Meltable Formwork Casting for Complex Geometry Construction Elements
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Solution Overview
Problem
Conventional methods for casting complex geometry construction elements with over-hanging surfaces using rigid formwork often result in difficulties in removing the formwork, leading to high costs and waste due to the complexity of multi-part formwork or consumable materials.
Innovation Solution
A computer-controlled apparatus deposits formwork material to create a meltable or dissolvable formwork that can be recycled, allowing for the efficient removal of the formwork from the construction element and enabling the reuse of the formwork material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid formwork is used to cast construction elements with over-hanging surfaces, then the formwork can provide structural support during casting, but the formwork becomes difficult or impossible to remove after curing
Solution Approach 1:
The formwork material's physical state is changed from solid (rigid) to liquid (flowable) through heating above its melting point, enabling it to be removed from the cured construction element without mechanical force that could damage the element
Solution Approach 2:
The formwork is designed as a consumable material that is destroyed (melted) after serving its purpose of supporting the construction element during casting, eliminating the need for complex removal mechanisms
2Ease of operation
If multi-part formwork is used to enable formwork removal, then the formwork can be disassembled to release the construction element, but the device complexity and cost increase significantly
Solution Approach 1:
The formwork is divided into multiple depositable sections that can be independently removed after curing, allowing complex geometries to be formed while maintaining ease of removal without requiring intricate multi-part assemblies
Solution Approach 2:
The formwork material transitions from solid to liquid state through heating, enabling simple removal of the entire formwork structure without complex disassembly mechanisms
3Ease of operation
If consumable formwork material is used to facilitate formwork removal, then the formwork can be destroyed after curing to release the element, but material waste and production costs increase
Solution Approach 1:
The formwork material is melted and collected after use, then recirculated and reused to create new formwork, significantly reducing material waste and production costs while maintaining the benefits of consumable formwork removal
Solution Approach 2:
The mechanical process of formwork removal is replaced with a thermal process (melting), which allows for cleaner separation and easier collection/recycling of the formwork material
4Manufacturing precision
If conventional formwork is used for complex geometry casting, then the desired geometry can be achieved, but the casting time and energy required for formwork removal increase considerably
Solution Approach 1:
The formwork material's melting point is utilized to enable rapid removal through heating, significantly reducing the time and energy required compared to mechanical removal methods while preserving complex geometry accuracy
Solution Approach 2:
The formwork is designed with dynamic properties allowing it to transition from a rigid support structure during casting to a flowable material during removal, optimizing both geometry precision and removal efficiency
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 method allows for the cost-effective and sustainable casting of complex geometry construction elements by enabling the reuse of formwork material and reducing waste, while efficiently removing the formwork without damaging the construction element.
Implementation Method 1
at least one meltable or dissolvable formwork fabricated by the apparatus is melted or dissolved to remove the formwork from the cured construction element
Implementation Method 2
as a settable building material changes state from a liquid to a solid, the material may be poured into a mould having an amorphous, complex shape and cured
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present invention relates to a method for casting building material to form a construction element using a computer-controlled apparatus. The method comprises the steps of: moving the material deposition head and selectively depositing material, to fabricate a formwork; pouring building material in contact with at least a portion of the formwork; at least partially curing the building material, thereby forming the construction element; and removing at least a portion of the formwork from the construction element.