3D-Printed Multi-Wythe Wall Structure for Faster Construction
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Solution Overview
Problem
Traditional building construction methods are labor-intensive, time-consuming, and require multiple steps that cannot be performed simultaneously, making them unsuitable for rapid construction needs.
Innovation Solution
Utilizing additive manufacturing techniques, specifically three-dimensional (3D) printing to construct building structures layer-by-layer using a printing assembly that deposits extrudable building materials, such as cementitious mixtures, to form walls with inner and outer wythes, cores, and protrusions for enhanced structural strength and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional building construction methods are used, then structural integrity and thermal insulation can be achieved, but construction time and labor intensity increase significantly
Solution Approach 1:
The wall structure is segmented into multiple wythes (inner and outer) with distinct functional zones. The printing assembly deposits material in discrete elongated beads that are stacked to form these segmented wythes, allowing parallel construction of different wall sections and reducing overall construction time while maintaining structural integrity.
Solution Approach 2:
The invention transitions from traditional two-dimensional layer-by-layer masonry to three-dimensional additive construction. The printing assembly deposits elongated beads that extend in the horizontal direction, building walls upward in the vertical dimension while simultaneously creating complex geometries including protrusions and cores that would require multiple steps in traditional construction.
2Strength
If traditional construction methods are used, then structural strength can be achieved, but the process requires multiple sequential steps that cannot be performed simultaneously
Solution Approach 1:
The invention merges multiple construction functions into a single printing assembly operation. The assembly simultaneously deposits structural wythes, creates insulation cavities, forms protrusions for structural reinforcement, and positions cores all in one continuous additive process, eliminating the need for sequential steps required in traditional construction.
Solution Approach 2:
The printing assembly serves multiple functions: it deposits structural building material, creates thermal insulation zones, forms structural protrusions, and positions core elements. This multi-functional approach consolidates what would traditionally require separate construction operations into a single universal device that performs all tasks through additive manufacturing.
3Reliability
If multiple wythes and structural elements are added to enhance structural strength and thermal insulation, then building performance improves, but material quantity and construction complexity increase
Solution Approach 1:
The wall structure employs local quality by creating different wythe configurations in different zones. Inner and outer wythes are positioned and dimensioned according to specific structural and thermal requirements of each wall section. Protrusions are added locally at positions where structural reinforcement is needed, rather than uniformly throughout the entire wall, optimizing material distribution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates the construction of building structures in a fraction of the time required by traditional methods, providing structural integrity and thermal insulation while reducing labor intensity and construction duration.
Implementation Method 1
The construction system applies three-dimensional printing technology at a relatively large, building-structure scale. The construction system additively deposits construction material layer upon layer to form the walls of the building.
Implementation Method 2
a cementitious mixture comprises the building material, which is then extruded from an outlet nozzle of the printing assembly as an elongated bead, layer by layer vertically upward to form the wall
Data Source
AI summary
A wall structure and a method for forming a wall structure is provided using three-dimensional printing of extruded building material applied to a surface of a building structure. According to one embodiment, the wall structure includes a pair of outer wythes spaced from an inner wythe. The outer wythes can include a core extending between the pair of outer wythes and toward the inner wythe. A protrusion can also extend toward the inner wythe a spaced distance from the inner wythe or entirely toward and adjoining the inner wythe. The core is configured with an inwardly facing spaced opposed surfaces of the outer wythes surrounding a vertically extending rebar, with grout surrounding that rebar. Horizontally extending support pins can be spaced parallel from each other and extend from the protrusions and into the inner wythe.