Contour Crafting Extrusion Nozzle for Uneven Surfaces
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Solution Overview
Problem
Construction processes are labor-intensive, material wasteful, and hazardous, with challenges in extruding walls with multiple layers and creating uniform bases on uneven surfaces, as well as crafting openings for windows and doors.
Innovation Solution
An automated extrusion construction system with controllable extrusion nozzles that move horizontally to form stacked layers, including a slicing mechanism for creating openings and an adjustable nozzle for uniform layer formation on uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated extrusion nozzles are used to construct walls, then productivity and safety are improved, but manufacturing precision and adaptability to uneven surfaces deteriorate
Solution Approach 1:
The nozzle assembly incorporates adjustable height mechanisms that allow the extrusion nozzle to dynamically adapt its position relative to the underlying surface. This enables the system to maintain consistent layer thickness and uniformity even when constructing on uneven terrain, resolving the contradiction between automated construction efficiency and manufacturing precision.
Solution Approach 2:
The system allows for real-time adjustment of extrusion parameters including nozzle height, extrusion rate, and layer thickness. By dynamically changing these parameters in response to surface variations detected by sensors, the system maintains high manufacturing precision while benefiting from automated construction productivity.
2Adaptability or versatility
If multiple layers are extruded to create complex wall structures, then adaptability and structural capability are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The wall construction process is divided into discrete horizontal layers that are extruded sequentially. Each layer can be independently controlled and adjusted, allowing complex multi-layer structures to be built using a relatively simple extrusion mechanism rather than requiring complex monolithic forming equipment.
Solution Approach 2:
The extrusion nozzle system is designed to handle multiple materials and create various layer configurations using the same basic apparatus. By adjusting extrusion parameters and material input, the system can create insulation layers, structural layers, and finishing layers without requiring separate specialized equipment for each layer type.
3Adaptability or versatility
If openings for windows and doors are created during extrusion, then adaptability and functional capability are improved, but manufacturing precision and structural integrity may deteriorate
Solution Approach 1:
The positions and dimensions of openings are pre-planned and programmed into the extrusion control system before construction begins. The nozzle system then precisely follows these pre-determined paths, creating openings with high dimensional accuracy while maintaining overall wall integrity through controlled extrusion and curing sequences.
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
The system enables efficient, automated construction with reduced material waste and improved safety by forming uniform layers and creating openings in walls, accommodating uneven surfaces and allowing for precise control over layer formation and opening creation.
Implementation Method 1
an extrusion nozzle configured to extrude construction material in a substantially horizontal direction
Data Source
AI summary
An automated extrusion construction system may include an extrusion nozzle configured to extrude construction material in a substantially horizontal direction against an elongated and substantially vertical surface. An extrusion nozzle may have a height adjustment mechanism configured to adjust the height of an outlet in response to level deviations in the surface on which the construction material is extruded by the extrusion nozzle. An automated extrusion construction system may include a slicing mechanism configured to controllably slice through the extruded layer.