Robotic Foam Spray Fabrication for Complex Geometries
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Solution Overview
Problem
Conventional construction methods face challenges in creating complex geometries and large-scale structures with overhangs or unsupported spans, as well as achieving spatially varying material properties, while also being cost-effective and time-efficient.
Innovation Solution
A method involving a spray nozzle that sprays low-density, high-strength, fast-curing foam layer by layer according to a CAD model, allowing for the creation of molds or internal forms with complex geometries and spatially varying properties, combined with subtractive fabrication to refine the surface and embed structural elements, enabling the construction of large-scale structures with overhangs and unsupported spans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional construction methods are used to create complex geometries and large-scale structures with overhangs, then structural stability may be maintained, but manufacturing complexity and time consumption increase significantly
Solution Approach 1:
The patent changes the physical and chemical parameters of the construction material by using sprayable foam that expands and cures in place. This allows complex geometries to be fabricated directly through digital modeling and robotic spraying without traditional formwork, molds, or assembly procedures, thereby reducing manufacturing complexity while achieving intricate shapes.
Solution Approach 2:
The invention replaces traditional mechanical construction systems (formwork, scaffolding, manual assembly) with a digital-robotic spraying system. The foam is sprayed layer by layer according to CAD models, and the material's expansion and curing properties enable it to hold complex geometries without mechanical support structures during construction.
2Strength
If conventional methods are used for large-scale structures with unsupported spans, then structural integrity can be achieved, but construction time and cost increase
Solution Approach 1:
The patent replaces time-consuming conventional construction processes with automated robotic foam spraying. The material is deposited layer by layer according to optimized paths, and the fast-curing foam achieves structural integrity quickly, enabling large-scale structures with unsupported spans to be built much faster than traditional methods.
Solution Approach 2:
The invention utilizes the unique parameters of sprayable foam material - its rapid expansion and fast curing properties - to achieve structural integrity in situ. The foam cures quickly after spraying, allowing unsupported spans and large-scale structures to gain strength without prolonged formwork or temporary supports, thereby reducing construction time.
3Adaptability or versatility
If spatially varying material properties are achieved through conventional methods, then functional requirements can be met, but material waste and processing time increase
Solution Approach 1:
The patent implements local quality by varying the material properties of the foam at different spatial locations through digital control of the spraying process. The CAD models and robotic positioning enable precise control over foam density, thickness, and composition at each location, achieving spatially varying material properties exactly where needed without excess material.
Solution Approach 2:
The invention replaces conventional methods of achieving spatially varying properties (which often involve multiple material batches, manual placement, or extensive formwork variations) with a digitally controlled robotic spraying system. This system can adjust material deposition parameters in real-time based on the digital model, minimizing material waste while achieving the required property variations.
4Ease of manufacture
If traditional construction methods are used, then ease of manufacture may be maintained for simple geometries, but complexity increases for unique shapes and overhangs
Solution Approach 1:
The patent replaces traditional formwork and mold systems with a digital-robotic spraying approach. Unique geometries and overhangs are fabricated directly from CAD models through automated path planning and robotic foam deposition, eliminating the need for custom-made formwork or complex assembly procedures, thereby maintaining ease of manufacture even for complex shapes.
Solution Approach 2:
The invention changes the state and properties of the construction material to sprayable foam that can be deposited in any orientation and direction. This material parameter change enables unique geometries and overhangs to be fabricated as continuously curved surfaces without joints or seams, simplifying the manufacturing process compared to traditional methods that would require multiple components and assemblies.
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 the rapid and cost-effective construction of complex structures with reduced material waste, faster production times, and the ability to create unique geometries, while maintaining structural integrity and allowing for on-site fabrication of large items like wind turbine blades.
Implementation Method 1
The foam chemically cures
Implementation Method 2
The foam thermally sets
Implementation Method 3
The foam optically cures
Data Source
AI summary
In exemplary implementations of this invention, a nozzle sprays foam, layer by layer, to fabricate a fabricated object according to a CAD model, and a subtractive fabrication tool removes material from the fabricated object according to a CAD model. The fabricated object comprises a mold or an interior form. The foam may be low-density, high strength and fast-curing. The foam may be used for large-scale 3D printing. For example, the foam may be used to 3D print molds for walls of homes. The foam molds may be left in place, after casting concrete in the molds, to serve as insulation. Or for example, the foam may be used to 3D print on site an internal form for a large wind turbine blade. The wind turbine blade may then be produced on site by depositing fiberglass on the outside of the internal form.