Monolithic Construction 3D Printing With Continuous Material Flow
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Solution Overview
Problem
Conventional construction 3D printing systems are limited to printing discrete elements of structures with interruptions between steps, leading to weak points and inefficiencies, such as cold joints and material inconsistencies, which affect the structural integrity and require additional materials and labor.
Innovation Solution
A continuous 3D printing process using a construction system with a volumetric mixer, pump, and various subsystems for extrusion, rebar, insulation, and plastic printing, allowing for uninterrupted construction of monolithic structures with on-the-spot batching and localized material control, reducing the need for traditional forms and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional construction 3D printing systems print discrete elements with interruptions between steps, then the system can complete construction tasks using standard discrete printing methods, but the structural integrity deteriorates due to cold joints and material inconsistencies
Solution Approach 1:
The patent implements continuous 3D printing operation without interruptions between discrete elements. The system maintains continuous material flow from the volumetric mixer through the extrusion nozzle, printing foundation walls, floor slabs, and upper structures in an unbroken sequence. This eliminates cold joints and material inconsistencies that would otherwise compromise structural integrity, while the single continuous print operation actually improves overall construction efficiency compared to multiple discrete printing steps.
2Stability of the object's composition
If conventional systems use discrete printing elements, then the printing process can be divided into separate steps, but material consistency deteriorates leading to weak points in the structure
Solution Approach 1:
The patent employs a single volumetric mixer that serves multiple functions throughout the entire construction process. This mixer continuously produces building material for all structural elements including foundation walls, floor slabs, and upper stories, maintaining uniform material composition throughout. The multi-functional mixer eliminates the need for multiple specialized mixing systems, thereby ensuring material consistency while actually reducing overall system complexity compared to coordinating multiple discrete printing operations.
3Loss of substance
If traditional forms and materials are used in construction, then the construction process follows conventional methods, but material waste increases and structural efficiency decreases
Solution Approach 1:
The continuous 3D printing process eliminates the need for traditional construction forms (molds, templates, and support structures). Material is deposited directly in its final configuration through continuous extrusion, removing the requirement for formwork that would otherwise be discarded after concrete pouring. This direct digital fabrication approach significantly reduces material waste while maintaining construction simplicity through automated layer-by-layer deposition.
Solution Approach 2:
The system recovers and reuses excess building material through the continuous volumetric mixing process. The mixer maintains optimal material consistency by continuously circulating and re-mixing material that may have begun to set, ensuring no material is wasted due to inconsistency or improper mixing. This closed-loop material management reduces waste compared to batch mixing methods where material must be discarded if consistency is compromised.
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
The method enables the production of stronger, more efficient, and cost-effective monolithic structures with reduced waste and material inconsistencies, enhancing structural integrity and energy efficiency while minimizing supply chain issues and labor requirements.
Implementation Method 1
a volumetric mixer fluidly connectable to a source of powder material and a source of water, the volumetric mixer configured to combine the powder material and water to produce a building material
Implementation Method 2
a pump configured to pump the building material through a material hose
Implementation Method 3
a first extruder subsystem comprising a material pipe fluidly connectable to the material hose and an extruder having a puck positioned on a distal end
Data Source
AI summary
A construction 3D printing system is provided. The construction 3D printing system includes at least one frame having tracks and an x-axis carriage having a front plate, a volumetric mixer fluidly connectable to a source of powder material and a source of water, the volumetric mixer configured to combine the powder material and water to produce a building material, a pump configured to pump the building material through a material hose, and at least two subsystems. The subsystems may be extruder subsystems, rebar subsystems, insulation subsystems, or plastic 3D printing subsystems. Methods of constructing a 3D printed structure are also provided.