Layered Buildup of Shaped Elements Using Support Materials
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Solution Overview
Problem
Existing methods for producing shaped elements from curing materials are expensive and limited to small volumes, making them unsuitable for large-scale, low-cost production of components like concrete, casting molds, and fiber-reinforced plastics, especially for applications in marine and vehicle construction.
Innovation Solution
The method involves applying subsequent layers before the previous layer is fully cured, using a variety of bonding types and binders, including concrete and wood glue, and employing support materials to prevent deformation and ensure precise dimensions, with the option of using different materials for inner and outer layers and introducing reinforcements like flexible fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional negative mold methods are used, then production cost is reduced for repeated use, but production time increases and complexity increases for one-off or small quantity production
Solution Approach 1:
The patent applies preliminary action by preparing and positioning reinforcement elements, formwork, and bonding agents before applying the curing material layers. This allows the next layer to be applied immediately after the current layer is poured, eliminating waiting time for curing between layers and significantly reducing total production time while maintaining cost-effectiveness for one-off or small quantity production.
2Manufacturing precision
If thin layers are applied to achieve precise dimensions, then manufacturing precision is improved, but productivity decreases due to increased number of layers
Solution Approach 1:
The patent applies parameter changes by varying the layer thickness based on the specific requirements of the shaped element. For areas requiring high precision, thinner layers are used; for bulk volume accumulation, thicker layers are applied. The system also adjusts bonding agent application timing and reinforcement placement to maintain dimensional accuracy while optimizing production speed through adaptive parameter selection.
Solution Approach 2:
The patent segments the curing material into multiple layers with different functional characteristics. Each layer can be optimized for specific purposes (e.g., reinforcement embedding, surface finish, structural strength) while maintaining overall dimensional precision. This segmentation allows parallel processing of different layer types and reduces total production time compared to uniform thin layering.
3Productivity
If fast-curing materials are used, then productivity is improved, but material cost increases and material selection is limited
Solution Approach 1:
The patent introduces bonding agents as intermediary substances applied between layers of curing material. These bonding agents enable the use of slower-curing, more cost-effective, and versatile materials (such as concrete, wood composite materials, or other construction materials) while still achieving fast overall production through the layer-by-layer buildup method. The bonding agent acts as a mediator that allows immediate placement of the next layer without requiring the previous layer to be fully cured.
4Manufacturing precision
If support material is applied to prevent deformation, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the support material application with the layer deposition process itself. Support materials are applied simultaneously with or immediately after the curing material layer, and both are cured together as a single integrated structure. This merging eliminates the need for separate support structure assembly and removal operations, reducing device complexity while maintaining shape accuracy through the combined curing process.
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 allows for the cost-effective production of large volume components with precise dimensions and smooth surfaces, enabling the creation of complex shapes and cavities that were previously unachievable with conventional mold-based methods, while reducing production time and material costs.
Implementation Method 1
the element material cures very quickly so that the next layer can be applied there above immediately thereafter
Implementation Method 2
This element material is initially applied in one layer over the entire base surface of the container. Subsequently, this powdery layer of element material is only cured in the portion that shall include the shaped element and is for example heated with a focused laser beam or another very limited heat source
Implementation Method 3
applying the next layer before the layer below or even more layers below are cured, in particular completely cured, the method is extended to a plurality of bonding types and binders which bond relatively slowly compared to the special plastic materials used so far
Data Source
AI summary
Since concrete materials do not cure quick enough when prototyping methods are used, so that a lower layer (2a) is already completely cured when the next layer (2b) is applied, a support material (4) is applied about the formed element (100) that is being built up in order to compensate for the lack of pressure resistance of the lower layer (2a), wherein the support material preferably has the same specific weight as the material (3) of the formed element (100). Thus, 3D-printing as well as selective curing are facilitated as build up methods.