3D Printed Concrete Feedthroughs via Support Pillar Removal
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Solution Overview
Problem
Current 3D printing methods for concrete or mortar struggle to create objects with bushings, such as window or door openings, due to the inability to stabilize unhardened concrete or mortar masses, limiting design flexibility and the feasibility of delicate support structures.
Innovation Solution
A method involving the application of concrete or mortar in layers using a print head, followed by the removal of specific areas after partial hardening to create support pillars, which are then removed after complete hardening, allowing for the creation of complex shapes and bushings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional 3D printing methods are used to create objects with openings, then the printing process cannot be completed, but design flexibility is limited
Solution Approach 1:
The invention applies preliminary action by depositing support structures during the 3D printing process before the final geometry is complete. These support structures are placed in advance to bear the weight of subsequent concrete layers, enabling the creation of openings and complex geometries that would otherwise be impossible to manufacture.
Solution Approach 2:
The invention applies the extraction principle by removing the deposited support structures after the concrete has hardened. This removal creates the desired openings, feedthroughs, and complex internal geometries in the final product, transforming the temporary support structures into the final design features.
2Adaptability or versatility
If support structures are printed during the process, then openings can be created, but the support structures require additional removal steps
Solution Approach 1:
The invention applies discarding and recovering by designing support structures that are intentionally temporary and meant to be removed after serving their stabilizing function. The support structures are discarded after the concrete hardens, and their removal is integrated into the manufacturing process rather than treated as a separate complex operation.
3Ease of manufacture
If material is removed before hardening, then feedthroughs can be created, but the concrete mass lacks mechanical support
Solution Approach 1:
The invention applies preliminary action by depositing support structures during the printing process before material removal is needed. These support structures are in place beforehand to provide the mechanical stability required to support subsequent concrete layers, enabling safe material removal to create feedthroughs and openings.
Solution Approach 2:
The deposited support structures act as intermediaries that temporarily provide mechanical stability during the manufacturing process. They mediate between the need to create openings and the requirement for structural stability, allowing material removal while maintaining support for the concrete mass.
4Stability of the object's composition
If support structures are left in place, then stability is maintained, but design flexibility is reduced
Solution Approach 1:
The invention applies discarding and recovering by removing the support structures after they have served their stabilizing function. This allows the final product to achieve the desired design flexibility with clean openings and feedthroughs, while the temporary support structures provided the necessary stability during manufacturing.
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
Enables the production of objects with increased design flexibility, including bushings, by ensuring stability and preventing deformation during the hardening process, allowing for precise and varied shapes that would otherwise be impossible with traditional 3D printing techniques.
Implementation Method 1
the concrete or mortar mass begins to harden, losing its flowability as a result of chemical processes (in particular the incorporation of the mixing water as crystal water: hydration)
Implementation Method 2
the concrete or mortar mass begins to harden, losing its flowability as a result of chemical processes (in particular the incorporation of the mixing water as crystal water: hydration) and evaporation of the mixing water
Data Source
Figure 1(a)~1(c)
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a method for producing an object (G) from concrete or mortar by means of 3D printing, wherein: (A) layers (2) of a concrete or mortar mass (1) are applied layer by layer by an industrial robot, thereby producing a raw object (G'), (B) an area (B) of the raw object (G') is removed by a separating manufacturing process, so that a through-hole (B') is produced.