3D Printed Formwork System with Rear-Side Shaped Elements
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Solution Overview
Problem
Conventional formwork systems for producing concrete structural elements face challenges in withstanding internal pressures without deformation and achieving a uniform surface, as visible fastening elements like screws can leave stains or deformations on the concrete surface.
Innovation Solution
A formwork system comprising a 3D-printed form lining and shaped elements attached to the rear side, using 3D printing methods to produce components that do not touch or pierce the front side, allowing for flexible connection to a substructure and preventing surface disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastening elements like screws are used to attach form lining to substructure, then the formwork system can be securely fastened, but visible stains and deformations appear on the concrete surface
Solution Approach 1:
The harmful fastening elements are extracted from the concrete-facing side and relocated to the rear side of the form lining. The patent attaches shaped elements to the rear side (4) of the form lining (2), which then connect to the substructure without penetrating the front side (3), thereby removing the source of surface defects while maintaining fastening security.
Solution Approach 2:
The fastening connection is moved from the two-dimensional front surface to the three-dimensional rear side of the form lining. By attaching shaped elements to the rear side and connecting them to the substructure in this additional spatial dimension, the system achieves secure fastening without compromising the front surface quality.
2Ease of operation
If conventional formwork systems are used with multiple separate components, then assembly is straightforward, but the surface uniformity and lack of visible fastening elements cannot be achieved
Solution Approach 1:
The form lining and shaped elements are merged into an integrated unit produced by 3D printing. This combining of components eliminates the need for separate fastening elements that would penetrate the front side, while the modular nature of the shaped elements attached to the rear side maintains assembly simplicity.
Solution Approach 2:
Different regions of the formwork system are given different functions: the front side (3) is designed for concrete contact with smooth, defect-free surface, while the rear side (4) contains the shaped elements (10) for substructure connection. This local differentiation allows surface uniformity without compromising fastening capability.
3Adaptability or versatility
If the form lining is made thin and flexible for complex geometries, then manufacturing flexibility improves, but structural strength to withstand concrete pressure decreases
Solution Approach 1:
The formwork system uses composite construction with the form lining (2) providing the concrete-facing surface and shaped elements (10) attached to the rear side providing structural reinforcement. This composite structure allows thin, flexible form linings for complex geometries while maintaining pressure resistance through the rear-side reinforcement system.
Solution Approach 2:
The formwork system is segmented into functional components: the form lining (2) for geometry definition and the shaped elements (10) for structural support and fastening. This segmentation allows each component to be optimized independently - the lining for flexibility and complex shapes, the shaped elements for strength and pressure resistance.
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 achieves high flexibility in handling temperature changes, produces undisturbed and uniform concrete surfaces, and reduces the need for laborious assembly and adhesive use, enabling the creation of complex geometries with minimal surface disturbances.
Implementation Method 1
The form lining (2) and the shaped element (10) have been produced by a 3D printing method
Data Source
AI summary
The present invention relates to a formwork system (1) comprising a form lining (2) and at least one shaped element (10) which is attached to the rear side (4) of the form lining (2). The form lining (2) and the shaped element (10) have been produced by a 3D printing method. This is preferably carried out in a common 3D printing process, but the form lining (2) and the shaped element (10) can also be produced in separate 3D printing processes, with the shaped element (10) then being attached to the rear side (4) of the form lining (2). This is effected using at least one first fastening element (50). If, by contrast, the form lining (2) and the shaped element (10) have been produced in a common 3D printing process, the additional use of a first fastening element (50) for fastening the shaped element (10) to the form lining (2) is not required. According to the invention, the shaped element (10) and optionally the first fastening element (50) are attached to the rear side (4) of the form lining (2) in such a way that they do not touch or pierce the front side (3) of the form lining (2). The present invention also relates to the use of such a formwork system (1), for example in the production of structural elements made of concrete.