Method for casting a construction element
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Solution Overview
Problem
Conventional formwork methods for casting complex geometry construction elements with over-hanging surfaces are inefficient, costly, and generate significant waste due to the complexity of multi-part formwork or consumable materials.
Innovation Solution
A computer-controlled apparatus fabricates formwork using a material deposition head that selectively deposits formwork material according to computer instructions, allowing for the creation of complex geometries and subsequent removal of formwork by melting or dissolving, with the option to apply composite materials for reinforcement and surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid formwork is used to cast construction elements with over-hanging surfaces, then the formwork can provide structural support during casting, but the formwork becomes difficult or impossible to remove after curing
Solution Approach 1:
The formwork material undergoes a parameter change from solid to liquid state through melting, enabling easy removal after casting. The formwork is made of a material that remains stable at casting temperature but melts at a higher temperature, transforming its physical properties to solve the removal problem.
Solution Approach 2:
The formwork uses a composite material system combining a refractory ceramic base with a meltable binder or coating layer. This composite structure provides both the structural integrity needed for casting support and the controlled meltability required for easy removal after curing.
2Shape
If complex multi-part formwork is used to create non-standard geometry construction elements, then the desired complex shapes can be achieved, but the formwork complexity and cost increase significantly
Solution Approach 1:
The formwork is divided into a reusable support structure and a consumable model material portion. The support structure provides the necessary strength and can be reused, while the model material is consumed during casting but simplifies the overall formwork design and enables complex geometries without increasing permanent structure complexity.
Solution Approach 2:
The formwork model portion is designed as a disposable, low-cost material that is consumed during the casting process. This eliminates the need for complex reusable formwork structures while enabling the creation of intricate non-standard geometries, reducing both formwork complexity and cost.
3Ease of operation
If consumable formwork material is used to create complex geometries, then the formwork can be easily removed after curing, but large volumes of waste formwork material are generated
Solution Approach 1:
The meltable formwork material is discarded in a controlled manner through melting and draining, allowing for easy removal while minimizing waste. The liquid formwork material can be collected and potentially recovered or disposed of more efficiently compared to breaking apart solid formwork, reducing overall material waste.
4Reliability
If conventional formwork methods are used for complex geometries, then traditional casting can be performed, but considerable time and energy are required to remove the formwork
Solution Approach 1:
The formwork material undergoes a phase transition from solid to liquid through melting, enabling rapid and easy removal after casting. This phase change occurs at a temperature above the curing temperature of the construction element, allowing the element to maintain its strength while the formwork becomes fluid and can be easily drained or removed, significantly reducing removal time and energy requirements.
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 efficient, cost-effective, and sustainable casting of complex geometry construction elements by reducing formwork material waste and energy consumption, while allowing for the integration of composite materials for enhanced properties.
Implementation Method 1
moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a formwork corresponding with the formwork geometry
Implementation Method 2
Substantially liquid building material is poured into the cavity and set (cured), solidifying the building material within the cavity
Implementation Method 3
removing at least a portion of the formwork from the construction element
Data Source
AI summary
The present invention relates to a method for casting building material to form a construction element using a computer-controlled apparatus. The method comprises the steps of: moving the material deposition head and selectively depositing material, to fabricate a formwork; pouring building material in contact with at least a portion of the formwork; at least partially curing the building material, thereby forming the construction element; and removing at least a portion of the formwork from the construction element.