3D Printing Finishing Unit for Curable Construction Materials

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Solution Overview

Problem

Current 3D printing technologies face limitations in efficiently finishing and modifying curable construction materials, such as concrete, due to unwieldy machinery, curing speed issues, and the need for manual labor, which hinders the adoption of 3D printing in construction and increases material waste and carbon footprint.

Innovation Solution

A 3D printing and finishing device system that integrates a print head with a finishing unit, allowing for real-time surface modification of curable construction materials by dispensing fluids through nozzles aligned with the printed layers, enabling smoothing, flattening, and texturing while the material is still in the curing process, reducing manual labor and material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual finishing methods are used for 3D printed curable materials, then surface quality can be improved, but labor costs and time consumption increase significantly

Engineering Contradiction:

Improvesurface qualityVSAvoidlabor efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines the 3D printing process with automated finishing operations by integrating a finishing unit directly onto the print head assembly. This merging eliminates the need for separate manual finishing steps, allowing the system to perform both deposition and surface modification in a continuous automated process, thereby improving productivity while maintaining surface quality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system performs self-finishing by equipping the print head with integrated finishing tools that automatically treat the surface of freshly deposited material. The finishing unit operates on the material immediately after deposition while it is still in a workable state, enabling the system to service itself without external manual intervention

Inventive Principle:

Principle #25Self-service

2Stability of the object's composition

If traditional construction methods are used, then structural stability is ensured, but material waste and carbon footprint increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidmaterial waste

Core Design Contradiction:

Stability of the object's compositionVSLoss of substance

Solution Approach 1:

The patent modifies the physical-chemical parameters of curable materials by controlling their curing process through fluid dispensing. By adjusting parameters such as curing speed and surface treatment timing, the system achieves both structural stability and reduced material waste through precise control of material properties during the construction process

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If finishing is performed after complete curing, then surface modification is possible, but the material becomes difficult to manipulate

Engineering Contradiction:

Improvesurface modification capabilityVSAvoidmaterial manipulability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent performs finishing operations preliminarily, immediately after material deposition while the curable material is still in a workable, uncured state. This timing allows the finishing unit to easily manipulate and modify the surface before the material hardens, achieving surface modification without the difficulty associated with treating fully cured materials

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If complex surface patterns are added manually, then aesthetic quality improves, but labor costs and processing time increase

Engineering Contradiction:

Improveaesthetic qualityVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent maintains continuous useful action by integrating pattern deposition into the ongoing 3D printing process. The finishing unit operates continuously alongside the print head, applying surface patterns and treatments in real-time without interrupting the building process, thereby achieving aesthetic quality improvements without additional processing time or manual labor

Inventive Principle:

Principle #20Continuity of useful action

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

The system enables efficient and automated surface finishing of 3D printed structures, reducing material waste and labor costs, while allowing for complex patterns and textures, thereby enhancing the structural stability and aesthetic quality of printed objects.

Implementation Method 1

The finishing unit can include at least one nozzle to dispense fluid toward the surface

Methodology Applied

Scientific EffectFluid dispensing:

Data Source

PatentUS20240300171A1A three-dimensional printing and finishing device for forming and finishing a curable construction material

Publication Date: 2024.09.12 REUSCH JAMES LYMAN

AI summary

A three-dimensional (3D) printing and finishing device (100) and a method for forming and finishing a curable construction material to produce a 3D printed object. The 3D printing and finishing device (100) can include a structural support (102), a print head (104), and a finishing unit (116). The print head (104) can move to dispense a curable material in layers and the finishing unit (116) can align with a side of the dispensed layers and can modify a surface of the material. The finishing unit (116) can include a nozzle to dispense fluid toward the surface.