Lightweight Cementitious 3D Printing Frame for Compact Large-Scale Builds
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Solution Overview
Problem
Existing 3D printing technologies for construction face challenges such as bulky gantry systems, complex crane installations, stability issues, high labor costs, and difficulty in printing around obstructions like rebar due to the bulk of the printhead or lattice structure, leading to suboptimal construction processes.
Innovation Solution
A lightweight 3D printing apparatus with trussing beams, a telescoping z-axis member, and a hose management system that allows for precise control of the printhead's position, enabling easy setup and teardown, maneuverability, and the ability to print around obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gantry system running on rails is used to support the printing head, then the system can maintain stability and support heavy materials, but the system becomes bulky and requires large installation space that completely encompasses the building to be created
Solution Approach 1:
The patent removes the gantry and rail system from the construction zone by using a robotic arm that can be positioned at or near the center. The robotic arm extracts the need for encompassing rails while maintaining material deposition capability, reducing installation space requirements
Solution Approach 2:
The robotic arm provides dynamic positioning capability, allowing the printing head to be rotated into desired positions without requiring fixed rails. This dynamic system replaces the static gantry structure, enabling compact installation while maintaining stability through controlled movement
2Volume of moving object
If a robotic arm is used to place the printing head at the center of the construction zone, then the installation space is reduced and no gantry is needed, but the robotic arm and support structure must be extracted after construction which adds complexity
Solution Approach 1:
The system is divided into modular components including the robotic arm, support structure, and printing head. This segmentation allows for easier assembly and disassembly, reducing the complexity of installation and extraction while maintaining compact installation space
3Length of moving object
If a crane with lattice structure is used to support the printing head, then the printing head can reach greater heights and perimeters, but the system becomes voluminous, heavy, and requires complex installation and licensing
Solution Approach 1:
The patent replaces the heavy crane and lattice structure with a robotic arm system that achieves similar or greater action perimeter through rotational capability. This substitution eliminates the need for heavy structural support while maintaining extended reach, reducing system weight and installation complexity
4Strength
If a bulk printhead or lattice structure is used, then the system can maintain structural integrity, but the bulk prevents reaching desired print locations around obstructions like rebar
Solution Approach 1:
The robotic arm system allows for localized material deposition at specific points around obstructions. The printing head can be precisely positioned to print around rebar and other obstructions while maintaining structural integrity of the deposited material, providing local adaptability without requiring bulk structure
Data Source
AI summary
An example apparatus for additive manufacturing can include at least three legs including trussing beams and an upper frame supported at a target height by the legs. The upper frame can include an x-axis member extending between two of the legs and a y-axis member extending between two of the legs. An x-axis gantry can be coupled to the y-axis member and extend parallel to the x-axis member. The x-axis gantry can be slidably moveable along the y-axis member. An x-axis carriage can be coupled to the x-axis gantry and slidable moveable along the x-axis gantry. A telescoping z-axis member can be coupled to the x-axis carriage. A cementitious material delivery hose can have an outlet coupled to the z-axis member so that the outlet moves along a z-axis.