3D Printed Cementitious Structural Panels with Truss Matrix

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current structural panel manufacturing methods are costly, inflexible, and limited in capacity, requiring specialized materials and machinery, which are often unavailable in rural areas or developing nations, and result in high production costs and inefficiencies due to linear manufacturing processes and inability to customize panel thickness and length.

Innovation Solution

A method for manufacturing structural panels using commercially available materials, with a process involving alignment of fillers and masonry reinforcement trusses in an alternating sequence, followed by pressing to form a panel core, overlaying wire mesh, and applying 3D printed cementitious skins of varying thickness to meet structural loads, allowing for customizable panel dimensions and reduced material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If specialized metal lattice structures and metal meshes with non-standard configurations are used, then structural strength is improved, but production cost increases and material availability decreases

Engineering Contradiction:

Improvestructural strengthVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies homogeneity by using standard industry masonry reinforcement trusses with uniform zigzag configurations throughout the panel structure. This eliminates the need for specialized non-standard lattice structures, reducing production costs while maintaining structural integrity through consistent, readily available materials.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent employs inexpensive, commercially available standard masonry reinforcement trusses and wire meshes that can be easily manufactured and replaced. These standard components are more economical than specialized custom-made lattice structures, achieving cost reduction while maintaining adequate structural performance through proper design and arrangement.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If structurally superior designs with altered wire gauges at key points are implemented, then load-bearing capacity increases, but expense increases

Engineering Contradiction:

Improveload-bearing capacityVSAvoidexpense

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies local quality by concentrating reinforcement at specific critical locations within the panel, such as at corners, edges, and load-bearing zones, rather than uniformly increasing wire gauge throughout. This allows the structure to achieve higher load-bearing capacity where needed while using standard, cost-effective materials in less critical areas, thereby controlling overall expense.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If preformed plastic foamed filler elements are used to create chambers, then structural functionality is improved, but material availability decreases and shipping cost increases

Engineering Contradiction:

Improvestructural functionalityVSAvoidmaterial availability

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent employs fillers made from locally available materials such as wood chips, straw, or other agricultural waste that can be processed on-site or near the construction location. These self-sufficient filler materials eliminate the need for imported preformed plastic foam elements, improving material availability in rural and developing areas while reducing shipping costs and maintaining structural functionality through proper filler design and arrangement.

Inventive Principle:

Principle #25Self-service

4Manufacturing precision

If fixed-dimension fabrication machines are used, then manufacturing precision is maintained, but adaptability to customize panel dimensions decreases

Engineering Contradiction:

Improvedimensional precisionVSAvoidcustomization capability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent employs adjustable and flexible fabrication equipment that can be reconfigured for different panel dimensions, thicknesses, and designs. The manufacturing system includes adjustable molds, variable press configurations, and flexible assembly processes that maintain dimensional precision while allowing customization of panel specifications to meet specific structural requirements and customer needs.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11293179B2Structural panels for buildings integrating 3D printed shells and method of fabrication

Publication Date: 2022.04.05 BLUE PLANET TECH INC

AI summary

A structural panel is manufactured from at least two generally parallel and spaced-apart thin-shell cementitious skins that are joined by a truss matrix. The elements creating the truss matrix, being the truss, the face mesh, and the insulating core, are selected to meet the structural loads to be placed thereon. The thickness of each cementitious skin is selected to meet the structural loads to be placed thereon.