Adaptive Toolpath Generation for Uneven 3D Printed Foundations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing technologies face challenges in constructing building structures on uneven or unlevel foundation surfaces, as conventional methods struggle to modify concrete slab foundations after they are poured.
Innovation Solution
A system and method that utilize a profilometer to scan and measure the 3D profile of the foundation surface, generating sublayers and sub toolpaths to compensate for unevenness, allowing the 3D printing assembly to extrude building material beads along these paths to create a level foundation surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional leveling mechanisms are used to level the foundation surface before 3D printing, then the print bed should be level, but it is very difficult to modify the concrete slab foundation surface after it is poured
Solution Approach 1:
The system performs preliminary measurement of the foundation surface using a profilometer before the 3D printing process begins. The measured topology data is used to generate compensated toolpaths that account for unevenness in advance, allowing the printing assembly to adapt to the existing foundation surface without requiring prior leveling modifications
Solution Approach 2:
The system changes the toolpath parameters dynamically based on the measured foundation surface topology. By adjusting the Z-axis position and extrusion parameters according to the measured surface variations, the system compensates for unevenness through software-controlled parameter modifications rather than physical foundation modification
2Productivity
If 3D printing is performed directly on uneven foundation surfaces, then the printing process can begin immediately, but the resulting wall structure will have poor evenness and structural integrity
Solution Approach 1:
The system incorporates feedback by measuring the actual foundation surface topology with a profilometer and using this measured data to generate compensated toolpaths. This closed-loop approach ensures that the printing process adapts to the actual surface conditions, maintaining wall structure evenness while proceeding directly on uneven foundations without requiring preliminary leveling
Solution Approach 2:
The system performs preliminary measurement and toolpath compensation before printing begins. The processor generates modified toolpaths that account for foundation unevenness in advance, allowing the printing assembly to deposit material at correct heights despite surface variations, thus maintaining structural integrity while preserving printing productivity
3Manufacturing precision
If the foundation surface is scanned and measured in 3D, then the topology data can be used to generate compensation paths, but additional measurement equipment and processing time are required
Solution Approach 1:
The profilometer and processing system serve multiple functions: measuring foundation topology, generating compensated toolpaths, and guiding the printing assembly. By integrating these functions into a unified system, the patent reduces overall device complexity while maintaining high measurement accuracy and compensation effectiveness
Solution Approach 2:
The system performs self-measurement and self-compensation by using the profilometer to scan the foundation surface and automatically generating corrected toolpaths without requiring external surveying equipment or manual intervention. This self-service capability simplifies the overall system while achieving high precision through automated measurement and compensation
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 construction of building structures on uneven foundations by creating a level surface through additive 3D printing, improving the structural integrity and evenness of the final product.
Implementation Method 1
A profilometer, encompassing any and all 3D scanning mechanisms and techniques, can be mounted on the printing assembly for measuring a 3D profile of the surface
Implementation Method 2
Exiting the printing assembly is a bead of extruded cementitious material that is placed along the toolpath
Data Source
AI summary
A system is provided for constructing a building structure, and specifically a wall of the structure, using a toolpath generation system and method to compensate for an uneven or unlevel foundation surface on which the wall is additively formed. The system includes a printing assembly and a mechanism for measuring a three dimensional topology of the surface. A processor is provided to receive a measured topology and to generate one or more sublayers and corresponding sub toolpaths. A nozzle mounted on the printing assembly can then extrude a sublayer bead in select recess or valley portions of the surface and below a subsequently extruded bead placed on high portions of the foundation surface. The sublayer beads compensate for the uneven foundation surface to produce a more even or level ensuing foundation surface using the additive printing process itself.