Custom 3D Printed Wall Panels for Complex Building Retrofits
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Solution Overview
Problem
Existing building energy retrofits face challenges due to the need for invasive and expensive on-site work, as traditional methods struggle with complex, non-planar building geometries, leading to inefficiencies and increased costs.
Innovation Solution
A system of lightweight, composite, insulating, and prefabricated wall panels that utilize 3D scanning and digital manufacturing to create custom geometries, allowing for precise fitting and rapid installation without disrupting existing structures, using Branch Technology's Cellular Fabrication process and 3D printing to produce panels that conform to the building's unique shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional flat sheet goods are used for building envelope retrofits, then installation is simplified on planar surfaces, but the method becomes ineffective and costly for complex non-planar building geometries
Solution Approach 1:
The patent transforms the physical state and geometric parameters of the insulation material by using additive manufacturing to create three-dimensional printed panels with complex curved surfaces that match non-planar building envelopes. This allows the insulation panels to adapt to varying building geometries while maintaining manufacturability through digital design and automated fabrication processes.
Solution Approach 2:
The patent employs composite construction by combining 3D-printed structural panels with insulation materials. The panels integrate multiple functions including structural support, thermal insulation, and geometric adaptation to building surfaces, creating a multi-functional composite system that resolves the contradiction between adaptability and ease of installation.
2Manufacturing precision
If custom geometries are created for each building facade, then precision and fit are improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent replaces traditional mechanical measurement and manual fabrication processes with digital 3D scanning and additive manufacturing technology. This substitution enables high geometric precision for custom building facades while reducing manufacturing complexity through automated digital workflows that eliminate manual measurement, template creation, and on-site cutting operations.
Solution Approach 2:
The patent performs preliminary digital scanning, modeling, and panel fabrication off-site before installation. By completing the complex geometric customization work in a controlled manufacturing environment using 3D printing technology, the system achieves high precision while minimizing on-site complexity and installation time.
3Adaptability or versatility
If invasive on-site work is performed for retrofits, then existing structures can be modified, but disruption and costs to building occupants increase
Solution Approach 1:
The patent applies preliminary action by fabricating all custom insulation panels off-site using 3D printing technology before delivery to the building location. This approach allows complex retrofits to be prepared in advance, minimizing on-site installation time and reducing disruption to building occupants while maintaining the ability to adapt to various existing structures.
Solution Approach 2:
The patent divides the building envelope retrofit into separate modular panels that can be manufactured independently and installed in sections. This segmentation allows the retrofit work to progress systematically with minimal disruption to occupied spaces, as panels can be installed in a controlled sequence without requiring complete demolition or building shutdown.
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 energy-efficient retrofits by reducing on-site labor and costs, improving thermal performance, and enhancing energy retention through precise geometric matching and automated manufacturing, while minimizing material usage and ensuring a durable, aesthetically pleasing finish.
Implementation Method 1
Additive manufacturing, or 3D printing, is a customizable fabrication process that has been in use for several decades in various industries
Implementation Method 2
a lightweight, structural composite material with a cellular matrix
Data Source
AI summary
Methods, systems, and panels for retrofitting an existing exterior of a building. In one example, the method may include: (a) obtaining data about an exterior geometry of the existing exterior; (b) using the obtained data, defining a custom retrofit panel system for the exterior geometry; and (c) constructing the custom retrofit panel system including a plurality of panels, in which constructing a panel includes: (i) forming a panel frame by additive manufacturing, the panel frame defining interstitial spaces; (ii) at least partially filling the interstitial spaces with at least one filler; and (iii) in which the constructed panel includes a building facing surface configured to mate with the exterior geometry of the existing exterior.