3D Printing Composite Material for Construction
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Solution Overview
Problem
Current 3D printing technologies for large-scale construction components, such as wall panels, face challenges in material efficiency and sustainability, particularly in reducing material wastage and environmental impact.
Innovation Solution
A method and system for producing 3D printable composites involving a mixture of (meth)acrylic monomers, photoinitiators, polymerization enhancers, mineral fillers, and recycled photopolymer composite materials, processed through mixing, filtration, curing, phase separation, and milling to create a composite material suitable for large-scale 3D printing of construction components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing techniques are used to form construction parts by reducing or removing material from bulk material, then parts can be manufactured with established processes, but significant material wastage occurs
Solution Approach 1:
The patent changes the fundamental parameter of material deposition from subtractive to additive manufacturing. The composition is designed to be deposited layer-by-layer in precise locations, completely eliminating material wastage associated with traditional subtractive manufacturing while maintaining ease of manufacture through automated 3D printing processes.
Solution Approach 2:
The construction parts are manufactured by segmenting the deposition process into discrete layers and locations. The 3D printing system deposits the composition sequentially at exact locations to build up the part, allowing precise material placement and eliminating waste from removing bulk material.
2Loss of substance
If 3D printing is used to deposit materials to exact locations, then material wastage is significantly reduced, but the material composition and processing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-mixing all necessary components (methacrylic monomer, photoinitiator, polymerization enhancer, mineral filler, and recycled material) in precise proportions before deposition. The composition is prepared in advance with all ingredients thoroughly mixed, so that during 3D printing, only the pre-formulated composition needs to be deposited without additional processing complexity during the printing process.
Solution Approach 2:
The patent uses composite materials by combining multiple components with different functions into a single deposition mixture. The composite includes methacrylic monomer for polymerization, photoinitiator for curing, polymerization enhancer for reaction control, mineral filler for mechanical properties, and recycled material for sustainability. This composite approach allows all functions to be achieved in a single material deposition process.
3Loss of substance
If recycled photopolymer composite material is mixed with new materials, then sustainability is enhanced and material efficiency improves, but the homogeneity and consistency of the composite may be compromised
Solution Approach 1:
The patent applies preliminary action by performing thorough mixing of recycled photopolymer composite material with new materials before deposition. The mixture is prepared in advance with all components (recycled material, methacrylic monomer, photoinitiator, polymerization enhancer, mineral filler) continuously agitated to ensure homogeneous distribution. This pre-mixing eliminates composition inconsistencies during the 3D printing process.
Solution Approach 2:
The patent explicitly addresses homogeneity by designing the mixing process to achieve uniform distribution of recycled material throughout the new composition. The mixture is continuously stirred and blended to ensure that recycled photopolymer particles are evenly dispersed among the fresh materials, creating a homogeneous composite with consistent properties throughout the printed part.
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
This approach reduces material wastage, enhances the sustainability of 3D printing in construction by utilizing recycled materials and improving the mechanical and flame-resistant properties of the printed components, making it suitable for building structures like walls, floors, and roofs.
Implementation Method 1
receiving a second component including a photoinitiator... curing the filtered mixture with a radiation unit into a gel component and a liquid component
Implementation Method 2
receiving a third component including a polymerization enhancer
Implementation Method 3
curing the filtered mixture with a radiation unit into a gel component and a liquid component
Data Source
AI summary
Systems, devices, and methods are provided for producing a 3d-printable composite material for large scale printing. A method can include receiving a first component comprising a (meth)acrylic monomer or a (meth)acrylic oligomer, or a combination thereof. The method can include receiving a second component comprising a photoinitiator and a third component comprising a polymerization enhancer. The method can include mixing the first component, second component, and third component with a mixing reactor to form a mixture. The method can include filtering the mixture with a filtration unit and removing a solid residue from the mixture. The method can include curing the filtered mixture with a radiation unit into a gel component and a liquid component. The method can include separating the gel component with a phase separation unit and then milling the gel component. And the method can include mixing the gel component, the photoinitiator, the mineral filler and optionally the recycled previously printed composite material to form the composite material.