Modular Formwork System with Additive Manufactured Plastic Molds
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Solution Overview
Problem
Existing formwork systems for concrete production are limited in achieving complex textures and undercuts, are expensive, and lack design flexibility, with known methods struggling to efficiently release molds and achieve desired surface details.
Innovation Solution
A modular formwork system using layer-wise hardened plastics for molds, which can be assembled with adjustable strengths and textures, featuring recyclable and water-soluble components for easy separation and reuse, along with additive manufacturing techniques like FDM or FFF for high-resolution surface accuracy and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If structural formwork made of flexible plastic is used to imprint undercuts on the wall, then design freedom and texture complexity are improved, but the strength and reusability of the formwork are reduced
Solution Approach 1:
The formwork is divided into a reusable base carrier (made of strong materials like aluminum or wood) and a detachable printed plastic component (made of flexible plastic). This segmentation allows the strong base carrier to provide structural strength while the flexible plastic component enables design freedom for undercuts and complex textures.
Solution Approach 2:
The formwork combines two different materials with complementary properties: a strong, rigid base carrier material (aluminum, wood, or plastic) and a flexible, form-giving plastic material. This composite structure resolves the contradiction by having each material perform its optimal function.
2Manufacturing precision
If individual forms are made with high-resolution surface details for complex textures, then surface accuracy is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The high-resolution surface component is made as a detachable, relatively simple plastic part that can be printed using additive manufacturing. This component is designed to be replaced rather than the entire formwork system, making high precision more affordable and less complex.
Solution Approach 2:
The invention changes the manufacturing parameter from traditional high-cost precision molding to additive manufacturing (3D printing), which can achieve high surface accuracy at lower cost and complexity for complex geometries like undercuts and textures.
3Strength
If traditional rigid plastic formwork is used, then formwork strength is improved, but ease of mold release and design flexibility are reduced
Solution Approach 1:
The formwork is segmented into a strong base carrier and a detachable flexible plastic component. The flexible plastic component can be easily removed from the hardened concrete, solving the mold release problem while the base carrier maintains structural strength.
Solution Approach 2:
The formwork uses a flexible plastic component (shell) that can deform during concrete pouring and ease of release after hardening. This flexible shell approach allows easy mold release while the rigid base carrier provides necessary strength.
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
Enables the creation of complex textures and undercuts at a lower cost, with improved ease of mold release and recyclability, allowing for greater design freedom and efficient concrete production while maintaining structural integrity.
Implementation Method 1
This type of plastic is primarily manufactured using additive manufacturing, specifically Fused Deposition Modeling (FDM) or, better yet, Fused Filament Fabrication (FFF).
Implementation Method 2
the shaping surface of the individual molds facing the concrete is made at least partially, i.e., section by section and/or with respect to certain components of the surface, from a water-soluble plastic
Data Source
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AI summary
The invention relates to a modular formwork system (1) for producing concrete elements (20), consisting of a plurality of individual moulds (2), said individual moulds (2) being produced at least on the surface (3) which faces the concrete, which is made of a plastic (4) that is cured layer by layer. The invention also relates to a method for producing the formwork system, and to a washer device for washing same.