3D Printing Nozzle Integrating Reinforcement Feeding

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Solution Overview

Problem

Current three-dimensional printing of concrete structures is limited by the reliance on fixed-form reinforcement cages and fiber admixtures, hindering the development of truly free-form structures and complex geometries.

Innovation Solution

A nozzle system that combines unreinforced concrete with elongate reinforcement members, allowing for mechanical configuration of reinforcement patterns and shapes during printing, eliminating the need for pre-assembled cages and enabling free-form construction of large-span, slender structures with integrated sensing, protection, and energy harvesting capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fixed-form reinforcement cages and fiber admixtures are used, then concrete structures can be printed, but the structures are limited in geometry and cannot achieve truly free-form configurations

Engineering Contradiction:

Improvestructural geometry freedomVSAvoidreinforcement configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The reinforcement system is segmented into discrete elongate members that can be individually positioned and configured within the concrete matrix, replacing monolithic fixed-form cages with modular, programmable elements that adapt to free-form geometries

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcement configuration transitions from static fixed-form cages to dynamic, reconfigurable systems where elongate members can be positioned and oriented during the printing process to match complex free-form structural requirements

Inventive Principle:

Principle #15Dynamics

2Strength

If pre-assembled reinforcement cages are used, then structural strength is provided, but material and labor costs increase

Engineering Contradiction:

Improveconcrete structure strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The reinforcement feeding system and concrete extrusion process are merged into a single integrated nozzle assembly, allowing simultaneous deposition of concrete and reinforcement members in one continuous operation, eliminating separate cage assembly and installation steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system automatically positions and distributes reinforcement members within the concrete matrix through automated feeding mechanisms, eliminating manual labor for cage assembly and placement while maintaining structural strength requirements

Inventive Principle:

Principle #25Self-service

3Reliability

If traditional reinforcement methods are used, then structural integrity is maintained, but construction speed and productivity are reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidconstruction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The printing process achieves continuous deposition of reinforced concrete through synchronized operation of the extruder and reinforcement feeder, eliminating interruptions for separate reinforcement installation and maintaining both structural integrity and construction speed

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

Facilitates the creation of complex, free-form reinforced concrete structures with efficient reinforcement patterns, reducing material and labor costs while enabling multifunctional building envelopes without shearing concrete or reinforcement interfaces during printing.

Implementation Method 1

The nozzle is configured to combine the unreinforced concrete extruded through the first inlet with the one or more elongate reinforcement members fed through the second inlet to form reinforced concrete in the nozzle

Methodology Applied

Scientific EffectMechanical mixing:

Implementation Method 2

a concrete extruder can extrude unreinforced concrete through the first inlet

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS12103232B2Three-dimensional printing of reinforced concrete and nozzle therefor

Publication Date: 2024.10.01 THE CURATORS OF THE UNIVERSITY OF MISSOURI

AI summary

A three-dimensional printing system for reinforced concrete and a nozzle therefore. The system employs an extruder for extruding unreinforced concrete and a concrete reinforcement feeder is for feeding one or more elongate reinforcement members. The nozzle has an outlet and is operatively connected to the extruder and the concrete reinforcement feeder to receive the unreinforced concrete from the extruder and to receive the one or more elongate reinforcement members from the concrete reinforcement feeder. The nozzle combines the unreinforced concrete from the extruder and the one or more elongate reinforcement members from the concrete reinforcement feeder into a reinforced concrete extrusion and imparts the reinforced concrete extrusion through the outlet.