3D Printing Vertical Slices for Rapid Building Construction

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Solution Overview

Problem

Traditional construction methods for structures, such as buildings, are time-consuming and require multiple skilled trades, extending the construction period significantly, which is undesirable in situations requiring rapid construction.

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, facilitated by a printing assembly that moves along orthogonal axes, reducing the need for multiple construction steps and skilled labor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional construction methods are used, then structural integrity and quality can be maintained, but construction time is significantly extended

Engineering Contradiction:

Improvestructural integrityVSAvoidconstruction period

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The construction process is segmented into discrete vertical slices that can be independently defined and manufactured. Each slice represents a manageable unit of the structure that can be constructed separately and then assembled, enabling parallel processing and reducing overall construction time while maintaining quality control for each segment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The master slice is defined in advance with all windows, door frames, and structural elements predetermined. This preliminary design and planning phase allows for optimized manufacturing sequences and reduces on-site construction time, as the blueprint for each vertical slice is prepared before actual construction begins.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If traditional construction methods with multiple skilled trades are used, then complex structural elements can be constructed, but the number of construction steps and labor requirements increase

Engineering Contradiction:

Improveconstruction capabilityVSAvoidnumber of construction steps

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The printing assembly is designed as a universal device capable of performing multiple construction functions through software control. The same physical apparatus can deposit different materials, create various structural forms, and construct different architectural elements by simply changing the digital instructions, eliminating the need for multiple specialized construction teams and equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system achieves versatility through changing parameters such as deposition rate, layer thickness, material composition, and geometric patterns rather than through physical reconfiguration of equipment. This allows a single construction system to adapt to different structural requirements by modifying digital parameters, reducing the complexity of having multiple specialized construction systems.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If additive manufacturing is used to deposit materials layer by layer, then construction speed is improved, but material deposition precision must be maintained

Engineering Contradiction:

Improveconstruction speedVSAvoidmaterial deposition precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system incorporates feedback mechanisms that monitor the deposition process in real-time, tracking the position and quality of each layer as it is deposited. This feedback allows for immediate adjustments to maintain precision while keeping the high-speed additive manufacturing process running continuously, ensuring both speed and accuracy are achieved simultaneously.

Inventive Principle:

Principle #23Feedback

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 enables the rapid, economical, and systematic construction of structures, significantly reducing the time and materials required compared to traditional methods, while maintaining structural integrity.

Implementation Method 1

depositing a plurality of first vertically stacked layers of an extrudable building material with a printing assembly

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS12168320B2Systems and methods for the construction of structures utilizing additive manufacturing techniques

Publication Date: 2024.12.17 ICON TECHNOLOGY INC

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.