Composite Construction Element Fabrication via Segmented Moulds
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Solution Overview
Problem
Existing methods for casting composite construction elements with complex geometries, such as those with over-hanging surfaces, face challenges in mold removal due to the complexity and cost of multi-part molds or consumable molds, which often result in waste and require significant time and energy.
Innovation Solution
A computer-controlled apparatus fabricates a mold with specific receiving portions for objects using 3D modeling and deposition techniques, allowing for the creation of complex geometries and efficient mold removal through meltable or soluble materials, enabling the production of composite construction elements with embedded objects in various geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a complex multi-part mould is used to cast construction elements with over-hanging surfaces, then the mould can be released from the cast element, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The mould is divided into multiple separable parts that can be detached from the cast element. Each mould part can be independently removed, allowing extraction of cast elements with over-hanging surfaces without requiring complex disassembly mechanisms.
Solution Approach 2:
Release features such as gaps and parting lines are incorporated into the mould design during fabrication. These features are prepared in advance to facilitate mould removal, eliminating the need for complex removal mechanisms during the casting process.
2Ease of operation
If a consumable mould is used to cast construction elements with complex geometries, then the mould can be removed by destruction, but the loss of substance and energy consumption increase
Solution Approach 1:
The mould is segmented into multiple reusable parts rather than being a single consumable structure. This allows the mould to be recovered and reused for multiple casting operations, significantly reducing material waste.
Solution Approach 2:
The mould design incorporates features that enable easy recovery and reuse. Instead of destroying the mould after a single use, the segmented structure allows for complete retrieval and preparation for subsequent casting cycles, reducing both material loss and energy consumption.
3Ease of manufacture
If planar mould surfaces are used to cast composite construction elements, then veneer tiles can be easily secured to the mould, but the geometry of the cast element is limited to planar panels
Solution Approach 1:
The mould surface is divided into multiple planar segments that can be arranged at different angles and orientations. This segmentation allows the creation of complex three-dimensional geometries while each individual segment maintains the simplicity of a planar surface for easy tile securing.
Solution Approach 2:
The mould transitions from a single planar surface to a multi-dimensional segmented structure. By arranging planar segments in three-dimensional space, the mould can produce cast elements with complex geometries including curves and angles, while each segment retains the ease of planar tile attachment.
4Manufacturing precision
If layout mats are used to retain veneer tiles on the mould, then tile arrangement is controlled, but the mats cannot be reliably secured to complex geometry moulds
Solution Approach 1:
The layout mat is divided into multiple smaller sections that can be independently attached to corresponding mould segments. This segmentation allows the mat to conform to complex mould geometries while maintaining the precision of tile arrangement through localized attachment points.
Solution Approach 2:
The layout mat system transitions from a single planar sheet to a multi-dimensional configuration that follows the segmented mould surface. This allows the mat to be securely attached to complex geometries by distributing attachment across multiple planar segments rather than requiring attachment to a continuous complex surface.
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 method enables the efficient and cost-effective fabrication of composite construction elements with complex geometries, reducing waste and energy consumption while allowing for precise control over mold geometry and object placement, facilitating the creation of structures with embedded veneer tiles, bricks, or other materials.
Implementation Method 1
a computer-controlled apparatus fabricates a mould by selectively depositing build material in successive layers
Implementation Method 2
introducing settable material into the cavity and at least partially curing the settable material
Implementation Method 3
The mould may comprise a meltable or soluble material configured to be destroyed to enable removal of the mould from the cast construction element
Implementation Method 4
The mould may comprise a meltable or soluble material configured to be destroyed to enable removal of the mould from the cast construction element
Data Source
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AI summary
The present invention relates to a method for fabricating a composite construction element using a mould fabricated by a computer-controlled apparatus. The method comprises the steps of fabricating the mould having one or more receiving portions dimensioned to receive one or more respective objects responsive to computer instructions relating to the mould geometry, positioning the one or more objects in respective receiving portions, covering at least a portion of the mould and the one or more objects with settable material, and at least partially curing the settable material, thereby forming the composite construction element having the one or more objects embedded therein.