fig. 20A illustrates an example of a slice of a model printed on day one, according to aspects of the present disclosure.

[0109] Fig. 20B illustrates an example of a slice of a model printed on day two, according to aspects of the present disclosure.

[0110] Fig. 20C illustrates an example of a slice of a model printed on day three, according to aspects of the present disclosure.

[0111] Fig. 20D illustrates a finished example of the model printed on day four, according to aspects of the present disclosure.

[0112] Fig. 21 A illustrates an exemplary CAD drawing of a first-floor cassette within a channel, according to aspects of the present disclosure.

[0113] Fig. 21B illustrates an exemplary test print of the first-floor cassette, according to aspects of the present disclosure.

[0114] Fig. 22A illustrates an example of a first-floor cassette, according to aspects of the present disclosure.

[0115] Fig. 22B illustrates an example of a closeup of the first-floor cassette, according to aspects of the present disclosure.

[0116] Fig. 23 illustrates an exemplary stress analysis of the first-floor cassette, according to aspects of the present disclosure.

[0117] Fig. 24 illustrates a closeup example of through-hole features of the first-floor cassette, according to aspects of the present disclosure.

[0118] Fig. 25A illustrates an example of a conventional channel that is used to install floor cassettes.

[0119] Fig. 25B illustrates an example a channel with an installed end connection, according to aspects of the present disclosure.

[0120] Fig. 26A illustrates an exemplary full-scale print of the first-floor cassette, according to aspects of the present disclosure.

[0121] Fig. 26B illustrates an exemplary closeup of a full-scale print of the first-floor cassette installed in a channel, according to aspects of the present disclosure.

[0122] Fig. 27A illustrates an example of a design variation of a second-floor cassette, according to aspects of the present disclosure.

[0123] Fig. 27B illustrates an example of a design variation of a second-floor cassette, according to aspects of the present disclosure.

[0124] Fig. 27C illustrates an example of a design variation of a second-floor cassette, according to aspects of the present disclosure.

[0125] Fig. 27D illustrates an example of a design variation of a second-floor cassette, according to aspects of the present disclosure.

[0126] Fig. 28 illustrates an exemplary ANSYS model of the second-floor cassette, according to aspects of the present disclosure.

[0127] Fig. 29A illustrates a closeup example of the second-floor cassette, according to aspects of the present disclosure.

[0128] Fig. 29B illustrates a closeup example of the second-floor cassette, according to aspects of the present disclosure.

[0129] Fig. 29C illustrates a closeup example of the second-floor cassette, according to aspects of the present disclosure.

[0130] Fig. 30 illustrates a flow chart diagram of a method of creating a panelized building, according to aspects of the present disclosure.

[0131] Fig. 31 is a flow chart diagram of a method of creating a volumetric structure, according to aspects of the present disclosure.

[0132] Fig. 32 is a flow chart diagram of a method of creating a volumetric structure, according to aspects of the present disclosure.DEFINITIONS

[0133] Additive Manufacturing: As used herein, the term “additive manufacturing” refers to a process that adds successive layers of material to create an object. Additive manufacturing methods include 3-D printing, powder-bed laser printing systems, fused deposition modeling, and other processes capable of creating highly complex assemblies from one continuous material and / or from one continuous build process.

[0134] Assembly OSM. As used herein, the term “Assembly OSM” refers to a modular high-rise builder using techniques from car and airplane manufacturers to build big buildings faster, cheaper, and with lower emissions (for example, using “OSM”, or “offsite manufacturing”). Assembling components offsite results in fewer gas-burning trucks on construction sites, and the buildings themselves are designed to be lighter and tighter.

[0135] Automated Fiber Placement (AFP): As used herein, the term “automated fiber placement (AFP)” refers to a manufacturing process that has three different inputs: fiber / polymer tape, heat, and pressure. The end-effector expertly handles the tape and deposits it onto a surface with the help of heat and pressure. The process allows the fabrication of highly customized parts as each ply can be placed at different angles to best carry the required loads. The use of robotics gives the operator active control over all of the process's critical variables, making the process highly controllable and repeatable.

[0136] Building Information Modeling (BIM): As used herein, the term “building information modeling (BIM)” refers to a process of planning, design, implementation and maintenance of a building that uses all the information regarding its entire life cycle. BIM makes it possible to recreate a virtual building model which is not only a simple 3D representation, but a dynamic model that contains a range of information such as geometry, materials, load-bearing structural members, thermal and energy performance characteristics, health and safety aspects, maintenance and facility management, costs, and life cycle.

[0137] Chase-way: As used herein, the term “chase-way” refers to a cavity and / or conduit within a wall which provides an area for pipes, ducts, wires, etc. to run through the building.

[0138] Digital Twin: As used herein, the term “digital twin” refers to a digital representation of a physical object, person, or process, contextualized in a digital version of its environment A digital twin spans its lifecycle and is updated from real-time data to help an organization simulate real situations and their outcomes, ultimately allowing it to make better decisions

[0139] Forward-Looking Infrared (FLIR) camera: As used herein, the term “forwardlooking infrared (FLIR) camera” refers to a thermographic camera that senses infrared radiation, typically emitted from a heat source (thermal radiation), to create an image.

[0140] FL0W-3D As used herein, the term “FL0W-3D” refers to a versatile CFD simulation platform for investigation of dynamic behavior of liquids and gas in a wide range of physical processes. FL0W-3D focuses on free surface and multi-phase applications, serving a broad range of industries including microfluidics, bio-medical devices, water civil infrastructure, aerospace, consumer products, additive manufacturing, inkjet printing, laser welding, automotive, offshore, energy and automotive.

[0141] Fused Granulate Fabrication (FGF): As used herein, the term “fused granulate fabrication (FGF)” refers to an extrusion-based 3D printing technique where granulates (AKA pellets) are melted and fed through a nozzle. It may also be referred to as ‘Fused Particular Fabrication’ or ‘Pellet 3D Printing’. FGF incorporates a robust barrel and screw extrusion system similar to traditional plastic extrusion and injection molding. Pellets are fed from a dryer to the extruder, where it makes contact with a screw. A motor drives the screw, which conveys the pellets through a heated barrel. Ideally, the extruder’s barrel has multiple heating sections, allowing the material to progressively heat up and melt.

[0142] Fused Filament Fabrication (FFF): As used herein, the term “fused filament fabrication (FFF)” refers to an extrusion-based 3D printing technique that feeds continuous filament through a heated extruder. As the filament travels through the extruder’s heating zones, it begins to liquify and is deposited along a controlled path to build parts one layer at a time. It may also be referred to as ‘Fused Deposition Modeling’ or ‘Filament 3D Printing’. The mechanics of the extrusion system entail the strand of filament being pushed or pulled (i.e., pultrusion) into a set of direct drive rollers in a pinch system format. This feeds the material into a heating zone and then through a brass or steel nozzle.

[0143] Human-In-The-Loop: As used herein, the term “human-in-the-loop” refers to a process that requires human interaction. Humans take action on a component while it is being printed or post-processed, as opposed to fully automated processes where no human intervention is required while a part is being made, manufactured and / or fabricated. As a result, human-in-the- loop is able to inform the design.

[0144] Industry Foundation Classes (IFC): As used herein, the term “industry foundation classes (IFC)” refers to a particular data format that has the purpose of allowing the inter-exchange of an information model without loss or distortion of data. It’s an open fde format, neutral, and created to facilitate interoperability between different operators. IFC is designed to process a building’s data model throughout its entire life cycle, from feasibility up to its realization and maintenance, passing through the various design and planning phases.

[0145] Near Net Shape Printing: As used herein, the term “near net shape printing” refers to using traditional subtractive equipment on 3D printed parts to be milled to final part design.

[0146] Performance-Based Codes / Performance-Based Design: As used herein, the term“performance-based codes” refers to building codes that specify the desired outcomes or goals of a building, rather than the specific methods or materials to achieve them. Performance-based codes allow more flexibility and innovation in design and construction, as long as the performance criteria are met. They can also adapt to changing technologies, materials, and practices, as they are not tied to specific methods or standards. In addition, they can reduce costs and waste, as they allow for the use of optimal materials and methods for each project.

[0147] Prescriptive-Based Codes / Prescriptive-Based Design: As used herein, the term “prescriptive-based codes” refers to building codes that specify the exact methods or materials to use in a building, rather than the desired outcomes or goals. Prescriptive codes are more rigid and uniform in design and construction, but they also provide uniformity and quality, due to their clear requirements and established methods. Additionally, they make compliance and inspection easier, as they have measurable criteria to check.

[0148] Print-In-Place: As used herein, the term “Print-In -Pl ace” refers to a 3D model designed to be printed in one piece, with all moving or interlocking pieces built into the original design. Print-in-place models are created to enable the parts to be printed in their final configuration, ready to be used or operated right away, in contrast to typical 3D printing, whereitems are produced in separate sections and assembled. The model's components are made with clearances and tolerances that provide smooth movement or operation after printing.

[0149] Subtractive Manufacturing: As used herein, the term “subtractive manufacturing” refers to controlled material removal processes that start with solid blocks, bars, rods, and / or other workpieces of various shapes which are further shaped by removing material through cutting, boring, drilling, milling, grinding, and / or other processes that remove material.DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0150] The present embodiments include construction components or sub-components that are intended to be utilized in a structure (e.g., a building). The components and / or sub-components may be fabricated using, inter alia, advanced manufacturing to implement two approaches: volumetric and panelized. Common examples of panelized components include interior walls, exterior walls, floors, ceilings, roofs, overhangs, and foundations. Common examples of volumetric components include bathroom spaces, kitchen spaces, bedroom spaces, living area spaces, and outdoor protected spaces. Use of advanced manufacturing allows for automation of fabrication, precise placement of inclusions and functionality, digital twin creation, usage of biobased materials, functionally dependent design and algorithmic usage of materials, minimization of materials, minimization of fabrication energy, precise panel and volumetric joints, jigs and tools for human in the loop actions involving the panels or volumes, and balancing of functional requirements by designers with fabricators and installers.

[0151] The present disclosure relates to a performance-based design philosophy as opposed to a more conventional prescriptive-based design philosophy. This change affects several aspects including structural performance, thermal performance, embodied energy, sequestered carbon, operational energy, operational cost, end-of-life cost, end-of-life recycling and reuse, and planning for multi -generational use of materials. These aspects may be considered in the initial design, throughout the life, and / or the end-of-life reuse plan. Multi-objective optimization methods may be utilized which consider owner priorities, varying from owner to owner, site to site, structure to structure, component to component, sub-component to sub-component, and material to material. The mass customization offered by ground-up performance-based design philosophy allows planning for end-goals throughout design, construction, use, and / or reuse.

[0152] The present disclosure offers several advantages to traditional construction methods. Mass customization is possible with minimal input effort which reduces costs of materials and labor. The design approach allows highly precise and repeatable constructs, an option that is not currently available by other modular or manufactured methods with similar reduced steps, materials, machines, labor, and / or locations. Due to precision of design and manufacturing, waste is minimal compared to the 20-30% waste in typical construction. Highly automated processes with built-in quality assurance (QA) and / or quality control (QC) reduce variations in design, materials, and production, which result in a decrease in the required overbuilding due to unknown strengths. The pre-design of services reduces waste and the need for redesign and / or inspection by trade’s persons in traditional construction. Pre-designed services eliminate the need for traditional timelines and specific orders in which sub-contractors access the site, by massively parallelizing and opening critical path methodology to reduce construction time. According to a recent research study, the availability of feedstocks which are recyclable, whether or not biobased, enables energy savings of up to 99.9% compared to using virgin materials in traditional construction. Use of local bio-waste and biomaterials as construction materials and the subsequent reduced transportation costs and impacts, result in lowering embodied energy and increasing sequestered carbon.

[0153] The present disclosure enables feedback loop controls throughout provided processes, where each part of a process informs one or more other parts of the process. Owing to a performance-based design philosophy owners and designers are able to make decisions about trade-offs based on several factors simultaneously. While traditional module manufactured housing requires several teams of humans following plans, the present embodiments allow the machines to guide humans to make correct decisions at the appropriate time and / or location, using suitable materials, and therefore diminishing the likelihood of errors. In some embodiments, for example, printed chase-ways allow only one pipe to go from a point A to a point B, thereby reducing or eliminating the likelihood of a pipe being placed in the wrong location due to human error (i.e., because the chase-way only goes from point A to point B). Various embodiments may also reduce or even eliminate trade’s persons interferences with each other (e.g., mechanical installers cutting electric lines, or plumbers running through finish carpentry).

[0154] Various embodiments involve using single machines and / or work cells to manufacture components and sub-components in controlled, low-cost environments where safety, ergonomics, and environmental controls are easily accessible as opposed to on-site variabilities. Manufactured components and sub-components are subsequently transported to the site where minimal work is involved to join and seal assemblies. Various aspects of the present disclosure provides opportunities to maximize safety, productivity, and quality while minimizing risk, costs, and time, in accordance with various methods and systems disclosed herein. Compared to other modular or manufactured methods which are multi -material, multi-step, multi-machine, or multilabor, various embodiments provide the opportunity for single machines or single work cells to produce integrated components and sub-components.

[0155] An exemplary high-level framework for creating a building according to the present disclosure includes: designing the building, determining the number and types of panels and modules, manufacturing panels and modules at the fabrication facility, shipping manufactured panels and modules to the site, assembling the panels and modules, and connecting the utilities.

[0156] The present embodiments may performs multiple functions (in some cases, via one or more components) that may include one or more of: a vertical force resisting system component, a lateral force resisting component, a vapor barrier component, a moisture barrier component, an impact resistant component, an energy dissipation system component, a thermal regulation component, a thermal mass component, an acoustic dampening element, a mechanical system containment, an electrical system containment, a plumbing system containment, an integral fenestration component, an integrated doorway attachment, an integrated barrier attachment, and / or an integrated functional attachments or inclusions.

[0157] In some embodiments, thermal mass may be optimized on a part-by part basis and / or within parts themselves. For example, the density of a material may be changed, functionally graded material additives may be added, connections of parts may be changed when necessary, and beads within and / or between layers may be redesigned.

[0158] In some embodiments, the combination of all the elements may act as a structure to help with acoustic dampening. The acoustic dampening may be considered as a part of multiple objectives during the design process, the multiple objectives including, for example, the composition of the elements, the density of the elements, the connectivity of the elements, thestiffness of the elements, and / or the addition of breaks and bridges. Tn some embodiments, the material and geometry may be changed to balance acoustic performance, while considering other factors such as structural, thermal, and moisture at the same time.

[0159] Various embodiments may include the use of a digital twin. In some embodiments, use of the digital twin may include reliability analysis of the structure. A digital twin may be employed by each step to inform other steps and design of subsequent structures, through making predictions, updating the predictions based on actual manufacturing data, and further updating the predictions based on actual conditions over time. In some embodiments, use of digital twin may include informing the end-of-life use and re-use (i.e., recyclability) of the material. As the structures age, the molecular weight and potential usages of the material may change over time. Digital twin, for example, may be used to predict when the roof (or other structures) need to be replaced.

[0160] In some embodiments, a digital twin may use data collected by sensors installed within the structure, such as thermal or moisture sensors. The sensors may be installed during manufacturing, post-print, and / or during life of the structure. In some embodiments, digital twin may use manufacturing data, material data, environmental data from climate / weather sources, electrical usage, water usage, gas usage, sewage usage, vibration sensing in seismic zones, and building systems data.Panelized Embodiments

[0161] The present disclosure includes panelized components that are intended to be utilized to build a structure (e.g., construct a building). In some embodiments, the panelized components may include structural components. Examples of structural components may include interior walls, exterior walls, floors, ceilings, roofs, overhangs, and foundations. In some embodiments, the panelized components may include aesthetic and / or functional components. Examples of aesthetic and / or functional components may include room dividers, supports, insulators, staircases, closets, built in shelves and cabinets, kitchen counters, balconies, porches, ice-fishing hut, and fences. The panelized components may divide the surrounding space into a positive space and a negative space. In some embodiments, the positive space may include the structural components, the aesthetic components, and / or the functional components. In someembodiments, the negative space may include the insulation, wiring, air conditioning, and / or plumbing / electric / gas appliances.Volumetric Embodiments

[0162] In accordance with another aspect, some embodiments provide structures (e.g., rooms, buildings) created using a volumetric approach. Specifically, in some embodiments, a desired interior space can be specified and then the corresponding structure produced defines that space (e.g., defines it through production of a single continuous surface or series of surfaces). By way of example, in some embodiments, a desired room size and shape can be defined, and the walls, floor and ceiling produced in one continuous process to produce the room (e.g., using one or more additive manufacturing techniques). This approach is in contrast to the standard production of rooms or buildings using individual components such as walls, floors, ceilings or components thereof, and then assembling them to form the desired room size and shape.

[0163] The present disclosure includes volumetric components that construct a room and / or a building. In some embodiments, a volumetric component may include a partial room, for example a floor and one or more walls. In some embodiments, a volumetric component may include a whole room. Examples of a whole room may include a bathroom, a kitchen, a bedroom, and a living area. In some embodiments, a volumetric component may include an entire building (e.g., a house). Fabrication of volumetric components may include a contiguous print, where the sub-components are printed together to form one three-dimensional space. The resulting volumetric components are considered whole and in final shape, and do not involve the joining of separately printed sub-components.

[0164] The volumetric embodiments of the present disclosure may be 3D-printed (i.e., additively manufactured) via a continuous build process, and may include a continuous unitary structure with an internal enclosure and / or interior volume of the volumetric embodiment or structure (e.g., to store items, house a human being, and / or perform other functions). In some embodiments, a volumetric structure includes a shed, a house, a lean-to, an ice-fishing hut, a porch and / or a temporary dwelling. In some embodiments, an interior volume of the volumetric structure may be from about 10 cubic feet to about 25,000 cubic feet (for example, from about 20 cubic feet to about 15,000 cubic feet, i.e., from about 40 cubic feet to about 10,000 cubic feet, i.e., from about60 cubic feet to about 5,000 cubic feet, i.e., from about 80 cubic feet to about 2,000 cubic feet, i.e., from about 100 cubic feet to about 1,000 cubic feet, from about 300 cubic feet to about 3,000 cubic feet, from about 500 cubic feet to about 2,500 cubic feet, from about 800 cubic feet to about 2,200 cubic feet, and / or from about 1,000 cubic feet to about 2,000 cubic feet). In some embodiments, the volumetric structure includes a geometry configured such that from the perspective of the interior volume, an outer wall of the volumetric structure spans substantially the full periphery (i.e., greater than about 240 degrees, i.e., greater than about 270 degrees, i.e., greater than about 300 degrees, i.e., greater than about 330 degrees, i.e., greater than about 345 degrees of the periphery). In some embodiments, the volumetric structure includes an aperture such as a window. In some embodiments, the volumetric structure defines more than one interior volume (i.e., multiple rooms) formed via a continuous additive manufacturing process, with multiple walls (i.e., defining the multiple rooms) all forming a single, unitary body. For example, in some embodiments, the volumetric structure defines a house including multiple interior volumes or rooms, each being connected to at least one other interior volume (or room) via one or more apertures (i.e., doorways, alcoves, hallways, etc.) defined within wall portions, each wall portion being connected to one or more adjacent wall portions, the multiple wall portions collectively forming a single unitary body defining both the volumetric structure (positive space) and interior volumes (i.e., open space). In some embodiments, the continuous build process may be temporarily paused to accommodate the end of a work shift, the resupplying of feed materials, and / or to accommodate other machine or process adjustments.Methods and Modalities

[0165] The present disclosure includes several manufacturing methods. In some embodiments, printing method may include additive manufacturing. In some embodiments, a printing method may include subtractive manufacturing. Subtractive manufacturing, for example, may involve near net shape printing. In accordance with various aspects of the present disclosure, near net shape printing may be used to form (for example, via 3D printing) a workpiece that is bigger (in some cases, slightly bigger) than the intended final geometry of the finished part. Subtractive methods can then be used to bring the workpiece to its final geometry, for example, in instances where direct-printing of the part is difficult or impossible due to the part geometry, and / orin instances where the part is susceptible to damage, sagging, and / or other undesirable deformation during the printing process. Near net shape printing can be used to design in additional robustness (for example, via increased localized thickness) during the printing process, which can then be removed during one or more subsequent subtractive processes. These methods may be used to mate multiple sub -components into a single component, or to achieve a more precise fit between multi-component assemblies. In some embodiments, a printing method may include pick and place process. The pick and place process may be used to place components such as doors, windows, junction boxes, cabinets, fixtures, etc. In some embodiments, a printing method may include winding. The winding may be used to install components such as pipes, electrical conduits, ducts, seals, etc.

[0166] The present disclosure may include several printing systems and processes. In some embodiments, printing systems may include Juggerbot Tradesman Series™ P3-44, Cincinnati Inc. Big Area Additive Manufacturing (BAAM), and Ingersoll Machine MasterPrint4' 3X to implement the fused granulate fabrication method. In some embodiments, printing systems may include Ingersoll Machine MasterPrint* 3X and Electroimpact to implement Automated Fiber Placement (AFP) processes. In some embodiments, printing systems may include Ingersoll Machine MasterPrint'® 3X, Thermwood and Hendrick CNC machine to implement subtractive manufacturing methods. In some embodiments, printing systems may include CEAD systems (i.e., large format 3D printer, robot, and / or gantry systems) to implement additive manufacturing methods. In some embodiments, printing systems and processes used in connection with the present disclosure may include build platforms / build areas with heights of 10-feet or more (for example, 12-feet or more, 15-feet or more, etc.), widths of 10-feet or more (for example, 12-feet or more, etc.), and lengths of 10-feet or more (for example, 12-feet or more, 15-feet or more, 20- feet or more, 25-feet or more, 30-feet or more, etc.). In some embodiments, printing systems and processes used in connection with the present disclosure may include build platforms that can accommodate printed work pieces that weigh more than 10,000 pounds (i.e., more than 15,000 pounds, more than 20,000 pounds, more than 25,000 pounds, more than 30,000 pounds, more than 35,000 pounds, more than 40,000 pounds, etc.). In some embodiments, Automated Fiber Placement (AFP) processes employ polyphenylene sulfide (PPS) materials (i.e., carbon-fiber reinforced polyphenylene sulfide (PPS-CF)).

[0167] The present disclosure includes various layer heights which may be determined by numerous factors. Determining factors may include one or more of geometry, printing machine, material, processing parameters, environmental cooling or heating, pellet geometry, pellet moisture, extruder pressure, throughput, travel speed, torque capacity, acceleration capacity, part size, part mass, part cross section distance, complexity and / or shape, geometry of a previously printed part, shiftwork timing, operator experience, machine maintenance condition(s), electrical / air availability, localized forced cooling and / or heating, filler percentage, size, shape, orientation and / or distribution, matrix / filler sizing efficacy, micro-void formation, and / or macrovoid formation. In some embodiments, the bead aspect ratio (i.e., the ratio of the width to the height of the extrudate cross section) may range from 0.1 to 14, where the width may range from 0.2mm to 55mm and the height may range from 0.01mm high to 20mm.

[0168] In some embodiments, printing process disclosed herein may include the use of binders and / or coatings between print layers. Examples include chemical treatments, thermal treatments, moisture treatments, and solvent treatments.

[0169] Methods and systems provided in the present disclosure may include different bead overlap approaches. In some embodiments, the bead overlap approach may include prescriptive equation-driven bead overlap approaches. The equation-driven bead overlap approach may use geometric analysis to determine volumes, distances, centerlines, overfill factors, and offset factors to place beads where the total volume in a space is desired. For example, equation-driven bead overlap may be utilized to maximize transverse bead adhesion. In some embodiments, a bead overlap approach may include a performance-based analysis bead overlap approach. In some embodiments, a performance-based analysis bead overlap may include using computational fluid dynamics / mechanics to determine bead shape at orifice exit. Computational fluid dynamics / mechanics, for example, may be performed using FLOW-3D and OpenFOAM software packages. In some embodiments, a performance-based analysis bead overlap may be needed to further refine the geometric based equation-driven approach.

[0170] Methods and systems provided in the present disclosure may include use of modular structures, such as bedrooms, bathrooms, and kitchen modules. Modular structures may be used in new construction or to retrofit buildings by installing kitchens and bathrooms within existing blank spaces. Assembly OSM, for example, provides bathroom and kitchen modules thatare drop-ins for a larger module which in turn is a component of the entire building. In some embodiments, modules may be designed as drop-in rooms with necessary fixtures, such as toilet, sink, shower, plumbing, electrical, heating, venting, cabinets, and wall fixtures, and later simply connected to the existing infrastructure. In some embodiments, volumetric joints may include commercial off-the shelf (COTS) components such as those used in shipping container nodes, and / or custom joints. The design of fenestration connections needs to allow thermal and hygrothermal expansion and contraction while maintaining weather-tightness. In some embodiments, COTS components may include gaps for a foam which later is covered with door trims (in the case of interiors) or roof membranes (in the case of exteriors).

[0171] Methods and systems provided in the present disclosure may include human-in-the- loop systems and methodologies, where humans can take actions while a structure, a panel, or a module is being printed and / or post-processed. These actions, for example, may include adding utility components, performing subtractive manufacturing, performing one or more post-print treatments, etc. With fully-automated construction, the construction is separated from direct human contact and / or interaction, while with human-in-the-loop processes, the human is able to inform the design interactively.Materials

[0172] The present disclosure offers the use of biobased as well as non-biobased materials for the 3D printed framework. While the ability to use bio-waste and recycled materials is a significant differentiator, non-biobased materials may be used when needed. A performance-based design philosophy may be employed for the materials as well as the structure and processing. Materials may be custom designed, using functionally graded material properties and modifying processing parameters to change material performance on a bead by bead and inch-by-inch basis. For example, some materials change density based on the thermal history, and as a result, insulative foam may be produced where insulation is a requirement, or fully dense material may be produced where strength is a requirement.

[0173] Materials, including bio-based materials, may be provided from any application- appropriate source. For example, non-limiting sources of biobased materials may include recycledmaterial from decommissioned structures, reclaimed waste material from agricultural sites, wood processing sites, and ocean product processing sites.Fillers

[0174] In some embodiments, materials used for printing (i.e., biobased printing) may include one or more fillers, according to the present disclosure. Fillers may be used to increase the volume of the materials used for printing, for internal binding or adhesion of the print materials, and / or for providing strength of the print materials, according to the present disclosure. In some embodiments, fillers may include biobased fillers. The biobased fillers may include cellulosic materials such as wood flour, grasses such as bamboo, com husks, coconut fiber, hemp fiber, flax fiber, agricultural waste in general, sea-resource based materials such as seaweed and kelp, and coffee grounds. In some embodiments, non-biobased fillers or resins may be used such as glass fiber, carbon fiber, wood fiber, aramid fiber, basalt fiber, talc filler, and gypsum filler.

[0175] In accordance with various embodiments, fillers provide any of several properties including strength and stiffness of the matrix, bulking, thermal and / or hygrothermal, interconnectivity, surface finishes, roughness, emissivity, and radiation. Fillers may also be modified in length for changing the bead shape.Matrices

[0176] In some embodiments, materials used for printing (i.e., biobased printing) may include one or more matrices, according to the present disclosure. Matrices may be used for structurally supporting (for example, providing tensile strength to) the print material(s). For example, matrices may be used for supporting filler material(s) and holding print material(s) together, according to the present disclosure. In some embodiments, a matrix may include biobased materials such as polycarbonate (PC), polypropylene (PP), polybutylene succinate (PBS), polyethylene (PE), Chlorinated Polyethylene (CPE), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), poly(lactic acid) (PLA), amorphous poly(lactic acid) (aPLA), and stereocomplex polylactide (scPLA).

[0177] In some embodiments, a matrix may include non-biobased materials such as acrylonitrile butadiene styrene (ABS), poly ether ether ketone (PEEK), poly etherketoneketone (PEKK), hydroxyl carboxyl sulfonated aminophenol (AH), polyether imide (PEI), polyamide or nylon (PA), and polyoxymethylene (POM).

[0178] In some embodiments, custom materials may be designed using one or more of kinetic compounding, cellulosic nano-fibrils, cellulosic nanocrystals, custom fungus, borates, silicates, and other mitigating Fire Smoke Toxicity additives. In some embodiments, application of performance-based design may enable use of a material for different purposes, based on several factors such as how it is processed, where it is located, what its thermal history is, etc.

[0179] In some embodiments, various materials may be utilized depending on the specific applications. For example, for outdoor applications and / or for structural or exterior features that are exposed to an exterior (outdoor) environment, the material systems may include ASA (i.e., ASA filament, e.g., acrylonitrile styrene acrylate and / or acrylonitrile styrene acrylate filament). In embodiments that require tight control of dimensional parameters such as furniture, appliances, and / or other components, PET-G (polyethylene terephthalate glycol) might be used. In some embodiments, polypropylene may also be used for various interior features such as furniture and / or appliances. Accordingly, in some embodiments, the systems and components may include ASA filament, e.g., acrylonitrile styrene acrylate and / or acrylonitrile styrene acrylate filament, PET-G (polyethylene terephthalate glycol), polypropylene and / or various combinations thereof.System Embodiments

[0180] Walls, floors and roofs may experience vertical and lateral loads including bending, shear, compression, and tension due to mechanical loading, thermal loading, moisture loading, creep, and stress relaxation. The present disclosure encompasses the systems designed as a shear wall and diaphragm roofs and floors with the potential to add moment connections between the components. This allows vertical, horizontal, and mixed (single, double, and multi-curvature) components to be used based on the performance needs (e.g., mechanical, hygrothermal, and spatial / temporal loading) of a particular component.

[0181] Structural strength provided by the internal structure of the provided embodiments has been evaluated in various ways. Examples include extensive material testing to determine the probabilistic material strength in as-printed configurations, compliant performance-based methods for analysis of the full design, thermal loading on full-scale components, full-scale beam and column linear elastic bending, and stiffness verification.

[0182] The present disclosure, in some embodiments, includes advanced performancebased designs to protect the bio-based materials and decelerate their deterioration, decomposition, and / or degradation. In some embodiments, performance-based designs also minimize maintenance over the life of the structure, for example painting, siding, roofing, moisture management, thermal management, insect management, mold management, and fungus or bacteria management.Method of creating a panelized building

[0183] Fig. 30 is a flow chart diagram of a method 300 of creating a panelized building, according to aspects of the present embodiments. At step 302, the method 300 may include determining performance criteria, using building codes and owner requirements. At step 304, the method 300 may include applying performance-based designs to achieve the determined performance criteria. At step 306, the method 300 may include determining the number and type of panels and / or modules. At step 308, the method 300 may include determining an advanced manufacturing method and / or machine to manufacture the panels and / or modules. In some embodiments, the advanced manufacturing method may include an additive manufacturing method. In some embodiments, the advanced manufacturing method may include a subtractive manufacturing method. At step 310, the method 300 may include manufacturing the panels and / or modules, by the advanced manufacturing method and / or machine. In some embodiments, manufacturing the panels and / or modules may include a human-in-the-loop. In some embodiments, as described herein, the manufactured panels include one or more internal utility conduits that integrally formed (i.e., monolithic, unitary, and / or continuous) with the panel. For example, in some embodiments, the one or more internal utility conduits are formed during the same additive manufacturing build process as other portions of the panels. In some embodiments, as described herein, the manufactured panels include a first plurality of structures optimized for providing structural strength to the panel (i.e., V’s) and a second plurality of structures optimizedfor providing an internal utility conduit. Tn some embodiments, the first and second pluralities of structures are arranged in an alternating configuration within the panel. At step 312, the method 300 may include transferring the manufactured panels and / or modules to the building site. At step 314, the method 300 may include assembling the transferred panels and / or modules at the building site. At step 316, the method 300 may include installing a drop-in room. In some embodiments, the drop-in room may include a plumbing appliance, an electric appliance, and / or a gas appliance. At step 318, the method 300 may include connecting utilities to the assembled panels and / or modules.Method of creating a volumetric structure

[0184] Fig. 31 is a flow chart diagram of a method 320 of creating a volumetric structure, according to aspects of the present disclosure. At step 322, the method 320 may include defining the design space based on owner vision and / or requirements. At step 324, the method 320 may include determining performance criteria, using building codes and owner requirements. At step 326, the method 320 may include applying performance-based designs to achieve the determined performance criteria. At step 328, the method 320 may include determining an advanced manufacturing method and / or machine to manufacture the volumetric structure. In some embodiments, the advanced manufacturing method may include an additive manufacturing method. In some embodiments, the advanced manufacturing method may include a subtractive manufacturing method. At step 330, the method 320 may include manufacturing the volumetric structure, by the advanced manufacturing method and / or machine, at a manufacturing facility. In some embodiments, manufacturing the volumetric structure may include a human-in-the-loop. In some embodiments, as described herein, the manufactured volumetric structure may include one or more internal utility conduits that are integrally formed (i.e., monolithic, unitary, and / or continuous) with the volume. For example, in some embodiments, the one or more internal utility conduits are formed during the same additive manufacturing build process as other portions of the volume. At step 332, the method 320 may include transferring the manufactured volumetric structure to the building site. At step 334, the method 320 may include manufacturing the volumetric structure, by the advanced manufacturing method and / or machine, at the building site. At step 336, the method 320 may include installing a drop-in room. In some embodiments, thedrop-in room may include a plumbing appliance, an electric appliance, and / or a gas appliance. At step 338, the method 320 may include connecting utilities to the volumetric structure.

[0185] Fig. 32 is a flow chart diagram of a method 340 of creating a volumetric structure, according to aspects of the present disclosure. At step 342, the method 340 may include defining a 2D footprint (i.e., within a horizontal plane) of a design space. At step 344, the method 340 may include establishing a threshold measurement of a third (i.e., vertical) dimension (or height). In some embodiments, the 2D footprint and the third dimension that is orthogonal to the 2D footprint may define a design volume. At step 346, the method 340 may include defining elements within the volume. In some embodiments, the elements may include attached elements. The attached elements, for example, may include walls, floors, ceilings, roofs, built-in shelving, doorway, alcove, stairs, window, molding, crown molding, millwork, window sill, closet, wainscotting, island, attached bar stools, breakfast nook, attached entryway bench, light fixture, sconce, pillar, archway, counter, cabinets, built-in entertainment center, duct work, wall hooks, sink, mantle, fireplace, chimney, hearth, ribbon fireplace (i.e., fire place that’s not against the wall but in the middle of the room), water features, window treatments, curtain rods and hangers, pantry, French doors, pocket doors, banister, railing and hand rails, window bench, bathroom elements (i.e., shower, sink, bath tub), crawl space, sky light, built-in bunk beds, built-in fish tank, built-in nightstand, room divider, partitions, submerged seating areas, chest, hamper chute, trash chute, window blinds, pipes, gutters, deck, elevator shaft, recessed lighting, architectural features, balconies, landings, patios, planters, firepit, attached outdoor benches and seating, trusses, and / or spiral staircases. In some embodiments, the elements may include detached elements. The detached elements, for example, may include desk, bookshelf, sofa / couch, table, chair, side tables, dresser, bed and / or appliances. In some embodiments, both the attached elements and the detached elements (i.e., furniture, etc.) are considered at the early design stages since design processes as described herein may be initiated by considering the design space first, and then designing the structure around the space.

[0186] Referring still to Fig. 32, at step 348, the method 340 may include refining the 2D footprint to accommodate the defined attached and / or detached elements. At step 350, the method 340 may revert to step 344. At step 352, the method 340 may include refining the 2D footprint according to one or more building codes. At step 354, the method 340 may revert to step 344. Insome embodiments, steps 346-354 may be performed in a different order than what is shown in Fig. 32. In some embodiments, one or more of steps 342-354 may be performed simultaneously. For example, in some embodiments, defining the footprint, height, attached elements, and detached elements may all be performed simultaneously while also considering the performance-based design factors and building code requirements. At step 356, the method 340 may include establishing vertical layers (i.e., in terms of an absolute vertical dimension) for each of the attached elements. The vertical layers may be established relative to each attached element itself and / other relative to other attached elements such that multiple attached elements may all be including in a single printing process (i.e., multiple attached elements must all be printed such they are dimensioned correctly and also positioned correctly relative to each other). At step 358, the method 340 may include constructing a digital build file for printing the attached elements based on the established vertical layers for each of the attached elements. The digital build file may include an advanced manufacturing method and / or machine, print materials, a rotation angle about an X-axis of printing surface, human -in-the-loop actions, etc. At step 360, the method 340 may include printing the attached elements. At step 362, the method 340 may include performing post process steps. The post process steps, for example, may include installing a drop-in room, duct work, piping, insulation, electrical, and / or adding in the detached elements.Wall Designs

[0187] Figs. 1A and IB illustrate examples of an internal structure of a wall 10, according to aspects of the present embodiments, including a schematic view of a wall with internal features visible (Fig. 1A) and a schematic illustration of the internal features (Fig. IB). In some embodiments, the wall 10 may include an outer skin 12, an inner skin 14, a wall cavity 16 and one or more structural members 22. In some embodiments, the outer skin 12 may include a planar surface, facing the exterior of the building structure. In some embodiments, the inner skin 14 may include a planar surface, facing the interior of the building structure. The outer skin 12 may be oriented such that it is substantially parallel to the inner skin 14. In some embodiments, the outer skin 12 and the inner skin 14 may be separated by a partially hollow space which may form the wall cavity 16. In some embodiments, the wall cavity 16 may be embedded within the structural members 22 to tie the inner skin 14 and the outer skin 12 together. In some embodiments, thestructural member 22 may form a continuous contact 18 with the outer skin 12 and a continuous contact 20 with the inner skin 14.

[0188] Still referring to Figs. 1A and IB, the wall 10, may be positioned and connected to another wall, floor, ceiling and / or roof, using different connection methods. In some embodiments, the connection method may include a pre-printed support printed alongside the wall. The printed support, for example, may include an internal stay-in-place support or a removable support. In some embodiments, the method may include a human-in-the-loop, for example, to place stay-inplace or removable lintels. The wall 10 may include insulation volumes at the joints and minimized connections between walls to prevent heat loss. These pre-designed and engineered connections may be optimized for both structural strength and thermal performance, as opposed to prescriptive methods of traditional construction which focus on structural design and have exceptionally large heat-loss coefficients.

[0189] Still referring to Figs. 1A and IB, in some embodiments, screws or nails may be applied to inner skin 14 depending on the material utilized during the printing process. Similar to wood species, for example, different sizes of nails may be used for different directions and coatings of selected material. In some embodiments, the utilities (e.g., electrical wires, plumbing lines and fixtures) may be installed within the wall cavity 16 during the printing process. In some embodiments, the utilities may be installed and / or replaced using traditional methods including drilling, cutting, stapling, snaking, adding conduit, adding exterior chase-ways, toe board, molding, and / or patching. Utilities, for example may be installed via pre-designed holes printed into the wall, using the provided instructions. In some embodiments, the instructions may include 3D-printed numbers, letters, and symbols, which allow the trade’s people to simply read the part, without having to guess or refer to drawings. In some embodiments, when utilities at a junction need to be replaced, the junctions may be provided to the owner as required by the code with traditional constructions.

[0190] Referring still to Figs. 1A and IB, in some embodiments, the wall 10 may provide water tightness. For example, the wall 10 may include a pipe for heating and / or cooling water ducts where heated metal connections are pressed into the end of the opening to make a self-sealing joint. In some embodiments, a coating may be needed depending on the material used for printing and the requirements of the pipe or conduit. The coating, for example, may include spray on orunrolled sealant, similar to coatings currently used in plumbing. In some embodiments, traditional plumbing pipes may include metallic or PEX / PVC pipes.

[0191] Fig. 2A illustrates an exemplary thermal image 24 of an interior surface of the wall 10, according to aspects of the present embodiments. In some embodiments, the thermal image 24 may be captured using a FLIR infrared camera, during a period of significant interior / exterior temperature differential. In some embodiments, a temperature scale 26 may indicate the temperature range in °F, where darker sections correspond to lower temperatures within the range and brighter sections correspond to higher temperatures within the range. For example, the temperature in the thermal image 24 may range from about 55 °F to about 64 °F. Darker sections (i.e., lower temperatures) may include the wall cavity 16 where lack of proper insulation results in greater heat loss. Brighter sections (i.e., higher temperatures) may include continuous contact 20 with the inner skin 14, where superior insulation properties of structural member 22, compared to that of the wall cavity 16, result in reduced heat loss.

[0192] Fig. 2B illustrates an exemplary thermal image 30 of an interior surface of the wall 10, according to aspects of the present embodiments. In some embodiments, the thermal image 30 may be captured using a FLIR infrared camera, during a period of significant interior / exterior temperature differential after installation of proper insulation. In some embodiments, a temperature scale 26 may indicate the temperature range in °F, where darker sections correspond to lower temperatures within the range and brighter sections correspond to higher temperatures within the range. For example, the temperature in the thermal image 24 may range from about 58 °F to about 67 °F. Brighter sections (i.e., higher temperatures) may include the wall cavity 16 where proper insulation result in reduced heat loss. Darker sections (i.e., lower temperatures) may include continuous contact 20 with the inner skin 14, where inferior insulation properties of structural member 22 (compared to that of the properly insulated wall cavity 16) resulted in thermal bridging.

[0193] Figs. 3A and 3B illustrate examples of a thermal simulation of the wall 10, according to aspects of the present embodiments. In some embodiments, the thermal images 32, and 34 may be generated using Abaqus finite element analysis software and / or other suitable software packages. In some embodiments, the changes in temperature are shown by different colors, where darker sections correspond to lower temperatures and brighter sections correspond to higher temperatures. In some embodiments, the thermal image 32 may include a thermalsimulation of an interior surface (i.e., inner skin) of the wall 10. The thermal patterning of thermal image 32 may correspond with the temperatures observed in the thermal image 20, as discussed in Fig. 2A. Darker sections (i.e., lower temperatures) may include the wall cavity 16, where lack of proper insulation results in heat loss. Brighter sections (i.e., higher temperatures) may include continuous contact 20 with the inner skin 14, where superior insulation properties of structural member 22, compared to that of the wall cavity 16, result in reduced heat loss. In some embodiments, the thermal image 34 may include a thermal simulation of an exterior surface (i.e., outer skin) of the wall 10. Darker sections (i.e., lower temperatures) may include the wall cavity 16, where lack of proper insulation resulted in greater heat loss. Brighter sections (i.e., higher temperatures) may include continuous contact 18 with outer skin 12, where superior insulation properties of structural member 22, compared to that of the wall cavity 16, resulted in reduced heat loss.

[0194] Fig. 4A illustrates an example of a window trim 36 and sealant 38 in the wall 10, according to aspects of the present embodiments. In some embodiments, window installation in the wall 10 may rely on application of traditional sealants 38, such as tripolymer, to fill the gaps between the window trim 36 and rough window opening, ensuring window weatherproofing.

[0195] Fig. 4B illustrates an example of a cross section 40 of the wall 10 at a rough window opening, according to aspects of the present embodiments. In some embodiments, the cross section 40 may include a rough window opening 44 and a windowsill 42. In some embodiments, the geometry of the rough window opening 44 may feature a flat windowsill 42 (i.e., lacks an outwardly sloping). In some embodiments, the flat geometry of windowsill 42 may cause potential moisture ingress and / or pooling in the event of a leakage.

[0196] Fig. 5A illustrates an example of internal structure of a second wall 50, according to aspects of the present embodiments. In some embodiments, the second wall 50 may include an outer skin 12, an inner skin 14, a wall cavity 16 and one or more structural members 52. In some embodiments, the structural member 52 may include ridges 54 resulting in an intermittent contact 56 with the outer skin 12, while forming a continuous contact 20 with the inner skin 14. The intermittent contact 56 may minimize the contact area between the structure member 52 and the outer skin 12, resulting in reduction of thermal bridging. The design of the second wall 50 may incorporate all the features of the wall 10 shown in Fig. 1 (i.e., a first wall 10), as well asimprovement to the design the of structural member 52, addition of insulation fdl ports 64, and modification of window seal 70, as further discussed herein in connection with Fig. 7.

[0197] Fig. 5B illustrates an example of a cross section 58 of the second wall 50, according to aspects of the present embodiments. In some embodiments, the cross section 58 may include an outer skin 12, an inner skin 14, a structural member 52, and one or more ridges 54. The spacing between the structural members 52 may be decided according to structural, thermal, and / or owner / designer / builder specific requirements. In some embodiments, material, machine time, and performance may be optimized without adhering to conventional housing standards.

[0198] Fig. 6 illustrates an example of a desktop scale prototype 60 of the second wall 50, according to aspects of the present embodiments. In some embodiments, the desktop scale prototype 60 may include an inner skin 14, a wall cavity 16, structural members 52, and ridges 54.

[0199] Fig. 7A illustrates an example of the second wall geometry 62 featuring insulation fill ports 64, according to aspects of the present embodiments. In some embodiments, the geometry 62 may include a modified rough window opening 66, and one or more insulation fill ports 64. In some embodiments, the design of the second wall geometry 62 may ensure accessibility of all volumes within the second wall via the insulation fill ports 64. In some embodiments, the insulation fill ports 64 may include print-in-place fill ports. The print-in-place fill ports 64, for example, may be in final configuration, and ready to be filled with certain insulation materials and / or methods. In some embodiments, the insulation fill ports 64 may include blind fill ports. The blind fill ports 64, for example, may require further assembly and / or adjustments for the use of certain insulation materials and / or methods. In some embodiments, instructions for the fill ports 64 may include 3D printed numbers, letters, and symbols on the wall which allow the trade’s people to simply read the part, without having to guess or refer to drawings. In some embodiments, insulation may be in a cellulosic form and blown in, where the design of insulation flow is preengineered and provides high reliability for a trade’s person. In some embodiments, insulation may be a foam and may be installed in multiple installments or batches during the printing process. The foam, for example, may be produced by the printer instead of solid material, or may be installed by a human-in-the-loop. In some embodiments, insulation may be a foam board which can be installed in courses, batches, or installments during the printing process and / or post-print using traditional methods. In some embodiments, insulation may include a plurality of printed sealed air-pockets in one embodiment. In some embodiment, insulation may include a plurality of 3D printed, discrete “popcorn” like work pieces, each with relatively high surface area to mass ratio (so as to maximize insulating effect while minimizing material use). In some embodiments, the modified window rough opening 66, may include a modified windowsill 70, as further described in Fig 7B.

[0200] Fig. 7B illustrates an example of a second wall cross section 68 at a modified rough window opening, according to aspects of the present embodiments. In some embodiments, the cross section 68 may include a modified rough window opening 66. In some embodiments, the modified rough window opening 66 may include a modified windowsill 70. In some embodiments, the modified windowsill 70 may include a 5° outward slope 72. The outward slope 72 may, for example, facilitate moisture egress (e.g., in the event of a window leak), and / or to ensure exterior moisture drainage.

[0201] Fig. 8A illustrates an example of a thermal simulation of an interior surface (i.e., inner skin 14) of the second wall 50, according to aspects of the present embodiments. In some embodiments, the thermal images 74 may be generated using Abaqus finite element analysis software as well as other suitable software packages. In some embodiments, the changes in temperature are shown by different colors, where darker sections may correspond to lower temperatures and brighter sections may correspond to higher temperatures. Brighter sections (i.e., higher temperatures) may include the wall cavity 16, where proper insulation results in reduced heat loss. Darker sections (i.e., lower temperatures) may continuous contact 20 with inner skin 14, where inferior insulation properties of structural member 52 compared to that of the insulated wall cavity 16, result in thermal bridging. The thermal image 74, for example, may display a reverse temperature distribution patterning compared to the thermal image 32, as discussed in Fig. 3, confirming prevention of heat loss through the wall cavities 16 via the added insulation. Furthermore, the thermal image 74 displays an increase in overall surface temperature, indicating decreased energy loss throughout the second wall 50.

[0202] Fig. 8B illustrates an example of a thermal simulation of an exterior surface (i.e., outer skin 12) of the second wall 50, according to aspects of the present embodiments. In some embodiments, the thermal image 76 may be generated using Abaqus finite element analysis software as well as other suitable software packages. In some embodiments, the changes intemperature are shown by different colors, where darker sections may correspond to lower temperatures and brighter sections may correspond to higher temperatures. Darker sections (i.e., lower temperatures) may include the wall cavity 16, and bright sections (i.e., higher temperatures) may include intermittent contact 56 with outer skin 12, confirming the intermittent contact 56 may result in decreased heat loss.

[0203] Fig. 9A illustrates an exemplary model 70 of the second wall 50 to be printed on a commercial 3D printer, according to aspects of the present embodiments. In some embodiments, a commercial 3D printer may include the Juggerbot Tradesman Series™ P3-44. In some embodiments, the dimensions of model 70 may be set to 42 inches wide by 42 inches high by 10 inches deep. The selected dimensions, for example, may correspond to Juggerbot’s build envelope (i.e., the maximum volume a 3D printer is capable of printing). In some embodiments, the model 70 may include a rotation angle 82 about the X-axis 84, to prevent print failures due to unsupported overhangs, as further discussed herein in connection with Fig. 9B. In some embodiments, the rough widow opening 66 may be designed to fit a 24-1 / 8 inches by 24-1 / 8 inches Andersen window, which is the smallest available commercial window.

[0204] Fig. 9B illustrates an exemplary design 80 of a structural member 52 of the second wall 50 featuring 35° rotation about the X-axis, according to aspects of the present embodiments. In some embodiments, the design 80 may include a structural member 52, one or more ridges 54 and a rotation angle 82 about the X-axis 84. The rotation angle, for example, may prevent print failures due to unsupported overhangs. Overhangs include geometric shapes in a 3D model that extend outward without a direct support and are challenging to print. Rotating the model, for example, may diminish overhangs by increasing the portions that are supported. In some embodiment, the rotation angle 82 may be set to 35° to enhance the structural integrity of the printed workpiece.

[0205] Fig. 9C illustrates an exemplary test print 86 resulting in print failure, according to aspects of the present embodiments. A series of test prints was undertaken to identify sections of the print deemed most likely to result in print failure. In some embodiments, test print 86 may include initial layers of the print. The test print 86 may further include one or more cross sections 88 of structural members 52, and one or more insulation fill ports 64. In some embodiments, potential bed adhesion (i.e., the extruded layer (i.e., the first extruded layer) adheres to the printerbed (i.e., the surface or substrate on which the workpiece is being printed)) and / or extruder initiation issues may result in print failure of the initial layers. In some embodiment, the complexity of fill ports’ toolpaths may result in print failure of the initial layers.

[0206] Fig. 9D illustrates an exemplary test print 90 resulting in print failure, according to aspects of the present embodiments. A series of test prints was undertaken to identify sections of the print deemed most likely to result in print failure. In some embodiments, the test print 90 may include the windowsill 70, and one or more cross sections 88 of structural members 52. In some embodiments, the windowsill / outer skin conjunction 92 may result in print failure due to unsupported overhang angle of 35° and complexity of the geometry. In some embodiments, the cross section 88 may include a trapezoid shape where the long base may face the inner skin 14 and the short base may face the outer skin 12. The long base for example, may correspond to the area of continuous contact 20 between the structural member 52 and inner skin 14. The short base, for example, may correspond to location of a ridge 54 and the area of intermittent contact 56 between the structural member 52 and the outer skin 12. In some embodiments, the unsupported overhang angle of 35° may result in print failure as structural member ridges 54.

[0207] Fig. 10A illustrates an exemplary model 94 of the second wall 50 to be printed on a commercial 3D printer, according to aspects of the present embodiments. In some embodiments, a commercial 3D printer may include the Juggerbot Tradesman Series™ P3-44. In some embodiments, the dimensions of model 94 may be set to 42 inches wide by 42 inches high by 10 inches deep. The selected dimensions, for example, may correspond to Juggerbot’ s build envelope (i.e., the maximum volume a 3D printer is capable of printing). In some embodiments, the model 94 may include a rotation angle 100 about the X-axis 84, to prevent print failures due to unsupported overhangs, as further discussed herein in connection with Fig. 10B. In some embodiments, the rough widow opening 66 may be designed to fit a 24-1 / 8 inches by 24-1 / 8 inches Andersen window, which is the smallest available commercial window. In some embodiments, the model 94 may include a support structure 96 added to rear of the geometry. In some embodiments, the support structure 96 may include a temporary structure printed underneath overhangs to prevent overhangs from collapsing during printing. The support structure, for example, may take the form of a tower, a wall, a pedestal, an I-beam, scaffolding, lattice structures, a tree, and / or other suitable frameworks. In some embodiments, the support structure 96 may be manually removedwhen print is complete. In some embodiments, the support structure 96 may be minimally gapped from the wall to generate toolpaths to facilitate efficient removal from the final print. In some embodiments, the support structure 96 may act as an extrusion substrate for an upper edge of the rough window opening 66.

[0208] Fig. 10B illustrates an exemplary design 98 of a structural member 52 of the second wall 50, featuring a 45° rotation about an axis (for example, rotation about the X-axis), according to aspects of the present embodiments. In some embodiments, the design 98 may include a structural member 52, one or more ridges 54 and a rotation angle 100 about the X-axis 84. The rotation angle, for example, may prevent print failures due to unsupported overhangs. In some embodiment, the rotation angle 100 may be set to 45° to simulate the Ingersoll Machine MasterPrintx3X 45° printing procedure.

[0209] Fig. 10C illustrates an example of a successful test print 102, according to aspects of the present embodiments. In some embodiments, the test print 102 may include one or more cross sections 88 of structural member 52. In some embodiments, the cross section 88 may include a trapezoid shape where the long base may face the inner skin 14 and the short base may face the outer skin 12. The long base for example, may correspond to the area of continuous contact 20 between the structural member 52 and inner skin 14. The short base, for example, may correspond to the location of a ridge 54 and the area of intermittent contact 56 between the structural member 52 and the outer skin 12. The ridge 55 and / or structural member, may further include a reinforcement feature 104. In some embodiments, the reinforcement feature 104 includes a double- lobed contouring to help evenly distribute the load of the structural member onto a bottom planar portion or surface of the test print 102. In some embodiments, the double-lobed contouring includes a curvature with at least 2 (and in some cases at least 3) inflection points. In some embodiments, the rotation angle 100 of 45° may address stability issue when structural member 52 ridges, as further discussed herein in connection with Fig. 9C.

[0210] Fig. 11A illustrates an exemplary model 106 of the second wall design 50 for an interrupted print using a commercial 3D printer, according to aspects of the present embodiments. In some embodiments, a commercial 3D printer may include the Juggerbot Tradesman Series™ P3-44. In some embodiments, the model 106 may include a rough window opening 66 and a support structure 96. In some embodiments, print speed may include about 4 minutes per layer (orfrom about 3 to about 5 minutes per layer) to balance print quality and time usage. The build time of the model 106, for example, may be about 17 hours and 25 minutes (or from about 10 to about 25 hours). In some embodiments, the model 106 may be printed using wood flour and aPLA. In some embodiments, the model 106 may include an estimated total mass of 88.12 kg or from about 50 kg to about 125 kg, and / or from about 75 kg to about 100 kg).

[0211] Fig. 11B illustrates an example of a slice 108 of the model 106 to be printed on day one, according to aspects of the present embodiments. In some embodiments, the model 106 may be split in two slices to be printed on two single days. In some embodiments, the split may be due to scheduling limitations. In some embodiments, the split may be due to printer operation limitations.

[0212] Fig. 11C illustrates an example of a slice 110 of the model 106 to be printed on day two, according to aspects of the present embodiments. In some embodiments, the model 106 may be split in two slices to be printed in two single days, as further described is Fig. 1 IB.

[0213] Fig. 12A illustrates an example of a final print 112 of the second wall 50, according to aspects of the present embodiments. In some embodiments, the final print 112 may include a rough window opening 66. In some embodiments, a FLIR IR camera may be used to monitor the temperature throughout duration of the print. In some embodiments, the FLIR IR camera may further include a user interface. In some embodiments, the print speed may be adjusted to maintain temperature within a range. In some embodiments, the temperature range may include 60 ± 10 °C.

[0214] Fig. 12B illustrates an example of the back of a final print 114 of the second wall 50, according to aspects of the present embodiments. In some embodiments, the back of the final print 114 may include a support structure 96.

[0215] Fig. 12C illustrates an example of a final print 116 of the second wall 50 after removal of the support structure, according to aspects of the present embodiments. In some embodiments, the final print 116 may include a rough window opening 66. In some embodiments, an interface of the final print 116 and the support structure 96 may be severed via an oscillating tool. In some embodiments, the support structure 96 may be removed from the final print 1 16 via a trim pry bar. The final print 116 may further demonstrate the interrupted print capability of the Juggerbot Tradesman Series™ P3-443D printer.

[0216] Fig. 13A illustrates an example of a final print 1 18 of the second wall 50 after positioning a window 120, according to aspects of the present embodiments. In some embodiments, the window 120 may be positioned using wood shims such as pine shims, cedar shims, etc. In some embodiments, the wood shims may be fastened into pre-piloted and countersunk holes, using wood screws. For example, the wood screws may include using #10 x 2.5" GRK wood screws.

[0217] Fig. 13B illustrates an example of a final print 122 of the second wall 50 after sealing the window 120, according to aspects of the present embodiments. In some embodiments, the window 120 may be smaller than the window considered when creating the model for the print. The difference in the sizes of the window 120 and the window considered when creating the model may result in a gap between the rough window opening 66 and the window 120. The gap, for example, may be about 0.25 inches. In some embodiments, a sealant may be used to fill the gap. The sealant, for example, may include labil 20% wood flour (WF) / poly(lactic acid) (PL ). In some embodiments, an extrusion welder may be used to apply the sealant. The extrusion welder, for example, may include a HSK26 GXS extrusion welder.

[0218] Fig. 14A illustrates an example of internal structure of a third wall 124, according to aspects of the present embodiments. In some embodiments, the third wall 124 may include an outer skin 12, an inner skin 14, a wall cavity 16, one or more structural members 126, one or more chase- ways 130 and one or more utility boxes 132. In some embodiments, the structural member 126 may include ridges 54 resulting in an intermittent contact 56 with the outer skin 12, and an intermittent contact 128 with the inner skin 14. The intermittent contacts 56 and 128 minimize the contact area between the structural member 126, and the outer skin 12 and inner skin 14, respectively, which may enable reduction of thermal bridging on both sides of the wall. In some embodiments, the utilities may be installed using the pre-designed chase-ways 130 and utility boxes 132. In some embodiments, utilities may be installed within the chase-ways 130 and the utility boxes 132 during the printing process. In some embodiments, utilities may be installed within the chase-ways 130 and the utility boxes 132 post-print, via robot end-effector and / or a human-in-the-loop. In some embodiments, instructions including numbers, letters, and symbols may be printed next to the chase- ways 130 and the utility boxes 132 which allow the trade’s people to simply read the part, without having to guess or refer to drawings. In some embodiments, whenutilities between junctions need to be replaced, they may be pulled through the chase-ways 130 more easily compared to traditional construction. In some embodiments, when utilities need to be moved to different locations, other than the existing chase- ways 130, traditional methods of replacement may be utilized.

[0219] Still referring to Fig. 14A The chase-ways 130 and the utility boxes 132 may establish an integrated infrastructure. In some embodiments, the integrated infrastructure may comply with the following sections of NFPA 70 and Building codes: NEC 330.10(11) MC Cable Uses Permitted, which specifies the wiring condition in wet locations; NEC 330.24(B), which specifies the allowable bending radius of conductors; NEC 33O.3O(B-D), which specifies required support of cables within concealed spaces; IRC P2603.2.1, which specifies protection of plumbing pipe from physical damage; IRC P2603.4, which specifies strain relief for plumbing pipe routed through foundation wall; IRC P2603.5, which specifies plumbing pipe protection from freezing; IRC P2605.2, which specifies plumbing pipe support requirements; IRC P2606.1, which specifies adequate sealing of pipe penetrations ofbuilding envelope; and / or IRC P2903.1.3, which specifies allowable locations of fixtures and piping. The design of the third wall 124 may incorporate all the features of the second wall 50, as well as further improvement to the design of the structural member 126, and addition of integrated utility infrastructure in the form of print-in-place chaseways 130 and utility boxes 132.

[0220] Fig. 14B illustrates an example of a cross section 134 of the third wall 130, according to aspects of the present embodiments. In some embodiments, the cross section 134 may include an outer skin 12, an inner skin 14, a structural member 126, and one or more ridges 54.

[0221] Fig. 15A illustrates an example of a desktop scale prototype 134 of the third wall 124, according to aspects of the present embodiments. In some embodiments, the desktop scale prototype 134 may include an inner skin 14, a wall cavity 16, one or more structural members 126, one or more chase-ways 130 and one or more utility boxes 132. The chase-ways 130 may include a double teardrop shape 136, further discussed herein in connection with Fig. 16B.

[0222] Fig. 15B illustrates an example of desktop scale prototype 138 of the third wall 124 with installed cables 140, according to aspects of the present embodiments. The desktop scale prototype 138 may include chase-ways 130 within which cables 140 were installed.

[0223] Fig. 16A illustrates an example of a horizontal utility chase-way profile 142. The horizontal chase-way profile 142 may include a circular profile 144. In case of horizontal holes and / or arches, the top of the circle 144 becomes an overhang 146. When printing, horizontal holes and / or arches form unsupported overhangs 144 that become steeper as the hole closes. As a result, the holes will be prone to drooping (i.e., becoming slightly squished) and blocking the opening. If the holes and / or arches have a visual purpose, using a support structure may be a desirable option. However, if the holes and / or arches are functional and intended to accommodate other objects, as for example utility chase-ways 130 (that are internal to the wall and not visible externally once the wall is fully formed), the design may be modified into a teardrop shape, as further described herein in connection with Fig. 16B.

[0224] Fig. 16B illustrates an example of a horizontal utility chase-way profile 148, according to aspects of the present embodiments. In some embodiments, horizontal utility chaseway profile 148 may include a double teardrop profile 150, and a teardrop angle 152. The double teardrop profile 150, may prevent the formation of unsupported overhangs 146, by introducing the teardrop angle 152 which may result in the hole to gradually close, at both the top and the bottom of the hole. In some embodiments, the teardrop angle 152 may be calculated as a function of desired inner diameter, print bead width and layer height to minimize. In some embodiments, the double teardrop profile 150 may ensure the proper installation of electrical and plumbing lines through the chase-ways 130. In some embodiments, the teardrop angle 152 may be set at about 25° (or in some embodiments, from about 23° to about 27°, or from about 20° to about 30°, or from about 15° to about 35°). Using the teardrop angle 152 of 25°, the radius may, for example, be set to various radii to generate the double teardrop profiles 154, 156 and 158, respectively. In some embodiments, the chase-way profile 148 may include a substantially diamond-shaped profile including a rounded profile at both of the lateral or side vertices, and with the teardrop shape at both the top and bottom vertices. Using a teardrop angle at the bottom vertex (i.e., versus a rounded bottom vertex) helps to minimize material use.

[0225] Fig. 17 illustrates an exemplary third wall chase-way 160 with an installed cable 162, according to aspects of the present embodiments. In some embodiment, the chase- way 160 may include the double teardrop profile 150 and an installed electrical cable 162.

[0226] Fig. 18A illustrates an example of a third wall modular chase-way assembly 164, according to aspects of the present embodiments. In some embodiments, the modular chase-way assembly 164 may include a 90° chase-way bend 166. In some embodiments, the modular chaseway assembly 164 may include a 180° chase-way bend 168, by attaching two 90° chase- way bends 166. In some embodiments, the modular chase-way assembly 164 may include a 270° chase-way bend 170, by attaching three 90° chase-way bends 166. In some embodiments, the modular chaseway assembly 164 may include a 360° chase-way bend 172, by attaching four 90° chase path bends 166. The difficulty of installation (i.e., effective coefficient of friction) of modular chase-way assemblies 164 may be influenced by multiple factors. For example, the overall chase-way length, angle of chase-way bend, installed materials and overall fill percentage may all influence the difficulty in installing conventional chase-way assemblies.

[0227] Fig. 18B illustrates exemplary completed prints of a third wall modular chase-way assembly 174, according to aspects of the present embodiments. The prints of modular chase-way assemblies 174 may include one or more 180° chase-way bend prints 176, and one or more 360° chase- way bend prints 178, as well as 45°, 90°, 135°, 270°, and / or chase-way bends at other angles. By printing the chase-way directly into the wall such that the chase-way assembly 174 is integral with the wall (or floor, or roof, or ceiling), chase-way bends of any angles can be achieved, and the difficulty of installing chase-way assemblies can be avoided.

[0228] Fig. 19A illustrates an exemplary model 180 of the third wall 124 for an interrupted print using a commercial 3D printer. In some embodiments, a commercial 3D printer may include the Cincinnati Inc. BAAM 3D printer. In some embodiments, the dimensions of model 180 may be set to 60 inches wide by 72 inches high by 10 inches deep. The dimensions, for example, may be selected to meet productivity and / or printer throughput goals and / or metrics. In some embodiments, the model 180 may include a rotation angle of 45° about the X-axis 84, to prevent print failures due to unsupported overhangs, as further discussed herein in connection with Fig.10. In some embodiments, the model 180 may include a support structure 182 added to the rear of the geometry. In some embodiments, the support structure 182 may include a temporary structure printed underneath overhangs to prevent them from collapsing during printing. In some embodiments, the support structure 182 may be manually removed when print is complete. In some embodiments, the support structure 182 may include gaps 184 from the wall to generate toolpathsto facilitate efficient removal of the support structure 182 from the final print. In some embodiments, the support structure 182 may act as an extrusion substrate for utility box openings. In some embodiments, the build time of the model 180 may be about 28 hours (or from about 24 to 32 hours, or from about 20 to 36 hours). In some embodiments, the model 180 may be printed using wood flour and aPLA. In some embodiments, the model 180 may include an estimated 142 kg (or from about 130 kg to about 150 kg, or from about 120 kg to about 160 kg) of print material.

[0229] Fig. 19B illustrates an example of a slice 184 of the model 180 to be printed on day two, according to aspects of the present embodiments. In some embodiments, the model 180 may be split in four slices to be printed on four single days. In some embodiments, the model 180 may be split using ORNL Slicer 2 software package. In some embodiments, the split may be due to scheduling limitations. In some embodiments, the split may be due to printer operation limitations. For example, the start of each slice cycle may include the beginning of an 8-hour shift and the end of the cycle may include the end of the shift.

[0230] Fig. 19C illustrates an example of a slice 186 of the model 180 to be printed on day three, according to aspects of the present embodiments. In some embodiments, the model 180 may be split in four slices to be printed on four single days, as further described in Fig. 19B.

[0231] Fig. 20A illustrates an example of a slice 188 of the model 180 printed on day one, according to aspects of the present embodiments. In some embodiments, the printed slice 188 may include a support structure 182, one or more structural members 126 and one or more chase-ways 130.

[0232] Fig. 20B illustrates an example of a slice 190 of the model 180 printed on day two, according to aspects of the present embodiments. In some embodiments, the printed slice 190 may include a support structure 182, one or more structural members 126, one or more chase-ways 130, and one or more utility boxes 132.

[0233] Fig. 20C illustrates an example of a slice 192 of the model 180 printed on day three, according to aspects of the present embodiments. In some embodiments, the printed slice 192 may include a support structure 182 and one or more structural members 126.

[0234] Fig. 20D illustrates a finished example 194 of the model 180 printed on day four, according to aspects of the present embodiments. In some embodiments, the finished example 194 may include a support structure 182.Floor cassette designs

[0235] Fig. 21A illustrates an exemplary CAD drawing 196 of a first-floor cassette 198 within a channel 204, according to aspects of the present embodiments. In some embodiments, the first-floor cassette design 198 may include a VVOOVVOOVV interior pattern 200, a shell 202, and squared end connections 202. In some embodiments, the shell 202 may include acoustic and / or insulating layers. In some embodiments, the squared end connections 206 may be used to slide the floor cassette 198 into the channel 204. In some embodiments, the sloted first-floor cassete 198 may link to one or more other floor cassettes to form a new floor. In some embodiments, the VVOOVVOOVV interior pattern 200 may include pipes and / or wires while providing truss like structural performance. In some embodiments, the O spaces may serve as mechanical air ducts (i.e., heating and / or air conditioning ducts) which meet with pre-designed circular input and / or output locations in the HVAC system. In some embodiments, the V spaces may be used as conduits, mechanical, electrical, and plumbing (MEP), and / or insulation. The V spaces provide support at the end connections and serve as shear reinforcement for the system (for example, at the end portions and also in the mid portion, where deformation may be highest). While the top of the floor cassette 198 carries the compression, the bottom carries the tension, and the end connections experience the shear. The O spaces are a compromise for the owner requirements such as air ducting, structural requirements for shear capacity, thermal requirements for minimizing heat transfer, natural frequency requirements for minimizing vibration and maximizing human comfort in sensitive frequency ranges, and manufacturability. In some embodiments that include the VVOOVVOOVV interior pattern 200, interspersing the V and O interior patterns (for example, in alternating adjacent sections as shown in Figs. 21 A and 21B) minimizes vibrations that permeate through the first-floor cassette design 198 when compared to designs that include only a single pattern (for example, only V's, only O’s, and / or only another single, repeated pattern).

[0236] Still referring to Fig. 21A, in some embodiments, the first-floor cassette 198, may be used together with conventional flooring systems, for example, tile, wood floors, and laminate.Screws or nails may be applied depending on the material utilized during the printing process. In some embodiments, the first-floor cassette 198 may provide water tightness in the same manner previously described for the first wall 10.

[0237] In some embodiments, the design may include the continuity of mechanical, electrical, and plumbing (MEP) from a wall to a floor cassette and vice versa. Movement of materials and / or electrical charges throughout the structure may be built-in to boundary conditions. In B1M and IFC modeling, for example, locations and flow rate capacities (e.g., flow of electricity, water, heat, air, etc.) are required. In some embodiments, continuity of MEP may include continuous designed connections if the sub-components are manufactured as a single component, and custom designed connections. In some embodiments, junctions may be used which are designed to be inspectable, repairable, and replaceable. All junctions may be provided to the owner as required by the code of traditional construction.

[0238] Fig. 21B illustrates an exemplary test print 208 of the first-floor cassette 198, according to aspects of the present embodiments. In some embodiments, the test print 208 may be printed by a UltiMaker 3D printer. In some embodiments, the test print 208 may include a 1 : 10 scale test print. In some embodiments, the test print 208 may include the VVOOVVOOVV interior pattern 200 and squared end connections 206.

[0239] Fig. 22A illustrates an example 214 of a first-floor cassette 210, according to aspects of the present embodiments. In some embodiments, the first-floor cassette 210 may include an alternating or varying interior pattern such as the VVOOVVOOVV interior pattern 200, a symmetry line 216, and angle-trimmed end connections 212. In some embodiments, the alternating or varying interior pattern of the first-floor cassette 210 includes internal structural members (in alternating portions) that are configured primarily for structural strength (for example, the V spaces) and / or that are configured primarily as utility (i.e., MEP) conduits (for example, the O spaces). In some embodiments, the V spaces may be used as conduits and the O spaces may provide structural strength. However, in some embodiments, the V spaces are optimized for structural strength more than the O spaces, and the O spaces are optimized for acting as conduits more than the V spaces. In some embodiments, each V of the V spaces includes multiple non- orthogonally angled segments that are substantially straight or planar. In some embodiments, each O of the O space are substantially round throughout their geometry (for each, the cross-section iscircular or oval-shaped and each O is substantially cylindrical and / or oval-prism shaped). In some embodiments, the design example 214 may set the first-floor cassette 210 in an orientation that is suitable for printing. In this orientation, the design example 214 may include a height of 65in and a width of 140in. In some embodiments, the angle-trimmed end connections 212 may alter the evenly distributed stress profile of the first-floor cassette 210. For example, the stress may be redistributed so that the center of the first-floor cassette 210 may experience higher stress levels while the angle-trimmed end connections 212 may experience lower stress levels, as further described herein in connection with Fig. 23.

[0240] Fig. 22B illustrates an example of a closeup 218 of the first-floor cassette 210, according to aspects of the present embodiments. In some embodiments, the closeup 218 may include angle-trimmed end connection 212 and self-intersecting paths 220, 222, 224, and 226. In some embodiments, the self-intersecting paths 220, 222, 224, and 226 are calibrated for manufacturability and final part tolerance.

[0241] Fig. 23 illustrates an exemplary stress analysis 228 of the first-floor cassette 210, according to aspects of the present embodiments. In some embodiments, the stress analysis 228 may be performed using the ANSY S software package. In some embodiments, a large deformation region 232 may include the center of the first-floor cassette 210. The center, for example, may correspond to the V spaces of the VV00VV00VV interior pattern 200. In some embodiments, medium deformation regions 234 may include the area between the center of the first-floor cassette 210 and the angle-trimmed end connections 212. This area, for example, may correspond to the two O spaces of the VVOOVVOOVV interior pattern 200. In some embodiments, minor deformation regions 230 may include the angle-trimmed end connections 212. These areas, for example, may correspond to the V spaces of at the edges of the VVOOVVOOVV interior pattern 200.

[0242] Fig. 24 illustrates a closeup example 238 of through-hole features 240 of the first- floor cassette 210, according to aspects of the present embodiments. The closeup 238 may include through-hole features in the transverse direction 242. In some embodiments, the closeup 238 may include one or more V spaces 241 and one or more O spaces 243 of the VVOOVVOOVV interior pattern 200. The through-holes 240 are disposed through sections between the one or more V spaces 241 and the one or more O spaces 243. The through-hole features 240 may include thedouble teardrop profile 150. In some embodiments, the through-hole features 240 may be utilized for ducting, electrical cables, etc.

[0243] Fig. 25A illustrates an example of a conventional channel 244 that is used to install floor cassettes. The channel 244 may include standard structural steel shapes 246 which provide support at the end connections. Each of the shapes shown in Figs. 25A and 25B may include a support surface 247, a plurality of vertical support members 249, and a plurality of anchoring members 251. In some embodiments, each of the vertical support members 249 of the plurality of vertical support members are arranged orthogonally to the support surface 247 in order to provide vertical strength and reinforcement thereto. In some embodiments, each of the vertical support members 249 of the plurality of vertical support members are rigidly coupled to the support surface 247 in order to provide vertical strength and reinforcement thereto. In some embodiments, the vertical support members 249 and the support surface 247 are rotatably coupled to corresponding anchoring members 251 such that the orientation of the support surface 247 can be adjusted to match the orientation of the angle-trimmed end connection 212 of the first-floor cassette 210. In some embodiments, each of the anchoring members 251 may be rigidly connected to the channel 204.

[0244] Fig. 25B illustrates an example a channel 248 with an installed end connection, according to aspects of the present embodiments. In some embodiments, the channel 248 may include structural steel chapes 246 and angle-trimmed end connection 212. The structural steel chapes 246 may provide support for the angle-trimmed end connection 212.

[0245] Fig. 26A illustrates an exemplary full-scale print 250 of the first-floor cassette 210, according to aspects of the present embodiments. In some embodiments, a commercial 3D printer may include the Cincinnati Inc. BAAM 3D printer. In some embodiments, full-scale print 250 may be printed using wood flour and PLA. In some embodiments, the dimensions of print beads may be set to 16mm wide by 5mm high. In some embodiments, the full-scale print 250 may include the VVOOVVOOVV interior pattern 200, through-hole features 240 and angle-trimmed end connections 212. In some embodiments, the full-scale print 250 may be installed in channel 252.

[0246] Fig. 26B illustrates an exemplary closeup 254 of a full-scale print of the first-floor cassette 210 installed in a channel 252, according to aspects of the present embodiments. In someembodiments, the closeup 254 may include angle-trimmed end connections 212 supported by a channel member 256 of the channel 252.

[0247] Fig. 27A illustrates an example of a design variation 260 of a second-floor cassette, according to aspects of the present embodiments. In some embodiments, design variation 260 may include end connection 262 which sits inside a channel 264.

[0248] Fig. 27B illustrates an example of a design variation 266 of a second-floor cassette, according to aspects of the present embodiments. In some embodiments, the design variation 266 may include end connection 268 which sits atop the channel 264.

[0249] Fig. 27C illustrates an example of a design variation 270 of a second-floor cassette, according to aspects of the present embodiments. In some embodiments, the design variation 270 may include end connection 272 which sits atop a channel member 274 and beneath the channel 264.

[0250] Fig. 27D illustrates an example of a design variation 276 of a second-floor cassette, according to aspects of the present embodiments. In some embodiments, the design variation 276 may include end connection 278 which encapsulates the channel member 274.

[0251] The mass customization features of the present disclosure enables various designs which consider additional requirements while maintaining structural capacity. In some embodiments, additional requirements may include build environments, transportation, handling, installation accessibility, post-installation fire-resistive additives, and finishing. For example, where a smaller printer is used, a full rectangular end connection, for example design variation 276, may not be possible due to build environments.

[0252] Fig. 28 illustrates an exemplary ANSYS model 280 of the second-floor cassette 276, according to aspects of the present embodiments. In some embodiments, the ANSYS model 280 may include the VV00VV00VV interior pattern 200 and the end connection 278. In some embodiments, floor cassettes 198, 276 according to the present embodiments may include one or more orthogonal members 279 separating O spaces from V spaces within the floor cassette and / or separating, for example, one V space from an adjacent V space and / or one O space from an adjacent O space.

[0253] Fig. 29A illustrates a closeup example 282 of the second-floor cassette 276, according to aspects of the present embodiments. In some embodiments, the closeup 282 may include an inner layer 284, one or more channels 264, and one or more channel members 274.

[0254] Fig. 29B illustrates a closeup example 286 of the second-floor cassette 276, according to aspects of the present embodiments. In some embodiments, the closeup 286 may include outer layer 288 and one or more channels 264.

[0255] Fig. 29C illustrates a closeup example 290 of the second-floor cassette 276, according to aspects of the present embodiments. In some embodiments, the closeup 290 may include end connection 278, a channel 264 and a channel member 274. In some embodiments, the end connection 278 may sit flush with the channel 264 and encapsulate the channel member 274 for a more robust connection. The end connection 278 may require more connection hardware. However, in some embodiments, connection hardware is easy to fabricate and / or acquire.Roof and Foundation

[0256] Roof and ceiling panels of the present disclosure may include similar structures to those of the wall and / or floor panels. In some embodiments, the roof and wall panels may be in a continuous configuration through a structural moment connection, where the fabrication may transition from truss elements in the roof to vertical trusses in the walls, and later to truss elements in the floor. The presents embodiments may include traditional surfacing for the roof panels, such as flat roofs, asphalt roofs, steel roofs, tin roofs, thatched roofs, copper roofs, slate roofs and / or other types of roofs. In some embodiments, the roof panels may include similar types of insulation to that of the wall panels.

[0257] Foundation panels of the present disclosure may include similar structures to that of the wall and / or floor panels. In some embodiments, 3D printed panels may be used as foundation walls for stay-in-place formworks for placed concrete and mortar. In some embodiments, 3D printed panels may be used as a formwork for compacted sand and / or gravel filled walls if they need to be removable and / or replicable. The present embodiments may include insulation by adding sand, concrete, or other natural on-site material such as muds, silts, or clays. These methodologies, structures, and systems can provide temporary structural and thermal performanceif the structure is meant to be moved quickly, i.e., where blast or ballistic protection is needed on short order and must be constructed so that it is able to be disassembled and moved quickly.

[0258] The present embodiments may include placing the floor on a traditional foundation, frost-wall, slab, beam, pile, post, or full wall basement. In some embodiments, the floor may be placed atop a traditional basement with placed or precast concrete or concrete masonry unit (CMU) walls. In some embodiments, the floor may be placed over a slab, or a light wood frame. In some embodiments, design of frost-walls or foundation walls as stay-in-place formwork may be optimized given performance requirements instead of prescriptive based requirements.

[0259] In some embodiments, the foundation walls may be designed to be significantly stiffer, by varying tornado loading, hurricane loading, earthquake seismic loading, and blast or ballistic loading. In some embodiments, the foundation walls may be designed for uplift for extreme wind environments. In some embodiments, the foundation walls may be designed for minimal thermal transference for extreme arctic environments. In some embodiments, the foundation walls may be designed to absorb vibrations by optimizing dampening in seismic natural frequencies. For example, in a design category E with site derived seismic frequency P and S waves, the dampening of the foundation may be designed around those with mass properties, thereby minimizing loading on the structure above.EQUIVALENTS

[0260] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the disclosure described herein. Therefore, the scope of the present disclosure is not intended to be limited to the above Description.

Claims

CLAIMSWhat is claimed:

1. A construction element, comprising: a front surface, a rear surface positioned proximate to the front surface, the front surface and the rear surface defining an interior space that is at least partially hollow; and at least one internal structural member disposed within the interior space, wherein the front surface, the rear surface, and the at least one internal structural member form a single, unitary structure.

2. The construction element of claim 1, wherein the front surface, the rear surface, and the at least one internal structural member are formed from a single, continuous build process.

3. The construction element of claim 1, wherein the unitary structure comprises an integrated utility conduit disposed within the panel interior, and wherein the integrated utility conduit comprises at least one of an electrical conduit, an air vent, and a piping conduit.

4. The construction element of claim 3, wherein the integrated utility conduit is disposed through an aperture disposed within the at least one internal structural member.

5. The construction element of claim 4, wherein the aperture is double teardrop shaped.

6. The construction element of claim 1, wherein the at least one internal structural member forms continuous contacts with the front surface and the rear surface.

7. The construction element of claim 1, wherein the at least one internal structural member comprises ridges on at least one side.

8. The construction element of claim 7, wherein the at least one internal structural member forms intermittent contact with the front surface.

9. The construction element of claim 1, wherein the at least one internal structural member comprises ridges on both sides.

10. The construction element of claim 9, wherein the at least one internal structural member forms intermittent contacts with the front surface and the rear surface.

11. The construction element of claim 1, comprising one or more edge surfaces, the one or more edge surfaces defining the panel interior, in connection with the front surface and the rear surface.

12. A system comprising the construction element of claim 1 and an additive manufacturing machine used for manufacturing the construction element, the additive manufacturing machine comprising a build surface, wherein the build surface is configured to be rotated from about 30 degrees to about 50 degrees while the construction element is being manufactured.

13. The construction element of claim 1, wherein the construction element comprises at least one of a wall panel, a floor panel, and a roof panel.

14. The construction element of claim 13, wherein the construction element is at least partially fabricated via additive manufacturing.

15. The construction element of claim 13, wherein the construction element is at least partially fabricated via subtractive manufacturing.

16. The construction element of claim 14 or 15, wherein the construction element is prefabricated at a first location and assembled with other construction elements into a building at a second location.

17. The construction element of claim 1, wherein each of the front surface and the rear surface comprises a window opening disposed therein.

18. The construction element of claim 17, wherein the window opening comprises an outward slope.

19. The construction element of claim 18, wherein the outward slope is oriented at an angle of about 5°.

20. The construction element of claim 13, wherein the floor panel comprises a VV00VV00VV interior pattern.

21. The construction element of claim 20, wherein at least one of O space of the VVOOVVOOVV interior pattern comprises at least one of an air vent and a piping conduit.

22. The construction element of claim 1, wherein the front surface, the rear surface, and the at least one internal structural member are composed of the same material.

23. The construction element of claim 22, wherein the material comprises a composite material comprising a filler and a matrix.

24. The construction element of claim 23, wherein the filler comprises a biobased filler.

25. The construction element of claim 24, wherein the biobased filler is a member selected from the group consisting of wood flour, bamboo, corn husks, coconut fiber, hemp fiber, flax fiber, seaweed, kelp, and coffee grounds.

26. The construction element of claim 23, wherein the filler comprises a non-biobased filler.

27. The construction element of claim 26, wherein the biobased filler is a member selected from the group consisting of glass fiber, carbon fiber, wood fiber, aramid fiber, basalt fiber, talc filler, and gypsum filler.

28. The construction element of claim 23, wherein the matrix comprises a biobased matrix.

29. The construction element of claim 28, wherein the biobased matrix is a member selected from the group consisting of polycarbonate (PC), polypropylene (PP), polybutylene succinate (PBS), polyethylene (PE), chlorinated polyethylene (CPE), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), poly (lactic acid) (PLA), amorphous poly (lactic acid) (aPLA), and stereocomplex polylactide (scPLA).

30. The construction element of claim 23, wherein the matrix comprises a non-biobased matrix.

31. The construction element of claim 30, wherein the non-biobased matrix is a member selected from the group consisting of acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), polyetherketoneketone (PEKK), hydroxyl carboxyl sulfonated aminophenol (AH), polyamide or nylon (PA), and polyoxymethylene (POM).

32. A method of creating a panelized building comprising: determining one or more performance criteria, using building codes and / or owner requirements; applying performance-based designs to meet the determined performance criteria; determining the number and type of panels and / or modules to be included in the panelized building; determining at least one advanced manufacturing method and / or machine to manufacture the panels and / or modules; manufacturing the panels and / or modules, by the at least one advanced manufacturing method and / or machine; transferring the manufactured panels and / or modules to building site; assembling the transferred panels and / or modules at the building site; and connecting utilities to the assembled panels and / or modules.

33. The method of claim 32, wherein the at least one advanced manufacturing method comprises an additive manufacturing method.

34. The method of claim 33, wherein the additive manufacturing method comprises automated fiber placement, fused granulate fabrication, and / or fused filament fabrication.

35. The method of claim 32, wherein the at least one advanced manufacturing method comprises performing near net shape printing.

36. The method of claim 35, wherein the at least one advanced manufacturing method comprises subtractive manufacturing.

37. The method of claim 32, wherein the at least one advanced manufacturing machine comprises a commercial 3D printer.

38. The method of claim 37, further comprising at least one method of preventing unsupported overhangs.

39. The method of claim 38, wherein the at least one method of preventing unsupported overhangs comprises printing the panels and / or modules in a plane rotated about an X-axis of a printing surface.

40. The method of claim 39, wherein the rotated plane comprises a 45° rotation about the X- axis of the printing surface.

41. The method of claim 37, wherein the at least one method of preventing unsupported overhangs comprises printing a structural support.

42. The method of claim 41, wherein the structural support is removeable.

43. The method of claim 32, wherein manufacturing the panels and / or modules further comprises at least one step performed via a human-in-the-loop process.

44. The method of claim 32, wherein assembling the transferred panels and / or modules further comprises installing at least one drop-in room.

45. The method of claim 44, wherein the drop-in room comprises at least one appliance, wherein the at least one appliance comprises at least one of a plumbing appliance, an electric appliance, and a gas appliance.

46. A drop-in room comprising a plurality of prefabricated components comprising: at least one appliance; and the structural element of any of claims 1-11 and / or 13-31, wherein the at least one appliance is at least one of fluidly coupled and electrically coupled to the structural element.

47. The drop-in room of claim 46, wherein the plurality of prefabricated components are configured such that they may be shipped and / or delivered to a location of the drop-in room, and may form the drop-in room based on only a final assembly process.

48. A drop-in room comprising a plurality of prefabricated components comprising: at least one wall panel according to claim 13; and at least one floor panel according to claim 13 and / or 21.

49. The drop-in room of claim 48, wherein, once assembled, the drop-in room comprises a continuous conduit extending from an interior of the at least one wall panel to the interior of the at least one floor panel, wherein the continuous conduit comprises at least one of an electrical conduit and an air duct.

50. A method for providing a structure comprising: defining a design space that includes at least one interior volume; determining performance criteria based on building codes and / or owner requirements; applying performance-based design methodologies to meet the performance criteria, thereby producing an updated design space and an updated interior volume; determining at least one advanced manufacturing parameter to enable production of the updated design space; and producing a continuous surface of the updated design space that borders the updated interior volume, wherein the continuous surface comprises multiple attached elements that are configured such that they define the updated interior volume.

51. The method of claim 50, wherein producing a continuous surface of the updated design space comprises using advanced manufacturing to produce the continuous surface at a site location.

52. The method of claim 50, wherein producing a continuous surface of the updated design space comprises using advanced manufacturing to produce the continuous surface at a production facility, the method further comprising shipping the continuous surface to a site location.

53. The method of claim 50, further comprising connecting at least one utility to the structure.

54. The method of claim 50, wherein producing a continuous surface of the updated design space comprises using at least one additive manufacturing process.

55. The method of claim 50, wherein determining performance criteria based on building codes and / or owner requirements comprises consideration of the multiple attached elements.

56. The method of claim 55, wherein determining performance criteria based on building codes and / or owner requirements comprises consideration of the at least one detached element.

57. The method of claim 50, wherein determining performance criteria based on building codes and / or owner requirements comprises defining a 2D footprint of the design space.

58. The method of claim 50, wherein determining at least one advanced manufacturing parameter comprises defining vertical layers for each of the multiple attached elements.

59. The method of claim 58, wherein determining at least one advanced manufacturing parameter comprises constructing a digital build file enabling 3D printing of the multiple attached elements.

60. The method of claim 50, wherein the multiple attached elements are composed at least partially of: glass fiber, carbon fiber, wood fiber, aramid fiber, basalt fiber, talc filler, and gypsum filler, polycarbonate (PC), polypropylene (PP), polybutylene succinate (PBS), polyethylene (PE), chlorinated polyethylene (CPE), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), poly(lactic acid) (PLA), amorphous poly(lactic acid) (aPLA), and stereocomplex polylactide (scPLA), acrylonitrile butadiene styrene (ABS),polyether ether ketone (PEEK), polyetherketoneketone (PEKK), hydroxyl carboxyl sulfonated aminophenol (AH), polyamide or nylon (PA), and / or polyoxymethylene (POM).

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