3D Printing Gantry for Rapid Construction
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Solution Overview
Problem
Traditional construction methods for buildings are time-consuming and require multiple skilled trades, extending the construction period to several months, which is undesirable for rapid structure development.
Innovation Solution
A construction system utilizing additive manufacturing techniques, specifically 3D printing, with a rail assembly and gantry system that allows for the controlled deposition of extrudable building materials in vertically stacked layers onto a foundation, enabling the rapid construction of structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional construction methods are used, then structural integrity and precision can be maintained, but construction time is excessively long (several months)
Solution Approach 1:
The patent changes the fundamental construction parameter from manual/sequential assembly to automated/layer-by-layer deposition. The additive manufacturing system extrudes material continuously in controlled layers, transforming the construction process from discrete component assembly to continuous material deposition, thereby dramatically reducing construction time while maintaining precision through computer-controlled positioning.
Solution Approach 2:
The patent replaces traditional mechanical construction systems (cranes, manual labor, sequential assembly operations) with an automated additive manufacturing system. The gantry-based extrusion system uses computer-controlled motion systems to deposit material layer by layer, substituting heavy mechanical assembly operations with precise automated deposition, achieving both speed and structural integrity.
2Ease of manufacture
If traditional construction methods with multiple skilled trades are used, then comprehensive construction quality can be ensured, but the process becomes complex and time-consuming
Solution Approach 1:
The additive manufacturing system performs multiple construction functions that traditionally required different skilled trades (masonry, concrete work, structural assembly) through a single integrated machine. The extrusion system can deposit various materials (concrete, mortar, infill materials) and perform different construction tasks (wall construction, infill, detailing) using the same gantry system, eliminating the need for multiple specialized trades.
Solution Approach 2:
The patent merges multiple construction operations into a single continuous process. The extrusion system combines material deposition, layer formation, and structural construction in one integrated operation, rather than requiring separate steps for different trades. The system merges the functions of multiple specialized construction teams into a single automated process that deposits and forms structure in one continuous workflow.
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 significantly reduces construction time, allowing structures to be built in a fraction of the time required by traditional methods, while maintaining structural integrity and precision.
Implementation Method 1
The printing assembly is configured to deposit vertically stacked layers of an extrudable building material onto a top surface of the foundation to construct a structure
Data Source
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AI summary
Embodiments of a constructions system for constructing a structure atop a foundation are disclosed. In an embodiment, the construction system includes a rail assembly. The rail assembly is configured to be mounted to the foundation. In addition, the construction system includes a gantry movably disposed on the rail assembly. The gantry is configured to translate along a first axis relative to the rail assembly. Further, the construction system includes a printing assembly movably disposed on the gantry. The printing assembly is configured to translate along a second axis relative to the gantry. The second axis is orthogonal to the first axis. The printing assembly is configured to deposit vertically stacked layers of an extrudable building material onto a top surface of the foundation to construct a structure.