Method for producing a constructive element, a related printing device and a related printing head

Abstract

The invention relates to a method and related printing device for producing a constructive element comprising a plurality of functional elements, wherein at least one functional element of said plurality of functional elements of said constructive element is characterized by at least one functional requirement, and wherein said method comprising the steps of printing, by means of a printing nozzle, on a layer-by-layer basis, by means of a first non-solid printing material and using a first printing method, a first functional element of said plurality of functional elements, wherein said method further comprises the steps of printing, by means of a printing nozzle, on a layer-by-layer basis, by means of a second non-solid printing material and using a printing method selected, a second functional element of said plurality of functional elements of said constructive element; wherein said method further comprises the steps of selecting, said first non-solid printing material, and selecting said first printing method based on said at least one functional requirement of said first functional element, wherein each non-solid printing material of said plurality of non-solid printing materials comprises distinct characteristics, each characteristic supporting a distinct functional requirement of said functional element; and selecting, said second non-solid printing and selecting said printing method based on at least one functional requirement of said second functional element.

Description

[0001] METHOD FOR PRODUCING A CONSTRUCTIVE ELEMENT, A RELATED PRINTING DEVICE AND A RELATED PRINTING HEAD

[0002] TECHNICAL FIELD

[0003] The present invention relates to a method for producing a constructive element, a related printing device and a related printing head.

[0004] BACKGROUND ART

[0005] Currently, methods for producing a constructive element such as buildings or parts thereof comprising at least one functional element, wherein a constructive element or parts thereof are characterized by at least one functional requirement. Such method comprises the steps of first producing / printing, by means of a first printing nozzle of a printing head of a printing device, on a layer-by-layer basis, of a first non-solid printing material, a mold of said constructive element which step is followed by a second step of filling, (by a second printing nozzle of said printing head of said printing device), said mold of said constructive element, in a layer-by- layer manner with a second non-solid printing material.

[0006] In this manner a constructive element such as a building, a part thereof, a vehicle like for example a boat or other design elements such as light fixtures and staircases can be built in a very efficient way further being very efficient in the use of material preventing waste of material as much as possible.

[0007] The known method for producing such a constructive element such as buildings however is disadvantageous in that it is difficult and laborious to combine multiple construction steps, spread over different disciplines such as shell construction and finishing of such a shell construction, incorporating for example technical equipment, flooring, interior walls, doors, windows and fixed furniture.

[0008] The method for producing such a constructive element such as buildings however is disadvantageous in that it is difficult and laborious to include various steps throughout the entire construction process (including the techniques and finishing phases) in the printing process instead of only being able to automate the shell construction step, as is the case with currently well-known traditional printing in concrete itself. DISCLOSURE OF THE INVENTION

[0009] It is an objective of the present invention to provide with a method for producing a constructive element, a related printing device and a related printing head of the above known type but wherein the aforementioned shortcoming or drawbacks of the known solutions are alleviated or overcome.

[0010] According to embodiments of the invention, this object is achieved by the method for producing a constructive element, as described in claim 1 and the related printing device as described in claim 6 and a related print head as described in respective claims 12

[0011] Indeed, this objective is achieved by said method for producing a constructive element by first printing, by means of a printing nozzle of said at least one printing nozzle of said printing device, on a layer-by-layer basis by means of a first non-solid printing material and using a first printing method, a first functional element of said plurality of functional elements of said constructive element, and printing, by means of a printing nozzle of said at least one printing nozzle of said printing device, on a layer-by-layer basis, by means of a second non-solid printing material and using a second printing method selected, a second functional element of said plurality of functional elements of said constructive element, wherein said method further comprises the steps of selecting, said first non-solid printing material, from a plurality of printing materials and selecting said first printing method from a plurality of printing methods based on said at least one functional requirement of said first functional element, wherein each non-solid printing material of said plurality of non-solid printing materials comprises distinct characteristics, each characteristic supporting a distinct functional requirement of said functional element and selecting, said second non-solid printing material from said plurality of non-solid printing materials and selecting said second printing method from a plurality of printing methods based on at least one functional requirement of said second functional element, wherein said printing method is defined by at least one of the speed of the printing nozzle, the temperature of the printing material in the printing nozzle, the pressure in the printing nozzle, shape of the printing nozzle and the printing path of said printing nozzle.

[0012] In other words, in this manner, by first printing a first functional element such as a mold or support construction forming the outer structure of the constructive element, where the constructive element includes further functional elements and where based on such further functional elements, e.g. a second functional element and third functional element, the optimum, appropriate or best suiting non-solid printing material can be selected from a plurality of non-solid printing materials to optimum support such functional element or functional requirement of the first functional element, i.e. the mold, the support structure, a structural element, a wall element, a floor element, a roof element, a staircase element, an element of a support beam or column of the said constructive element.

[0013] Each non-solid material that is selected having characteristics, optimum supporting functional requirements of said first functional element of said constructive element, where said non-solid printing material is selected based on said at least one functional requirement of said first functional element of said constructive element, where these characteristics of the non-solid printing material optimum support the functional requirements of the first functional element.

[0014] Subsequently, or at the same time, said second printing material is selected from said plurality of non-solid printing materials and additionally a printing method is selected from a plurality of printing methods based on said second functional element of said constructive element and / or based on said at least one functional requirement of said second functional element of said constructive element wherein said printing method selected is defined by at least one of: the speed of the printing nozzle, the temperature of the printing material in the printing nozzle , the pressure in the printing nozzle, shape of the printing nozzle and the printing path of said printing nozzle and where the second printing material and a printing method that is selected, optimum supports the printing of such functional element or functional requirements of the second functional element of the constructive element and hence the optimum results are obtained in matching the requirements of the produced constructive element.

[0015] Each unique combination of a certain printing material and certain printing method results in a distinct print having distinct characteristics such as mechanical characteristics like strength, stiffness, hardness, tensile strength, thermal characteristics like melting point, fire resistance, expansion coefficient, durability characteristics like UV resistance, corrosion resistance, visual characteristics like texture, heat conduction and acoustic characteristics like acoustic permeability.

[0016] The method for producing such a constructive element, according to the present invention is advantageous in that it is enabled to integrate distinct elements, e.g. elements supporting electricity facilities, sanitary facilities, HVAC elements, finishing steps, like plastering step, openings for interior and exterior doors and windows, elements of fixed furniture, or further (functional) elements, in such a constructive element and moreover to integrate the earlier mentioned functional requirements of such functional elements of the constructive element in a one and the same step of producing the first functional element such as a first functional element, such as a mold for the constructive element or a support structure of the constructive element, while at the same time or subsequently producing the additional functional elements and or functional requirements of the constructive element e.g. like a building or a part thereof, a vehicle like for example a boat or other design elements such as light fixtures and staircases.

[0017] The constructive element may be a building, a part thereof a vehicle, like a boat and added design elements like light fixtures and staircases or any further distinct element.

[0018] A "first functional element" of a constructive element is a distinct element of such constructive element e.g., being a mold of such constructive element, a support structure or a structural element, a wall element, a floor element, a roof element, a staircase element, an element of a support beam or column of a wall element, a floor element, a roof element, staircase element, element of a support beam or column.

[0019] A "second functional element" of a constructive element is a distinct element of such constructive element for example, a finishing layer having a certain texture and / or color, an insulation layer having a certain U-value (thermal transmittance value) or an acoustics layer having certain acoustic properties, a duct for pipes, a hollow space for wall box - tap for gas, water, but additionally also an additional element, layer for reinforcement of the construction or be a structural layer for a door frame or window, a structural layer for fixed furniture element, level guides for screed and flooring.

[0020] A functional requirement of a constructive element defines characteristics of the various functional elements that make up the constructive element that is printed and constitutes an additional requirement regarding special functionalities of a constructive element such as sturdiness of the outer wall of the constructive element or a part thereof, a smoothness, a water-repellent characteristic, - rough surface finish, colored finish of parts of the constructive element. A Printing method is defined by at least one of: the speed of the printing nozzle, the temperature of the printing material in the printing nozzle, the pressure in the printing nozzle, shape of the printing nozzle and the printing path of said printing nozzle.

[0021] A non solid Printing material is a material that is printable by a printing nozzle, where such material may be characterized by certain properties such as viscosity, hardening time, and further chemical properties like cross linking ability, UV resistance, water resistance, etc.

[0022] A non limitative list of examples of such printing materials is as follows: insulating materials, concrete, biodegradable material such as PLA or PLA mixed with solid compounds like limestone, natural fibers (wood, flax), etc and liquid compounds like glycerin, etc. Plastics like recycled PVC, ABS, PETG and metals like steel, aluminum are further examples of such printing materials.

[0023] A Printing nozzle is an element of the print head that extrudes the printing material, using an appropriate mix of printing methods characterized by parameters such as pressure, heat, speed, nozzle shape, etc.

[0024] Such printing device may comprise several printing nozzles each dedicated to different printing methods.

[0025] Examples of such three-dimensional printing according to the present invention are pressurized extrusion, material jetting, direct energy deposition, sheet lamination or other means of polymerization like chemical polymerization or UV, heat exposure, crosslinking of materials.

[0026] A further characteristic feature of the present invention is described in claim 2 and the related printing device as described in claim 7.

[0027] The method further comprises the step of filling, by means of a filling nozzle of said at least one filling- nozzle of said printing device, at least said first functional element of said constructive element, with a filling material selected from a from a plurality of filling materials.

[0028] In this manner the earlier constructed first functional element such as a mold comprising further functional elements and / or functional requirements is filled with the printing material having special specific characteristics supporting special characteristics of the constructive element in that the further material may provide isolating characteristics or strengthening the constructive element or both or provides with thermal insulation, acoustic insulation, provide water repellant characteristics or air tightness.

[0029] A filling method is defined by parameters such as pressure, temperature, filling speed, nozzle shape, oscillation of the filling nozzle, etc. A filling material is a material that is usable by means of a filling nozzle FN, where such filling material, for instance, has following properties such as a suitable value of viscosity, a suitable value of hardening time, a suitable value of Weight and / or a suitable value of abrasiveness, etc.

[0030] Examples of such filling materials are EPS, concrete, PUR or natural insulating fibers like thatch and wool, self-reinforcing concrete, other cement mixtures, lime and stone mixtures, clay.

[0031] A further characteristic feature of the present invention is described in claim 3 and the related printing device as described in claim 8.

[0032] The method according to the present invention further comprises the step of selecting a further printing material and a printing method based on at least one functional requirement of said at least one functional element of a third functional element.

[0033] Hence, further functional elements of the constructive element can be printed in a manner optimum supporting features of such functional element by selecting the appropriate printing material having suitable characteristics and a printing method, optimum supporting the printed functional elements.

[0034] Still a further characteristic feature of the present invention is described in claim 4 and the related printing device as described in claim 9.

[0035] A functional element may include at least one of a: mold, a support structure of said constructive element, ducts for a climatization and / or ventilation system, duct for pipes, a hollow space for wall box-tap for gas or water and an additional element or layer for reinforcement of the construction, construction an additional layer for finishing, an additional layer for insulation.

[0036] Still a further characteristic feature of the present invention is described in claim 5 and the related printing device as described in claim 10.

[0037] The functional requirement includes at least one of: sturdiness of the outer wall of the constructive element or a part thereof, a smoothness, a water- repellent characteristic, isolation properties, vapor barrier properties, rough surface finish, colored finish of parts of the constructive element. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The invention will be further elucidated by means of the following description and the appended figures.

[0039] Figure 1 shows a functional overview of the printing device PD comprising respective functional means; and

[0040] Figure 2 shows an overview of the structure of a constructive element CEL with corresponding functional elements and respective functional requirements to be produced by means of the printing method and printing device according to embodiments of the present invention; and

[0041] Figure 3 shows an overview of printing methods PME1 ,...PMEn; and

[0042] Figure 4 shows an overview of the printing materials PMA1 ,...PMAn; and

[0043] Figure 5 shows an overview of the filling materials FMA1 ,...FMAn; and

[0044] Figure 6 shows a functional element FEL being (a) printed using a printing method PME1 ,..,PMEn and a print material PMA1 , ,.,PMAn or (b) filled with a filling material FMA1 ,..FMAn.

[0045] Figure 7 shows an example of a printed constructive element.

[0046] MODES FOR CARRYING OUT THE INVENTION

[0047] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the invention.

[0048] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the invention can operate in other sequences than described or illustrated herein.

[0049] Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the invention described herein can operate in other orientations than described or illustrated herein.

[0050] The term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

[0051] In the following paragraphs, referring to the drawing in Figure 1 , an implementation of the printing device PD according to an embodiment of the present invention is described. At first all essential means of the printing device PD are described.

[0052] In a further paragraph, all connections between mentioned means are defined.

[0053] Subsequently, all relevant functional means of the printing device as presented in Figure 1 are described followed by a description of all interconnections.

[0054] In the succeeding paragraph the actual execution of the printing method according to embodiments of the present invention is described.

[0055] A first essential element of the Printing Device PD for producing a constructive element comprising a plurality of functional elements, wherein at least one functional element of said plurality of functional elements of said constructive element is characterized by at least one functional requirement, are a printing nozzle PN1, ..PNx of at least one printing nozzle, that is configured to print, on a layer-by-layer basis, by means of a first non-solid printing material and a first printing method, a first functional element of said plurality of functional elements of such constructive element; and optionally further a printing nozzle PN1 ..PNx ,that is configured to print on a layer-by-layer basis, by means of a second non-solid printing material and / or a second printing method , a second functional element of said plurality of functional elements of said constructive element. The printing device PD further comprises a selecting means SEM, that is configured to select said first non-solid printing material, from a plurality of printing materials and additionally to select said first printing method from a plurality of printing methods based on said at least one functional requirement of said first functional element, wherein each non-solid printing material of said plurality of non-solid printing materials comprises distinct characteristics, each characteristic supporting a distinct functional requirement of said functional element. The selecting means SEM is further configured to select, said second non-solid printing material from said plurality of non-solid printing materials and / or select said second printing method from a plurality of printing methods based on at least one functional requirement of said second functional element.

[0056] The printing device further may comprise a nozzle control means NCM that is configured to control a printing nozzle of the at least one printing nozzle PNi ....PNx to print each of the functional elements of the constructive element based on a design of the constructive element using selected printing material and a printing method of each functional element of said constructive element.

[0057] The printing method is defined by at least one of the speed of the printing nozzle, the temperature of the printing material in the printing nozzle, the pressure in the printing nozzle, the shape of the printing nozzle and a printing path of said printing nozzle. Hence by adapting one of the heat settings, the speed, the pressure setting the printing path the printing and consequently the printing result, e.g. a functional element, is determined based on these print settings. Hence the characteristics of the printing results such as a functional element are adapted in accordance with the settings of the printing method.

[0058] The printing device further may comprise a computer processing means PRM that based on a design is configured to instruct the nozzle control means NCM to drive the nozzle control means NCM to print the meant constructive element. The processing means PRM may be included in the printing device PD or alternatively be located remotely from said printing device in a personal computing device or a dedicated computing device.

[0059] The computer processing means PRM that is configured to execute a software application such as software application that is configured to design, to manage the 3-dimensional model (i.e. store, design, amend retrieve, send etc.) a design of a 3-dimensional model of said constructive element such as a building. A second relevant element of the computing device is the memory for storing the software application for designing the 3-dimensional building. The memory is configured to store further application for being executed by the computer processing means PRM. Such a memory may be a local memory device but alternatively may be an external and optionally a distributed external memory. This computer processing means may be implemented by means of a computer microprocessor.

[0060] The computing device may be a part of a computing system like a workstation as a desktop personal computer or a laptop personal computer or equally suitable device or be implemented at a server device being located locally or remotely from the user.

[0061] Such system, currently is applied for designing 3-dimensional models of buildings by means of the building information modeling software further referred to as 3-dimensional building model software, being a computer aided design software, which is widely used by many construction businesses — big and small — especially in the architecture, engineering and construction sector. The outcome of the building design process using the Building information modeling (BIM) software is a Building Information Model also / further referred to as a three- dimensional model of a building. This Building Information Modeling BIM is a digital representation of all the physical and functional characteristics of a building and may comprise information on geometry, used materials strengthcharacteristics thereof, used system set-ups, relation between building elements, cost and time, etc., for which the details can vary in amount and complexity, depending on the specific project, and phase in the project. Such a 3-dimensional building model i.e., the BIM model is a shared knowledge source or file with information about the building that serves as a reliable basis for making decisions during the entire life cycle of the building. The BIM model, i.e. the three- dimensional building model such as a CAD computer file, is used from the first design, during construction, during management to the demolition of the building by the all-relevant parties as the basic information source and communication tool in their activities, e.g. to efficiently plan, design, construct, and manage buildings. Such a BIM model (coming from the industry like architect or engineer) may be converted by custom software to a 3D printable model, which is then fed to the computing device for the factual printing of the constructive element according to embodiments of the present invention.

[0062] The Printing Device PD further comprises at least one filling nozzle FNi, ...FNX, configured to fill at least said first functional element of said constructive element, with a filling material selected from a from a plurality of filling materials.

[0063] A filling method is defined by parameters such as pressure, temperature, filling speed, nozzle shape, oscillation of the filling nozzle, etc.

[0064] A filling material is a material that is usable by means of a filling nozzle FN, where such filling material, for instance, has following properties such as a suitable value of viscosity, a suitable value of hardening time, a suitable value of Weight and / or a suitable value of abrasiveness, etc.

[0065] Examples of such filling materials are EPS, concrete, PUR or natural insulating fibers like thatch and wool, self-reinforcing concrete, other cement mixtures, lime and stone mixtures, clay.

[0066] A processing means PRM receives instructions for the creation of a construction element CEL. The PRM controls the selecting means (SEM) and the nozzle control means NCM. The SEM in turn controls the material selecting means MSM. The NCM controls the correct printing nozzle (PN) or filling nozzle FN1 ...FNx while the MSM supplies the material.

[0067] Figure 1 further shows control data flow such as control signals by means of a solid connection-line and material flows such a printing material and filling materials by means of a dashed connection line.

[0068] A constructive element CEL consists of various functional elements FEL. Each functional element FEL fulfills a number of functional requirements FRE1 ,.,FRE6, as presented in Figure 2.

[0069] At printing a functional element FEL, one printing method PME1 , ,.,PMEn is selected from a plurality of printing methods, as presented in Figure 3.

[0070] At printing a functional element FEL, one printing material PMA1 ,..,PMAn is selected from a plurality of printing materials PMAs, as presented in Figure 4.

[0071] When filling a functional element FEL, one filling material FMA1 ,..,FMAn is selected from a plurality of FMAs, as presented in Figure 5. A functional element FEL is (a) printed using a printing method PME and a print material PMA1 , ,.,PMAn or (b) filled with a filling material FMA1 ,..,FMAn, as presented in Figure 6.

[0072] In order to explain an embodiment of the present invention it is assumed that a constructive element such as a building or a part thereof, a vehicle like for example a boat or other design elements such as light fixtures and staircases where such constructive element for instance comprises three functional elements, FEL 1 , FEL2, FEL3, at first there is a first functional element such as a mold or support construction forming the outer structure of the constructive element. In practice the first functional element forms a rectangular shaped wall with openings for doors and windows. Figure 7 shows a wall with adjacent door to be printed including the shown functional elements and requirements.

[0073] In order to explain the present invention, it is assumed that single layer of such building is printed such as for example a ground floor that is fit for mounting concrete floor elements on top of the walls of the first functional element FEL1 .

[0074] Alternatively, such first functional element could be a formwork to produce elements of a building such as a staircase, column or a beam.

[0075] The constructive element, i.e., the building includes further functional elements such as a second functional element that is an insulating layer, a third functional element being a plaster layer mounted on top of the outer wall of the first functional element. Furthermore, the constructive element comprises a fourth functional element being a duct for pipes, a hollow space for wall box, tap for gas and / or water.

[0076] Before the step of actual printing based on such further functional elements, e.g., a second functional element and third functional element, the optimum, appropriate or best suiting non-solid printing material can be selected from a plurality of non-solid printing materials to optimum support such functional element or functional requirement of the first functional element, i.e., the mold, the support structure of the said constructive element. Examples of such non- solid printing materials are PLA or PLA mixed with solid compounds like limestone, natural fibers (e.g. wood, flax) and liquid compounds like glycerin. Other examples are plastics like recycled PVC, ABS, PETG and metals like steel, aluminum. Each non-solid material that is selected having said characteristics, optimum supporting functional requirements of said first functional element of said constructive element where said non-solid printing material is selected based on said at least one functional requirement such as strength, a value of fire resistance of said first functional element of said constructive element, where these characteristics of the non-solid printing material optimum support the functional requirements of the first functional element. Based on those functional requirements it is assumed that pure PLA is chosen for printing this first functional element. In addition, a printing method supporting the strength of the first functional element and texture is chosen being a printing method applying a unique combination of settings like temperature, pressure, speed and nozzle shape to obtain the desired functional requirements of the first functional element.

[0077] Hence, based on a design of the first functional element that e.g., based on Building Information Modelling data is input to the processing means PRM The inputting can be performed via a BIM file or alternatively be manually entered via a coupled display, mouse and keyboard.

[0078] Hence the processing means PRM, PRM” is configured to instruct, based on a design of the first functional element, i.e. the building, the nozzle control means NCM to drive the printing nozzle PN1 to print on a layer-by-layer basis, the meant constructive element using the selected first non-solid printing material being pure PLA and the first printing method, being a printing method with the appropriate combination between speed, pressure, heat, etc. for the chosen pure PLA material.

[0079] The selected first non-solid printing material is fed to the printing nozzle PN1 , from a silo SIM1 containing this the selected first non-solid printing material which is transported via a flexible hose coupling this first silo SIMi with the printing nozzle. The further silo’s SIM2 up to and SIMx are also coupled to the respective printing nozzles PNi,..PNxor filling nozzles FNi,...FNx.

[0080] The first functional element subsequently is printed on a layer-by-layer basis, the meant constructive element using the selected first non-solid printing material being pure PLA and the first printing method.

[0081] It is assumed that the first functional element, being the support structure of the said constructive element may comprise a spaced inner and outer wall. Subsequently, or at the same time the processing means PRM based on Building Information Modelling data input related to the second functional element of the constructive element, the Computer processing means PRM processes the data and derives instructions for the nozzle control means NCM to drive one of printing nozzles PNi, PN2..PNXto print on a layer-by-layer basis, the meant second functional element, being an insulation layer on top of the mold, i.e. the first functional element, using the selected second non-solid printing material being for example being a foamed PLA and printing method being again the appropriate mix between speed, pressure, heat for this PLA type. The insulation layer has a certain II value and additionally acoustic characteristics.

[0082] This second functional element being an insulating layer can be printed next the outer / inner wall of the first functional element.

[0083] Before the step of actual printing based on the second functional element, the optimum, appropriate or best suiting non-solid printing material can be selected from a plurality of non-solid printing materials to optimum support such functional element or functional requirement of the second functional element, i.e., the insulation layer to be mounted against the inner wall of the first functional element being the support structure of the said constructive element.

[0084] A non limitative list of examples of such printing materials is as follows: insulating materials, concrete, biodegradable material such as PLA, PLA plus limestone or PLA mixed with solid compounds like limestone, natural fibers (wood, flax) and liquid compounds like glycerin. Plastics like recycled PVC, ABS, PETG and metals like steel, aluminum are further examples of such printing materials.

[0085] Each non-solid material that is selected having said characteristics, optimum supporting functional requirements of said second functional element of said constructive element where said non-solid printing material is selected based on said at least one functional requirement such as insulation value and a value of fire resistance, water and air tightness properties, weight, UV resistance of said second functional element of said constructive element, where these characteristics of the non-solid printing material optimum support the functional requirements of the second functional element. Based on those functional requirements it is assumed that foamed PLA is chosen for printing this second functional element. Moreover, PLA can be mixed with starch or other chemical compound to improve fire resistance (so focusing on the fire resistance). In addition, a printing method supporting the insulation value of the second functional element and fire resistance is chosen being a printing method being again the appropriate mix between speed, pressure, heat for this foamed PLA type to obtain the desired functional requirements of the second functional element being the insulating value.

[0086] It is further assumed that the selected second non-solid printing material is fed to the second printing nozzle PN2, from a second silo SIM2 that in turn contains the selected second non-solid printing material being foamed PLA which is transported via a flexible hose coupling this second silo SIM2 with the second printing nozzle.

[0087] The second functional element subsequently is printed on a layer-by-layer basis, the meant constructive element using the selected second non-solid printing material being foamed PLA and the suitable second printing method.

[0088] Subsequently, or at the same time the processing means PRM based on in Building Information Modelling data input related to the third functional element of the constructive element, the Computer processing means PRM process the data and derives instructions for the nozzle control means NCM to drive one of printing nozzle PNi, PN2..PNXto print on a layer-by-layer basis, the meant third functional element using the selected third non-solid printing material e.g. being PLA mixed with limestone where the printing method being the appropriate combination between speed, pressure, heat in the printing nozzle PN2..PNx.

[0089] This third functional element being a finishing layer such as a plaster layer mounted on top of the inner wall of the first functional element or on top of the insulating layer printed next the outer / inner wall of the first functional element.

[0090] Before the step of actual printing based on the third functional element, the optimum, appropriate or best suiting non-solid printing material can be selected from a plurality of non-solid printing materials to optimum support such functional element or functional requirement of the third functional element, i.e., the finishing layer such as a plaster layer.

[0091] Each non-solid material that is selected having said characteristics, optimum supporting functional requirements of said third functional element of said constructive element where said non-solid printing material is selected based on said at least one functional requirement such as smoothness, texture, a value of fire resistance or water absorption properties (hygroscopic), flexibility (tendency to crack) of said third functional element of said constructive element, where these characteristics of the non-solid printing material optimum support the functional requirements of the third functional element.

[0092] Based on those functional requirements it is assumed that PLA mixed with limestone or PLA mixed with natural fibers is chosen for printing this third functional element. In addition, a printing method supporting the smoothness of the third functional element being the finishing layer such as a plaster layer fire resistance is chosen being a printing method applying the appropriate mix between speed, pressure, heat for this PLA mixed with limestone.

[0093] It is further assumed that the selected third non-solid printing material is fed to the third printing nozzle PN3, from a third silo SIM3that in turn contains the selected second non-solid printing material being PLA mixed with limestone, which is transported via a flexible hose coupling this second silo SIM3containing the PLA mixed with limestone with the third printing nozzle PN3.

[0094] The third functional element subsequently is printed on a layer-by-layer basis, the meant constructive element using the selected third non-solid printing material being PLA mixed with limestone and the third printing method, being a printing method applying the appropriate mix between speed, pressure, heat for this PLA mixed with limestone.

[0095] The Printing Device PD further comprises at least one filling nozzle FNi,..FNxconfigured to fill at least said first functional element of said constructive element, with a filling material selected from a from a plurality of filling materials FMi, ...FMn.

[0096] In this manner the earlier constructed first functional element such as a mold comprising further functional elements and / or functional requirements is filled with the printing material having special specific characteristics supporting special characteristics of the constructive element in that the further material may provide isolating characteristics or strengthening the constructive element or both or provides with thermal insulation, acoustic insulation, provide water repellant characteristics or air tightness.

[0097] A filling method is defined by parameters such as pressure, temperature, filling speed, nozzle shape, oscillation of the filling nozzle, etc.

[0098] A filling material is a material that is usable by means of a filling nozzle FN, where such filling material, for instance, has following properties such as a suitable value of viscosity, a suitable value of hardening time, a suitable value of Weight and / or a suitable value of abrasiveness, etc.

[0099] Examples of such filling materials are EPS, concrete, PUR or natural insulating fibers like thatch and wool, self-reinforcing concrete, other cement mixtures, lime and stone mixtures, clay.

[0100] The method for producing such a constructive element, according to the present invention is advantageous in that it is enabled to integrate distinct elements, e.g. elements supporting electricity facilities, sanitary facilities, HVAC elements or further (functional) elements in a first phase, in such a constructive element and moreover integrate the earlier mentioned functional requirements of such functional elements of the constructive element in a same / single step of producing the first functional element such as a first functional element, such as a mold for the constructive element or a support structure of the constructive element, while at the same time or subsequently producing the additional functional elements and or functional requirements of the constructive element e.g. like a building.

[0101] It is first to be noted that distinct functional requirements can be obtained by a dedicated combination of a printing method and a non solid printing material characteristic. In other words, a unique functional requirement of a functional element is obtained by the unique combination of printing method and nonsolid printing material.

[0102] It is to be noted that the first, the second third and further printing method may refer to different printing methods but not necessarily need to be different from each other.

[0103] It is to be noted that the first, the second third and further non-solid printing material may refer to different printing materials but not necessarily need to be different from each other.

[0104] It is contemplated that some of the steps discussed herein as software methods may be implemented within hardware, for example, as circuitry that cooperates with the processor to perform various method steps. Portions of the present invention may be implemented as a computer program product wherein computer instructions, when processed by a computer, adapt the operation of the computer such that the methods and / or techniques of the present invention are invoked or otherwise provided. Instructions for invoking the inventive methods may be stored in fixed or removable media, transmitted via a data stream in a broadcast or other signal bearing medium, and / or stored within a working memory within a computing device operating according to the instructions.

[0105] Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.

[0106] A final remark is that embodiments of the present invention are described above in terms of functional blocks. From the functional description of these blocks, given above, it will be apparent for a person skilled in the art of designing electronic devices how embodiments of these blocks can be manufactured with well-known electronic components. A detailed architecture of the contents of the functional blocks hence is not given.

[0107] While the principles of the invention have been described above in connection with specific apparatus, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the invention, as defined in the appended claims.

Claims

CLAIMS1 . Method for producing a constructive element comprising a plurality of functional elements, wherein at least one functional element of said plurality of functional elements of said constructive element is characterized by at least one functional requirement, CHARACTERISED IN THAT said method comprising the steps of: printing, by means of a printing nozzle of at least one printing nozzle of a printing device, on a layer-by-layer basis, by means of a first non-solid printing material and using a first printing method, a first functional element of said plurality of functional elements, wherein said method further comprises the steps of: printing, by means of a printing nozzle of said at least one printing nozzle of said printing device, on a layer-by-layer basis, by means of a second non-solid printing material and using a (second) printing method selected, a second functional element of said plurality of functional elements of said constructive element; and wherein said method further comprises the steps of: selecting, said first non-solid printing material, from a plurality of printing materials and selecting said first printing method from a plurality of printing methods based on said at least one functional requirement of said first functional element, wherein each non-solid printing material of said plurality of non-solid printing materials comprises distinct characteristics, each characteristic supporting a distinct functional requirement of said functional element; and selecting, said second non-solid printing material from said plurality of non-solid printing materials and selecting said (second) printing method from a plurality of printing methods based on at least one functional requirement of said second functional element, wherein said printing method is defined by at least one of: the speed of the printing nozzle, the temperature of the printing material in the printing nozzle, the pressure in the printing nozzle, the shape of the printing nozzle and the printing path of said printing nozzle.

2. Method for producing a constructive element according to claim 1 , CHARACTERISED IN THAT said method further comprises a step of filling, by means of a filling nozzle of said at least one filling nozzle of said printing device,at least said first functional element of said constructive element, with a filling material selected from a from a plurality of filling materials.

3. Method for producing a constructive element according to claim 1 or 2, CHARACTERISED IN THAT said method further comprises the step: selecting a further printing material and a printing method based on at least one functional requirement of a third functional element.

4. Method for producing a constructive element according to any of claims 1 to 3, CHARACTERISED IN THAT said at least one functional element comprises at least one of: a mold, a support structure, ducts for climatization- or ventilation system, duct for pipes, a hollow space for wall box, tap for gas or water, an additional element / layer for reinforcement of the construction an additional layer for finishing, an additional layer for insulation.

5. Method for producing a constructive element according to any of claims 1 to 4, CHARACTERISED IN THAT said at least one functional requirement of said constructive element comprises at least one of: sturdiness of the outer wall of the constructive element or a part thereof, a smoothness, a water-repellent characteristic, isolation properties, vapor barrier properties, texture, colored finish of parts of said constructive element.

6. Printing Device (PD) for producing a constructive element (CEL) comprising a plurality of functional elements (FEL1..FEL3), wherein at least one functional element of said plurality of functional elements (FEL1..FEL3) of said constructive element (CEL) is characterized by at least one functional requirement (FRE1 ,...,FRE6), CHARACTERISED IN THAT, said printing device comprises: at least one printing nozzle (PN1 ..PNx), configured to print, on a layer-by- layer basis, by means of a first non-solid printing material and a first printing method, a first functional element of said plurality of functional elements; and in that said at least one printing nozzle, further is configured to print on a layer-by- layer basis, by means of a second non-solid printing material and / or a secondprinting method, a second functional element of said plurality of functional elements of said constructive element; and a selecting means (SEM), configured to select said first non-solid printing material, from a plurality of printing materials and / or select said first printing method from a plurality of printing methods based on said at least one functional requirement of said first functional element, wherein each non-solid printing material of said plurality of non-solid printing materials comprises distinct characteristics, each characteristic supporting a distinct functional requirement of said functional element; and in that said selecting means (SEM), further is configured to select, said second non solid printing material from said plurality of non-solid printing materials and / or select said second printing method from a plurality of printing methods based on at least one functional requirement of said second functional element.

7. Printing Device (PD) according to claim 6, CHARACTERISED IN THAT said printing device (PD) further comprises: a filling nozzle (FN1 ..FNx), configured to fill at least said first functional element of said constructive element, with a filling material selected from a from a plurality of filling materials.

8. Printing Device (PD) according to claim 6 or 7, CHARACTERISED IN THAT said selecting means (SEM), further is configured to select a further printing material and / or a further printing method based on at least one functional requirement of a third functional element.

9. Printing Device (PD) according to any of claim 6 to 8, CHARACTERISED IN THAT said at least one functional element comprises: at least one of a mold, a support structure, ducts for climatization- or ventilation system, duct for pipes, a hollow space for wall box, tap for gas or water, an additional element / layer for reinforcement of the construction an additional layer for finishing.

10. Printing Device (PD) according to any of claim 6 to 8, CHARACTERISED IN THAT said at least one functional requirement of said constructive element comprises at least one of: sturdiness of the outer wall of the constructive element or a part thereof, a smoothness, a water-repellent characteristic, isolation properties, vapor barrier properties, texture, colored finish of parts of said constructive element.11 . Printing Device (PD) according to any of claim 6 to 8, CHARACTERISED IN THAT said printing method is defined by at least one of: the speed of the printing nozzle, the temperature of the printing material in the printing nozzle, the pressure in the printing nozzle, the shape of the printing nozzle and the printing path of said printing nozzle.

12. Printing head for use in a printing device according to any of claims 6 to 11.

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