Method for manufacturing architectural building products

Abstract

The invention relates to the field of producing architectural building products. The technical result consists in a reduction in the manufacturing complexity of architectural building products with an arbitrary three-dimensional shape, a reduction in the material and time costs entailed in production, and an increase in the geometric precision and structural and decorative characteristics of the products. A method for manufacturing architectural building products includes the steps of: generating a three-dimensional digital model of an architectural building product; performing, on the basis of the generated digital model, 3D printing of a shaping structure of the product, which determines the shape of said product, wherein the edges of the shaping structure of the product have removable edge elements formed thereon by 3D printing, said edge elements being formed integrally with the shaping structure; applying to the shaping structure a structural load-bearing layer; removing the removable edge elements from the shaping structure; applying an outer layer to the load-bearing layer.

Description

[0001]METHOD FOR MANUFACTURING ARCHITECTURAL CONSTRUCTION PRODUCTS Technical Field The present invention relates to the field of manufacturing architectural construction products using additive technologies. Prior Art The technology currently used for producing certain architectural construction products, such as facade panels for cladding buildings and various structures, essentially includes three stages. In the first stage, a master model (prototype) of the future product is produced. Depending on the complexity of the model, the material used to manufacture it may be plasticine, clay, or gypsum. Some large-scale models are manufactured by milling from wood or plywood. In the second stage, an inverse matrix is ​​produced using the master model. In the final stage, the final product is manufactured by applying materials to the inverse matrix.This process is labor-intensive and complex, and its complexity increases when manufacturing custom façade panels designed to create 3D designs and bas-reliefs. Furthermore, due to the significant amount of human labor involved, this production method does not allow for high-precision manufacturing of façade panels in accordance with the design. Therefore, there is a need in the art for a method for manufacturing architectural and construction products of arbitrary shape that overcomes the aforementioned disadvantages. Summary of the Invention: The present invention aims to solve at least some of the above problems.In accordance with the present invention, a method for manufacturing architectural and construction products is proposed, which includes the following stages: forming a three-dimensional digital model of the architectural and construction product; based on the formed digital model, 3D printing (three-dimensional printing) of the form-generating structure of the product is carried out, defining the shape of the product, wherein detachable edge elements are formed on the edges of the form-generating structure of the product by means of 3D printing, made in one piece with the form-generating structure, in order to form a precise edge of the product; a structural supporting layer is applied to the form-generating structure; the detachable edge elements are separated from the form-generating structure; an outer layer is applied to the mentioned supporting layer. According to one embodiment, the method further comprises the stage of mechanical processing of the product after applying the supporting layer.According to another embodiment of the method, the mechanical processing includes at least one of milling, grinding, and rolling. According to another embodiment of the method, the outer layer is configured to perform a decorative and / or protective function. According to another embodiment of the method, the architectural construction products are decorative products or small architectural forms. According to another embodiment of the method, the architectural construction products are facade panels for the exterior cladding of buildings. According to another embodiment of the method, during the 3D printing step of the forming structure, 3D printing of fasteners formed integrally with the forming structure is also performed. According to another embodiment of the method, the fasteners are used to move and secure the product during its manufacture.According to another embodiment of the method, the step of forming a three-dimensional digital model includes the steps of: - forming a three-dimensional model of the building facade; - forming a three-dimensional model of individual facade panels; - forming a three-dimensional model of the form-generating structure of the facade panels, including detachable edge elements and fasteners; - forming a three-dimensional model of the structural load-bearing layer; - forming a three-dimensional model of the outer layer. According to another embodiment of the method, the shape, location and orientation of the fasteners on the facade panels are set in such a way that the said fasteners are in one-to-one mutual correspondence with the mating fasteners on the building. According to another embodiment of the method, the location of the mating fasteners on the building is determined by scanning the building.According to another embodiment of the method, a coating is applied to the mating fasteners prior to scanning, facilitating their detection. According to another embodiment of the method, the shape, location, and orientation of the mating fasteners on the building are determined during modeling. According to another embodiment of the method, the shape, location, and orientation of the fasteners on the façade panels are determined such that said fasteners are in one-to-one correspondence with the mating fasteners on adjacent façade panels, enabling the connection of adjacent façade panels to each other.According to another embodiment of the method, during the 3D printing step of the forming structure, fasteners are 3D printed on detachable edge elements, the fasteners are used to move and secure the product during its manufacture, and after the carrier layer is applied, the edge elements are separated along with the fasteners. According to another embodiment of the method, the forming structure has a cellular structure. According to another embodiment of the method, the detachable edge elements are designed as flanges. According to another embodiment of the method, the detachable edge elements are designed as smooth flanges to form smooth edges of the product. According to another embodiment of the method, the detachable edge elements are designed as flanges with a stepped profile to form stepped edges of the product.According to another embodiment of the method, the detachable edge elements are printed from the same material as the forming structure. According to another embodiment of the method, the detachable edge elements are connected to the forming structure of the product by a perforated section, which ensures their temporary connection to the forming structure and the possibility of their detachment. According to another embodiment of the method, a structural support layer is applied to the forming structure on one side, which is defined as the front side of the product. According to another embodiment of the method, the structural support layer is applied to the forming structure on the side defined as the front side of the product and on the reverse side, on which the fastening elements are located, wherein the fastening elements are not covered with a support layer.According to another embodiment of the method, the detachable edge elements are separated from the form-generating structure after the applied supporting layer has gained strength. According to another embodiment of the method, the step of forming a three-dimensional digital model includes the steps of: forming a three-dimensional model of the form-generating structure of the architectural and construction product, including the detachable edge elements; forming a three-dimensional model of the structural supporting layer; forming a three-dimensional model of the outer layer. The present invention reduces the complexity of the process of manufacturing architectural and construction products of arbitrary three-dimensional shape, reduces material and time costs for production, and increases the geometric accuracy, structural and decorative characteristics of the products. Brief description of the drawings The invention is further explained by a description of preferred embodiments of the invention with reference to the accompanying drawings, in which: Fig.1 depicts a block diagram of a method for producing façade panels. Figs. 2a-2b depict variants of joining adjacent façade panels with stepped edges. Figs. 3a-3g depict an exemplary embodiment of fasteners and counter fasteners. Description of preferred embodiments of the invention The present invention discloses a technology for producing architectural construction products using additive technologies to create a form-forming structure with the subsequent application of one or more layers of one or more materials to obtain the required strength and surface appearance. This technology can be used to produce architectural or construction products, such as façade panels for exterior cladding of buildings, wall panels for interior decoration, decorative elements, small architectural forms, etc.In accordance with one aspect of the present invention, a method for manufacturing architectural construction products is proposed using 3D printing to create a shaping structure for the product of any shape, onto which a supporting layer and an outer layer are then applied. For simplicity, the following description of an exemplary embodiment of the present invention will be disclosed with respect to three-dimensional (3D) façade panels. However, it is obvious that the features of the present invention can be similarly applied to the manufacture of other types of products. The essence of the technical solution consists in combining the use of additive manufacturing (3D printing) to create the internal shaping structure of façade panels (façade elements), followed by the application of a reinforcing supporting layer made of structural materials used for the production of façade panels, such as glass fiber reinforced concrete, polymer composites with glass fiber, and others (hypofiber, polymer concrete, polymers, etc.).This makes it possible to obtain durable 3D facades of various shapes and configurations without compromising the technical characteristics, but without using molds for their production. In this application, the terms "additive manufacturing" and "3D printing" are used interchangeably. The method for producing facade panels in accordance with the present invention includes the following stages: - 3D printing of the form-generating structure of the facade panel is carried out, wherein detachable edge elements are formed on the edges of the form-generating structure of the facade panel by means of 3D printing, made in one piece with the form-generating structure, in order to form a precise edge of the facade panel; - a structural supporting layer is applied to the form-generating structure; - the detachable edge elements are separated from the form-generating structure; - an outer layer is applied to the mentioned supporting layer.In the context of building materials, the term "structural load-bearing layer" refers to a layer that provides the basic mechanical characteristics of a structure, such as strength, rigidity, and stability. This layer serves as the foundation that bears all loads and transfers them to other structural elements. An exemplary embodiment of the aforementioned method for manufacturing façade panels will be described in detail below with reference to Fig. 1. Initially, at step S1, the façade is modeled. Architects develop the design of the façade system for the structure (building) and create 3D models of the objects. Using specialized software or 3D modeling, the façade system is "cut" into individual façade panels of the required dimensions (this can be done either automatically or manually). Generative 3D design algorithms can be used for this purpose. Such algorithms can automatically generate various design options based on predefined rules and parameters.Examples of such generative 3D design algorithms include fractal generation algorithms, machine learning methods, Voronoi algorithms, Delaunay diagrams, random generation methods, and more. Generative 3D design algorithms enable the creation of various façade shapes and structures. These algorithms consider various parameters, such as appearance, strength, lighting, and so on. This allows for the rapid creation and visualization of design concepts. Generative algorithms are also used to optimize façade parameters. For example, an algorithm can be configured to find the optimal dimensions and arrangement of façade elements to achieve desired characteristics, such as aerodynamics. Furthermore, generative design can be used to automatically create façade details. This includes not only geometry generation but also the creation of textures, reliefs, ornamentation, and other details that make the façade unique.These algorithms enable an iterative design process, rapid prototyping, and evaluation of various façade options. This allows for design optimization and consideration of diverse user needs. A significant advantage is that generative design can integrate analysis and simulation algorithms to evaluate façade characteristics such as thermal conductivity, sound insulation, and other physical properties. Next, based on the resulting façade panel model, the form-generating structure (frame) of the façade panel is modeled. For this purpose, specialized software is used to generate the façade panel frame onto which the load-bearing layer will be applied, and files for 3D printing are generated. The façade panel frame is modeled using various 3D modeling programs, such as CAD systems (AutoCAD, SolidWorks, CATIA, Fusion 360) or specialized architectural modeling programs (Revit, Rhino).At this stage, algorithms can be used to automatically calculate and create a frame, taking into account the required strength, flexibility, and other design parameters. Such algorithms can optimize the size and shape of frame elements to achieve the desired characteristics. Examples of such algorithms include, but are not limited to, the finite element method (FEM), finite volume method (FVM), finite difference method (FDM), and boundary element method (BEM). After modeling the form-generating structure, the structural load-bearing layer and outer layer are modeled. Various methods and software tools can be used to perform engineering calculations and computer modeling of the mechanical properties of the façade panel, depending on its thickness and the materials used. Stress and strain calculations in materials are performed using the fundamental principles of strength of materials.To evaluate the strength and elasticity of a material, equations such as Hooke's law for elasticity and Tresca's theory for estimating strength under different stresses can be used. Computer modeling is advisable for these tasks. Finite element analysis (FEA) programs such as ANSYS, Abaqus, COMSOL, and others can be used to simulate the mechanical properties of a façade panel. For example, using ANSYS, you can create a 3D model of the element, define materials with dimensions (e.g., fiberglass-reinforced epoxy resin, a frame layer), determine boundary conditions (how the façade is attached to the building), and then run an analysis that shows the stress distribution in the element depending on its thickness and loads. The thickness of the façade panel is also selected based on the desired elasticity.Elasticity theory determines how a material will deform and return to its original shape under load. Key factors considered in façade design include wear resistance, wind and moisture protection, fire resistance, and frost resistance. Key structural characteristics of façade panels considered during design include thickness, panel size, weight, service life, etc. The result of stage S1 is the creation of a model of the architectural or construction product (façade panel) and its transfer to further production. Next, stage S2 involves 3D printing the façade panel's form-forming structure based on the generated model. In the preferred embodiment, the form-forming structure has a cellular (mesh) structure.Alternatively, the molding structure may have a solid surface with integrated ribs to support the product's shape and provide strength and rigidity. Resins with added fiberglass can be used for printing to reinforce the façade and increase strength, as well as other materials such as concrete, gypsum, sand, metal, polymers, and so on. Table 1 below lists some examples of 3D printing polymers, along with temperature ranges for their use and platform heating during 3D printing: Table 1. Polyetherether insulation material with high 250-400°C tone (PEEK) mechanical and chemical resistance, widely used in aerospace and medical industry The selection of materials for printing the shaping structure is based on the required functions and specified characteristics of the product. Using 3D printing to create the shaping structure of façade panels enables a high degree of geometric complexity and individuality in façade structures. The present invention provides for the use of detachable edge elements on the edges of the façade panel's shaping structure. Detachable edge elements, realized as borders, are additional elements that are printed along with the façade panel's shaping structure during the 3D printing process. Detachable edge elements can also be realized as smooth borders. 3D printing these edge elements on the edges of the shaping structure guarantees the geometric accuracy of all shapes and dimensions of the manufactured façade panels, ensuring precise joining of the façade panels.This also solves the problem of difficult cleaning of the edges of façade panels and ensures a tight fit between the façade panels. Alternatively, the detachable edge elements may have, for example, a stepped profile, which results in the formation of a stepped edge of the façade panel. The shape of the stepped edge of the façade panel may be complementary to the shape of the edge of the adjacent façade panel, allowing them to be installed flush against each other without a gap (see Fig. 2a) or with a minimal gap (see Fig. 2b). In this case, the overlapping stepped edges of adjacent façade panels reduce the likelihood of displacement of the said panels relative to each other. In a preferred embodiment, the edge elements are printed from the same material as the façade panel's form-forming structure.The edge elements are connected to the product's core structure via a perforated section, allowing for their temporary attachment to the core structure and the ability to be removed. Alternatively, the edge elements can be connected to the core structure via a point connection. Alternatively, the edge elements can be printed from a material different from the core structure, such as a water-soluble material. Furthermore, fasteners are also printed at this stage, creating a single structure consisting of the core structure, edge elements, and fasteners. Using a 3D model of the fasteners for the façade panels on the building, the fasteners are printed directly onto the façade panel at the required locations. This structure is created using appropriate materials that ensure strength and reliability.The façade's formwork, edge elements, and fasteners are printed as a single, integrated unit, allowing them to be connected without the need for additional fasteners. To avoid the need for a subsequent coating of the fasteners, printing parameters in areas where fasteners are located can be adjusted to increase the infill and the number of outer layers. This means more material is used in these areas to print the fasteners onto the formwork, ensuring a strong and secure connection. This also ensures that the coating does not completely cover the fasteners when applied, leaving the fasteners exposed. This approach ensures a strong and reliable connection between the façade panel's formwork and the fasteners, allowing them to perform their function without the need for complete coating with the coating.The aforementioned fasteners can also be used by robotic manipulators during the production process to grip, move, and secure the façade panel at various stages. For this purpose, the aforementioned robotic manipulators use a façade panel model at subsequent stages to determine the locations of the fasteners on the façade panel. Automating the façade panel positioning process using technical fasteners simplifies the application of the base layer, subsequent processing, application of the outer layer, and painting of the façade. Furthermore, securing the façade panel with fasteners during the production process prevents deformation of the façade panel's form-forming structure during the application of the base layer and until it dries. It is worth noting that in some embodiments of the present invention (e.g., when producing decorative elements or small architectural forms), the manufactured product does not necessarily require fasteners.Furthermore, such products may require the application of an outer layer on all sides of the product, eliminating the need for fasteners on the finished product. In this case, fasteners used during production to move and secure the product can be formed on detachable edge elements and then, after the carrier layer is applied, separated from the product along with the edge elements. 3D printing of a free-form 3D forming structure with edge and fastener elements increases the speed and reduces the complexity of the manufacturing process. The result of step S2 is a single structural structure ready for transfer to step S3. After printing is complete, a robotic arm detaches the part (the façade panel frame) from the print platform and transfers it to a conveyor line for further processing, or this can be done manually.Next, at step S3, the façade panel's structural structure is transferred to the reinforcing load-bearing layer application area, where it is installed on a fixed fixture using frame fasteners. A robotic arm initiates the process of applying the structural load-bearing layer to the façade panel's structural structure in accordance with a previously developed model. Various materials are used in the process, including phenolic resin, silicone resin, glass-fiber-reinforced polyester resins, epoxy resins, reinforced polyurethanes, acrylic resins, polyester materials, glass fiber-reinforced concrete, polymer composites with glass fiber, gypsum fiber, polymer concrete, and other suitable binders with a reinforcing component. Fiberglass or glass fiber-reinforced concrete is predominantly applied as the load-bearing layer. After drying, the load-bearing layer imparts the necessary strength and stability to the façade panel, ensuring its reliability and durability.In a preferred embodiment, the support layer is applied to the forming structure on only one side, which is designated as the front side of the future product. This embodiment allows for a product to be produced that meets specified requirements, has a low thickness and weight, and also requires minimal support layer material consumption. At the same time, the support layer can prevent the fasteners, which are primarily formed on the back side of the future product, from being exposed to the fasteners. Alternatively, the support layer is applied to the forming structure on both the side designated as the front side of the product and the back side, where the fasteners are located, without the fasteners being coated with the support layer. The use of various materials for façade reinforcement ensures high strength and adaptability to various architectural requirements.Table 2 provides several examples of binder and fiberglass application systems that can be used in this technology. Table 2. After the base layer has been applied and the product has achieved its initial strength, the detachable edge elements can be carefully separated from the façade panel's core structure in step S4. This is accomplished by carefully breaking the perforated joint, similar to tearing paper along a cut. This mechanism allows the edge elements to be easily separated without damaging the façade panel's core structure. After separation of the edge elements, each façade panel fits snugly against the next, allowing them to snap or connect with precision. This ensures a tight fit between the façade panels in the façade system and conforms to all shapes and sizes. The result of step S4 is a single structural assembly with an applied base layer, ready for transfer to the machining zone. After the base layer has been applied and dried, the resulting part is moved to the machining zone.Next, at step S5, the part is secured in a special fixture, and a robotic manipulator performs its mechanical processing. Mechanical processing may include, for example, milling, grinding, rolling, etc. This processing can also be performed manually. The mechanical processing step after applying the base layer is not always mandatory and depends on the specific requirements of the final product and its design characteristics. If the design calls for a textured surface that does not require absolute smoothness, then mechanical processing can be omitted. Mechanical processing allows for surface leveling, improvement of the surface texture of the part, and removal of excess base layer. If the façade surface must be absolutely smooth and free of defects, then milling or other methods can be used to level the surface.If excess material is created during the application of the base layer and must be removed, for example, to conform the product to a specific size or shape, mechanical processing may be necessary. After mechanical processing, the part is moved to the final processing area. Next, at step S6, the outer layer is applied to the product. This outer layer is designed to perform a decorative and / or protective function. Application of the outer layer to the product can be accomplished using various methods (e.g., airless spraying, pneumatic spraying, electric arc metallization, UV printing, etc.), and the choice of method depends on the specific requirements, as well as the type of outer decorative or protective layer required. A robotic arm or a person applies a layer of façade paint, plaster, metallic coating, or other final coating to the façade.To accurately apply patterns using a robotic arm, it is important to accurately digitally model the appearance of the façade panel. This model is then used to program the robotic arm. To accurately apply the pattern to the façade panel, the robot can be calibrated using markers or marks on the façade. These markers are applied to the panel during the surface preparation stage before the robotic arm begins applying the pattern and help the robot determine its position and orientation on the surface. Furthermore, it is important to configure the robot so that it moves with the necessary precision and speed to create the desired pattern or texture. Special types of paints or coatings may be required to create certain effects or textures. It is worth noting that in some embodiments of the present invention, the application of the outer layer may be optional.Thus, the manufacturing method described above enables the production of façade panels of arbitrary three-dimensional shape with high geometric precision and superior structural and decorative properties. Furthermore, the present invention reduces the complexity of the manufacturing process, as well as the material and time costs of production and installation. In accordance with another aspect of the present invention, an architectural construction product is provided, comprising an internal forming structure manufactured using 3D printing technology, a load-bearing layer applied to the forming structure, and an outer layer applied to the structural load-bearing layer. In an exemplary embodiment, said product is a façade panel.The said façade panel further includes fasteners integrated with the internal forming structure for attaching the façade panel, for example, to a building wall. In accordance with another aspect of the present invention, a fastening system for façade panels is provided. The façade panel fasteners described in more detail below allow for automated production and precise positioning of façade panels during installation, meaning the same fasteners can be used both during production and for installing the façade panels on a building façade. Robots can use these fasteners during production to grip, move, and secure the product, simplifying the process of applying the base layer, subsequent machining, and application of the outer layer. This contributes to improved production quality and reduced turnaround time.In an alternative embodiment, different fasteners are used during the production and installation of the façade panels on the building. Generally, the fastening system consists of at least two fasteners located on the façade panel and at least two counter-fasteners installed, for example, on the building wall where the façade panels are to be secured. According to the present invention, for each respective pair of fastener and counter-fastener, the following is achieved: one of the fastener and counter-fastener includes a shaped protrusion, while the other of the fastener and counter-fastener includes a complementary groove for receiving said shaped protrusion. The number of fasteners and counter-fasteners is specified in the modeling step S1 to ensure secure fixation of the façade panel.In an exemplary embodiment of the present invention, the fastening elements (see Fig. 3a) are parts that include "T-shaped" protrusions and are located on the back side of the façade panel. Fixation (connection) occurs with the help of complementary elements, such as mating fastening elements with "T-shaped" grooves (see Figs. 3c, 3d), which are installed on the wall of the building. The shape of the protrusion of the fastening element may be different from the T-shape. For example, the protrusion of the fastening element may have a cross-shaped, square, triangular, rectangular, etc. shape, and the mating fastening element must have a groove of the corresponding shape to accommodate the protrusion. In the exemplary embodiment, all fastening elements on the façade panels have a protrusion, while all mating fastening elements on the wall of the building to which the façade panels are to be fastened have a corresponding groove.In an alternative embodiment, all fasteners on the façade panels have a groove, while all counter fasteners have a corresponding projection. In yet another alternative embodiment, a mixed implementation of fasteners and counter fasteners is possible, i.e., on the façade panels, some fasteners have projections, while others have grooves, and the counter fasteners on the building wall have corresponding complementary grooves and projections. The counter fasteners can be secured to the building wall by adhesive, threaded, or welded connections, or by other suitable known fastening methods. Counter fasteners can also be manufactured using additive manufacturing (3D printing).According to yet another alternative embodiment, the counter fasteners, installed, for example, on the wall of a building, may be any (standard) fasteners known in the art. They may be made of plastic, metal, composite materials, etc. In this case, the fasteners located on the façade panel are formed in step S2 in such a way as to be capable of interacting (connecting) with said known counter fasteners. Alternatively, the fasteners located on the façade panel are formed so as to be capable of being mounted on (connected to) other fasteners known in the art, which in this case play the role of intermediate fasteners intended for connection with said counter fasteners known in the art. The connection of the fasteners and the counter fasteners is carried out using the "key-and-lock" method.This means that fasteners and counter-fasteners have a one-to-one correspondence, and specific façade panels can only be installed in specific locations using these fasteners. This prevents incorrect installation and improves the positioning accuracy of façade panels. Thus, the "key-and-lock" method ensures precise correspondence and protection against incorrect installation. A one-to-one correspondence between fasteners and counter-fasteners is ensured by specifying the shape, position, and orientation (rotation angle, inclination angle) of the fastener (see Fig. 3b) and the complementary shape, position, and orientation of the counter-fastener. The shape, position, and orientation of the fasteners and counter-fasteners are specified in stage S1 of façade modeling.According to another alternative embodiment, the facade panels can be connected to each other by means of fasteners and corresponding counter fasteners placed on adjacent facade panels. After connecting the fastener and the counter fastener, the key-and-lock connection is secured by means of an adhesive connection, a glueless connection, or by means of additional fasteners such as latches, clips, rivets, hardware, etc. Thus, the fastening system according to the present invention ensures a strong and reliable fastening of the facade panels to the support (building wall) and a connection of the facade panels to each other, prevents their incorrect installation, and also facilitates the processes of applying the bearing layer, mechanical processing, applying the outer layer, and handling the product during the production process. In one embodiment, the fastening elements in the form of a "dowel" (see Fig.3d), to which thermal insulation materials are attached, in this solution additionally serve as counter fasteners for the fasteners of the façade panels. These counter fasteners are first used to secure the thermal insulation materials to the wall. The façade panels are then attached to them via their fasteners. Thus, the counter fasteners may be used not only for attaching the façade panels themselves, but also for attaching other related materials and products. In addition to the façade panel fastening system described above, the present invention may utilize other methods for attaching façade panels to the building, such as adhesive, a profiled subsystem, brackets, etc. In accordance with another aspect of the present invention, a method for positioning fasteners in a façade panel is proposed.According to the mentioned method, mating fasteners are installed on the surface of the structure (building) to be covered with façade panels, and a special coating is applied to the ends of the mating fasteners, which facilitates their detection by the camera. The mentioned coating can be one of the following: - a luminescent coating (e.g. GloNation Paint), which emits light in the visible range after irradiation with ultraviolet (UV) rays (100-400 nm). Such coatings can be used for visualization and marking on surfaces, facilitating detection and scanning; - a fluorescent coating (e.g. Rust-Oleum 214944), which absorbs light in one wavelength range and emits it in another range (e.g. absorbs UV (100-400 nm) for excitation and emits visible light (400-700 nm)).Such coatings provide bright visibility of markers under UV light, which facilitates their precise positioning; - infrared (IR) reflective coating (e.g. 3M Scotchlite 7610), which reflects infrared rays. Such coatings are used for thermal scanning and object detection in low visibility conditions. Then the structure is scanned, for example, using one of the following methods: - laser scanning, which ensures the creation of accurate three-dimensional maps of objects and terrain with high detail. Carried out using a lidar (e.g. Leica BLK360); - photogrammetry, used to collect images to create three-dimensional models of buildings and objects. Carried out using drones with a high-resolution camera (e.g. DJI Phantom 4 RTK); - scanning using structured light. Carried out using projectors and cameras that create and record deformations of the light pattern on the object (e.g. Artec Eva scanner).By scanning the building, a digital map is created with the markings of the corresponding fasteners. This digital map is a 3D model of the building or object, created using one of the aforementioned scanning methods. This model includes precise data on the locations of all corresponding fasteners and other structural components, enabling efficient planning and execution of installation work. This digital map of the corresponding fasteners on the building is used in the S1 stage of façade panel modeling to determine the location of fasteners on the façade panels. The required positions for complementary fasteners on the façade panels are determined based on the 3D model of the building façade and the map of corresponding fasteners on the building, ensuring a one-to-one correspondence between the aforementioned fasteners and the corresponding corresponding fasteners.This ensures precise alignment of fasteners and counterfasteners, and therefore accurate installation of the façade panels. Façade panels are then manufactured with fasteners in the specified positions, as described above. There are several ways to specify the positions of counterfasteners on the building. One alternative method involves pre-determining the attachment points for the façade panels on a digital 3D model of the building. During construction, a projector can be used to project the attachment points onto the wall based on the digital model. Builders can follow this projection to precisely place the counterfasteners on the building. Based on this digital model, façade panels are formed as described above and mounted on the building wall.Alternatively, the attachment points for the counter fasteners can be pre-marked on the building's façade at predetermined intervals, such as every meter. Builders can use levels and laser pointers to maintain these marks. After installing the counter fasteners, their placement can be verified, for example, by photographing the wall and processing the resulting image using appropriate software. Alternatively, the correct placement of the counter fasteners can be verified by scanning the building wall, as described above. Then, based on the digital model, façade panels are created as described above and mounted on the building wall. Furthermore, based on the developed digital building model, mobile devices and augmented reality apps can be used to display the attachment points on the building façade in real time.Builders can use these points to correctly position the counter fasteners. If a building's façade is being restored, existing counter fasteners can be used, such as those left over from the removal of old façade panels. In this case, these counter fasteners are coated with the aforementioned coating, facilitating their detection. Subsequent scanning of the counter fasteners and the formation of the fasteners on the façade panels at the specified locations are carried out as described above. Thus, the present invention ensures high structural (e.g., strength and durability) and decorative (custom design, high level of detail, and architectural expressiveness of façades) characteristics of architectural construction products, high geometric accuracy of shape and size, and accelerates their production.Furthermore, the present invention enables the production of three-dimensional products of arbitrary shapes. The automated process of production and positioning products during manufacturing, using fasteners, simplifies production and processing and eliminates the risk of human error. These factors, taken together, improve the efficiency of architectural and construction product production and reduce material and time costs.

Claims

Claims of the invention 1. A method for manufacturing architectural and construction products, comprising the following stages: - forming a three-dimensional digital model of the architectural and construction product; - based on the formed digital model, 3D printing (three-dimensional printing) of the form-generating structure of the product is carried out, defining the shape of the product, wherein detachable edge elements are formed on the edges of the form-generating structure of the product by means of 3D printing, made in one piece with the form-generating structure, in order to form a precise edge of the product; - a structural supporting layer is applied to the form-generating structure; - the detachable edge elements are separated from the form-generating structure; - an outer layer is applied to the mentioned supporting layer.

2. The method according to claim 1, additionally comprising a stage in which, after applying the supporting layer, the product is mechanically processed.

3. The method according to claim2, wherein the mechanical processing includes at least one of milling, grinding and rolling with a roller.

4. The method of claim 1, wherein the outer layer is designed to perform a decorative and / or protective function.

5. The method of any one of claims 1-4, wherein the architectural construction products are decorative products or small architectural forms.

6. The method of any one of claims 1-4, wherein the architectural construction products are facade panels for the external cladding of buildings.

7. The method of claim 6, wherein at the stage of 3D printing of the form-forming structure, 3D printing of fasteners made in one piece with the form-forming structure is also carried out.

8. The method of claim 7, wherein the fasteners are used to move and fix the product during its manufacture.

9. The method of claim 7, wherein the step of forming a three-dimensional digital model includes the steps of: - forming a three-dimensional model of the building facade; - forming a three-dimensional model of individual facade panels; - forming a three-dimensional model of the form-generating structure of the facade panels, including detachable edge elements and fasteners; - forming a three-dimensional model of the structural load-bearing layer; - forming a three-dimensional model of the outer layer.

10. The method of claim 9, wherein the shape, location and orientation of the fasteners on the facade panels are set in such a way that the said fasteners are in one-to-one mutual correspondence with the mating fasteners on the building.

11. The method of claim 10, wherein the location of the mating fasteners on the building is determined by scanning the building.

12. The method of claim11, wherein, before scanning, a coating is applied to the mating fasteners that facilitates their detection.

13. The method of claim 10, wherein the shape, location and orientation of the mating fasteners on the building are specified during modeling.

14. The method of claim 9, wherein the shape, location and orientation of the fasteners on the façade panels are specified in such a way that the said fasteners are in unambiguous mutual correspondence with the mating fasteners on the adjacent façade panels to ensure the possibility of connecting the adjacent façade panels to each other.

15. The method of claim 1, wherein, at the stage of 3D printing of the form-generating structure, 3D printing of fasteners on the detachable edge elements is also carried out, fasteners are used. elements for moving and fixing the product during its manufacture, and after applying the supporting layer, separating the edge elements together with the fastening elements.

16. The method according to claim 1, wherein the form-generating structure has a cellular structure.

17. The method according to claim 1, wherein the detachable edge elements are made in the form of sides.

18. The method according to claim 17, wherein the detachable edge elements are made in the form of smooth sides to form smooth edges of the product.

19. The method according to claim 17, wherein the detachable edge elements are made in the form of sides with a stepped profile to form stepped edges of the product.

20. The method according to claim 1, wherein the detachable edge elements are printed from the same material as the form-generating structure.

21. The method according to claim 1, in which the detachable edge elements are combined with the form-forming structure of the product by a perforated section, ensuring their temporary connection with the form-forming structure and the possibility of their separation.

22. The method according to claim1, wherein the structural supporting layer is applied to the form-generating structure from one side, which is set as the front side of the product.

23. The method according to claim 7, wherein the structural supporting layer is applied to the form-generating structure from the side, which is set as the front side of the product, and from the back side, on which the fastening elements are located, wherein the fastening elements are not covered with the supporting layer.

24. The method according to claim 1, wherein the detachable edge elements are separated from the form-generating structure after the applied supporting layer has gained strength.

25. The method according to claim 1, wherein the step of forming a three-dimensional digital model includes the steps of: - forming a three-dimensional model of the form-generating structure of the architectural and construction product, including the detachable edge elements; - form a three-dimensional model of the structural supporting layer; - form a three-dimensional model of the outer layer.

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