Extrusion Head Fiber Insertion for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing of architectural structures using cementitious materials faces challenges in achieving tensile strength, as existing solutions either damage metering and booster pumps with rigid fibers, limit geometry designs, increase project duration, or complicate the process with metal reinforcement.
Innovation Solution
An extrusion system that incorporates a device for projecting and inserting structural reinforcement fibers into extruded cords, allowing for non-collinear fiber insertion to enhance tensile strength and cohesion between layers without damaging the extrusion system components, and enabling more complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid fiber reinforcement is used to improve tensile strength, then the tensile strength of the structure is improved, but the metering and booster pumps deteriorate quickly
Solution Approach 1:
The fiber reinforcement function is extracted from the extrusion system and implemented separately through a projection device that inserts fibers into the extruded cords after they leave the nozzle. This prevents fibers from contacting and damaging the metering and booster pumps while still achieving tensile strength reinforcement.
Solution Approach 2:
The reinforcement process is segmented into two independent operations: (1) extrusion of the cord material through the nozzle, and (2) separate projection and insertion of fibers into the extruded cord. This segmentation allows each process to be optimized independently without interfering with the other.
2Strength
If traditional steel reinforcement is used to improve tensile strength, then the tensile strength is improved, but the construction process becomes more complex and time-consuming
Solution Approach 1:
The fiber projection device is integrated with the extrusion head assembly, combining the cord extrusion and fiber reinforcement operations into a single synchronized process. Both operations occur simultaneously during one pass, eliminating the need for separate reinforcement steps and reducing construction complexity.
Solution Approach 2:
Fibers are pre-positioned and projected into the extruded cords during the extrusion process itself, rather than requiring post-extrusion reinforcement operations. This preliminary action integrates reinforcement into the primary manufacturing step.
3Strength
If fiber reinforcement is inserted during extrusion to improve tensile strength, then the tensile strength is improved, but the fiber insertion must not damage the extrusion system components
Solution Approach 1:
The fiber projection function is extracted from the extrusion system and implemented through a separate projection device that operates independently. This ensures fibers are never forced through the metering pump or booster pump, eliminating the risk of component damage while maintaining reinforcement effectiveness.
4Reliability
If geometry is designed to limit tensile forces to avoid reinforcement, then the pump durability is maintained, but the possible geometries are limited
Solution Approach 1:
The invention uses inexpensive, easily insertable fibers that can be projected into cords without requiring complex reinforcement structures. This allows versatile geometry designs to be implemented with simple, cost-effective reinforcement that does not constrain design freedom.
Data Source
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AI summary
The invention relates to a system for extruding beads (9) of building material for a robot (8) for the additive manufacture of architectural structures (6), comprising: an extrusion head (30) extruding beads of building material and intended to be moved by the additive-manufacturing robot (8) in a predetermined path in order to form an architectural structure (6) by the stacking of the layers of extruded beads (8); a feed circuit (20) feeding the said extrusion head (30) with building material; characterized in that it further comprises a spray device (40) spraying fibres (48) for structurally reinforcing the extruded beads (8), which spray device is designed to be able to spray fibres (48) that structurally reinforce these beads and insert same into said extruded beads.