3D Printing Additive Manufacturing Construction Speed
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Solution Overview
Problem
Traditional construction methods for buildings are time-consuming and require multiple skill sets, extending the construction period to several months, which is undesirable for rapid structure development.
Innovation Solution
The use of additive manufacturing techniques, specifically 3D printing, to construct structures by depositing extrudable building materials in vertically stacked layers, allowing for the simultaneous formation of walls, windows, and infill, with a computer-controlled printing assembly and non-transitory computer-readable medium defining master slices and tool paths for efficient construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional construction methods are used, then multiple skill sets and conventional processes are employed, but construction time is extended to several months
Solution Approach 1:
The patent changes the state of building materials to an extrudable form that can be deposited layer by layer, fundamentally altering the construction process from traditional assembly methods to additive manufacturing. This parameter change enables continuous construction without the need for multiple skill sets and dramatically reduces construction time from months to days or hours.
Solution Approach 2:
The patent replaces traditional mechanical construction systems (manual labor, heavy machinery, multiple trades) with a computer-controlled printing assembly that deposits material precisely according to digital models. This substitution eliminates the need for multiple skill sets and accelerates the construction process significantly.
2Loss of time
If additive manufacturing techniques are used, then construction time is significantly reduced, but new manufacturing processes and equipment are required
Solution Approach 1:
The printing assembly is designed as a multi-functional system that can deposit various types of building materials (concrete, mortar, insulation materials) through a single integrated platform. This universality reduces the need for multiple specialized construction equipment and skill sets, making the complex technology more manageable and adaptable to different construction needs.
Solution Approach 2:
The construction process is segmented into discrete vertical slices and horizontal layers that can be deposited independently by the printing assembly. This segmentation allows the complex construction task to be broken down into manageable steps, controlled by computer software that generates toolpaths for each slice, thereby managing device complexity through systematic decomposition.
3Shape
If vertical slices with different lateral cross-sections are deposited, then complex structural shapes are achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs preliminary action by creating digital 3D models and generating computer-controlled toolpaths before construction begins. The master slice and subsequent vertical slices are precisely calculated in advance, allowing the printing assembly to follow predetermined paths that ensure accurate deposition of each layer. This pre-planning compensates for the increased precision requirements by eliminating manual measurement and positioning errors.
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 significantly reduces construction time, enabling structures to be built in a fraction of the time taken by traditional methods, while maintaining structural integrity and allowing for economic and systematic construction.
Implementation Method 1
depositing a plurality of first vertically stacked layers of an extrudable building material with a printing assembly to form the first vertical slice
Implementation Method 2
depositing a bead of the extrudable material to form a first enclosed border of the wall
Data Source
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AI summary
Embodiments disclosed herein relate to methods of constructing a structure and related non-transitory computer readable medium. In an embodiment, the method includes (a) defining a vertical first slice and a second vertical slice of the structure. A lateral cross-section of the structure within the first vertical slice is different than the lateral cross-section of the structure for the second vertical slice. In addition, the method includes (b) depositing a plurality of first vertically stacked layers of an extrudable building material with a printing assembly to form the first vertical slice. Further, the method includes depositing a plurality of second vertically stacked layers of the extrudable building material atop the first vertical slice with the printing assembly to form the second vertical slice.