3D Mortar Printing with Foam-Defined Temporary Supports
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Solution Overview
Problem
Existing 3D printing methods for mortar-based elements face limitations in creating complex shapes due to the need for temporary supports and specialized measures for openings like windows or doors, leading to increased labor and material costs and reduced efficiency.
Innovation Solution
A method that adjusts mortar density by adding aqueous foam to the base wet mortar, allowing for the creation of both dense, structural zones and lightweight, removable zones, using the same equipment and nozzle, enabling the production of complex shapes with reduced material and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temporary supports are used to create complex shapes, then structural stability during printing is improved, but device complexity and labor costs increase
Solution Approach 1:
The patent applies preliminary action by printing temporary support structures (secondary zones) before the main structural elements (primary zones). These supports are pre-positioned to enable subsequent layers to be deposited without requiring additional support mechanisms during printing. The supports are later removed after serving their temporary function, eliminating the need for complex support systems throughout the entire process.
Solution Approach 2:
The patent changes material parameters by using mortar with different density characteristics for different zones. Secondary zones use mortar with lower density or different rheological properties that allow easy removal after printing, while primary zones use standard structural mortar. This parameter differentiation enables temporary supports to provide necessary stability during printing while being easily removable afterward, reducing overall device complexity.
2Adaptability or versatility
If openings like windows or doors are created during printing, then functional requirements are met, but manufacturing complexity and time increase
Solution Approach 1:
The patent applies preliminary action by printing temporary mortar supports (secondary zones) at the locations where openings will eventually be created. These temporary supports allow the printing process to proceed with continuous layer deposition without requiring complex real-time adjustments or separate operations for creating openings. After the structure is printed, the temporary supports are removed to reveal the desired openings, simplifying the manufacturing process.
Solution Approach 2:
The patent applies the extraction principle by removing the temporary mortar supports (secondary zones) after printing to create openings. Instead of attempting to print openings directly or using complex formwork, the method extracts the temporary material that was used to enable printing, leaving behind the desired void spaces for windows or doors. This separates the printing process from the opening creation process.
3Strength
If uniform dense mortar is used throughout, then structural strength is ensured, but material consumption and weight increase
Solution Approach 1:
The patent applies local quality by differentiating mortar properties between different zones of the structure. Primary zones that require structural strength use dense, standard mortar composition, while secondary zones that serve as temporary supports use mortar with different characteristics (lower density or modified rheology) that facilitate easy removal. This localized differentiation ensures structural strength where needed while reducing overall material consumption and weight.
Solution Approach 2:
The patent segments the structure into functionally distinct zones: primary zones for permanent structural elements and secondary zones for temporary supports. This segmentation allows optimization of material usage in each zone according to its specific function, avoiding the overuse of dense structural mortar in areas where only temporary support is needed, thereby reducing total material consumption.
4Manufacturing precision
If multiple equipment types are used for different zones, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a single printing system that can deposit different types of mortar (for primary and secondary zones) using the same nozzle and equipment. The system achieves this through material formulation differences rather than equipment differentiation, allowing one multi-functional printer to handle both structural and temporary support materials with the same hardware, thereby maintaining manufacturing precision without increasing device complexity.
Solution Approach 2:
The patent uses parameter changes in material composition (density, rheology, additives) rather than changing equipment parameters to differentiate between primary and secondary zones. This approach allows the same printing equipment to deposit materials with different properties by adjusting material formulation, maintaining equipment simplicity while achieving the necessary differentiation in zone characteristics.
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 rapid and economical manufacturing of complex shapes with integrated temporary supports and openings, reducing material consumption and labor costs while ensuring structural integrity and ease of support removal.
Implementation Method 1
The density of the mortar layers or of portions of the mortar layers is adjusted through the controlled addition of aqueous foam to the base wet mortar
Data Source
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AI summary
The invention relates to a 3-D printing method for manufacturing an element (1, 200) made of a material which comprises hydraulic binder and aggregates, said element comprising at least a primary zone (14, 206) and at least a secondary zone (16, 202, 204), the density of the material being higher in the or each primary zone (14, 206) than in the or each secondary zone (16, 202, 204), said method comprising mixing (22) a dry mortar composition with water to form a base wet mortar, conveying said base wet mortar towards a printer head (28) and, by moving said printer head, depositing superposed mortar layers (11, 12) to form said element (1, 200), wherein, before depositing the mortar layers, or the portions of mortar layers, that belong to the secondary zone (16, 202, 204), an aqueous foam is added to said base wet mortar during said conveying of the base wet mortar towards the printer head (28), and wherein at least part of the mortar layers, or portions of mortar layers, that belong to a secondary zone (16, 202, 204) support some of the mortar layers, or portions of mortar layers, that belong to a primary zone (14, 206).