Mobile Autonomous 3D Printer for Gantry-Less Construction
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Solution Overview
Problem
Current 3D printing technologies using Ordinary Portland Cement (OPC) are limited by the need for large gantry systems, which restrict structure size and accessibility due to the rapid hardening of OPC with water, leading to either collapse or inadequate layer adhesion.
Innovation Solution
A mobile autonomous printer system with switchable pump arms and a mixing vessel at the print head, allowing for the combination of materials in small quantities just before deposition, eliminating the need for gantry systems and enabling gantry-less construction by embedding printers within the structure to form a network of pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If OPC slurry is pumped through gantry conduits, then material can be supplied to print head, but print speed is limited and structure size is constrained by gantry dimensions
Solution Approach 1:
The system divides the cement slurry supply into multiple separate conduits (first conduit for Part A, second conduit for Part B) that can be independently controlled. This segmentation allows each conduit to be optimized for its specific material flow requirements and enables the print head to receive materials at different rates, thereby increasing print speed without requiring a larger gantry system.
Solution Approach 2:
The invention transitions from traditional gantry-based X-Y plane movement to a system that incorporates Z-axis independence by allowing the print head to move vertically without being constrained by gantry height. The articulated arm mechanism enables the print head to reach positions that would be inaccessible to conventional gantry systems, effectively adding dimensional freedom to the printing process.
2Reliability
If OPC reacts quickly with water, then hardening occurs, but wet cement collapses under its own weight before hardening
Solution Approach 1:
The system prepares both Part A and Part B materials separately in controlled environments before mixing them at the print head. This preliminary separation and control of each component allows the materials to be optimally prepared for mixing, ensuring immediate and uniform reaction upon combination, which prevents collapse while maintaining rapid hardening.
Solution Approach 2:
The system introduces a controlled mixing zone at the print head that acts as an intermediary between the two separate material conduits. This intermediary mixing chamber ensures thorough and immediate mixing of Part A and Part B, creating a uniform reactive mixture that hardens consistently without collapsing, while the controlled environment manages the reaction timing.
3Productivity
If two-part cement chemistry is used, then fast cure in minutes is achieved, but exothermic nature and bulk form limitations prevent traditional construction methods
Solution Approach 1:
The invention replaces traditional mechanical mixing and pouring methods with a precision pump-based delivery system. The pump system controls the mixing ratio and flow rate of Part A and Part B, ensuring proper mixing without the need for manual mixing. This substitution of mechanical mixing with controlled pump delivery enables the use of fast-curing two-part chemistry in a 3D printing context, overcoming the limitations of bulk form construction methods.
4Productivity
If large gantry systems are deployed, then OPC can be printed, but accessibility to confined construction sites is restricted
Solution Approach 1:
The system replaces the rigid, fixed gantry structure with a dynamic, articulated arm mechanism that can adapt its configuration to various workspace geometries. The articulated arms can extend, retract, and reposition to access confined spaces, making the printing system versatile enough to operate in sites with limited accessibility while maintaining full printing capability.
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 construction of larger structures in confined spaces by mixing and depositing materials on demand, reducing the need for large gantry systems and enabling continuous printing with improved layer adhesion and structural integrity.
Implementation Method 1
a pump system in each of the plurality of hollow arms, wherein the pump system in each of the plurality of hollow arms is switchable to extrude or take in material
Implementation Method 2
a vessel disposed within the body for mixing materials prior to deposition
Implementation Method 3
Articulation of the hollow arms provides for mobility of the mobile autonomous printer
Data Source
AI summary
A mobile autonomous printer includes a body, a plurality of hollow arms extending outwardly from the body, a pump system in each of the plurality of hollow arms, wherein the pump system in each of the plurality of hollow arms is switchable to extrude or take in material, and a vessel disposed within the body for mixing materials prior to deposition. Articulation of the hollow arms provides for mobility of the mobile autonomous printer. A method of building a structure includes printing portions of the structure using a plurality of printers and embedding the plurality of printers into the structure. The printers embedded in the structure may function as a network of switchable pumps. Distinct conduits constructed into the structure supply chemically reacting constituents of the material that forms the structure.