Photocurable 3D-Printed Building Panels for Structural Integrity
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Solution Overview
Problem
Current 3D printing technologies for building construction face challenges such as material limitations, particularly with concrete, which lacks thermal efficiency, requires manual reinforcement, and has long curing times, limiting the ability to create load-bearing walls and complex structures efficiently, and is restricted by the size of the printer, resulting in limited design flexibility and verticality.
Innovation Solution
The use of photocurable composite materials for 3D printing, which hardens under UV light, allowing for the creation of solid monolithic structures with improved compressive and tensile strength, enabling the production of 3D-printed integrated building panel systems that can form multi-story structures without traditional construction materials, incorporating load transfer components and connectors for enhanced structural performance and thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If concrete is used for 3D printing building structures, then structural mass and compressive strength are achieved, but thermal efficiency deteriorates and curing time increases
Solution Approach 1:
The patent changes the material parameter from traditional concrete to photopolymer composite material that cures through UV light exposure. This parameter change reduces curing time from days to minutes while maintaining structural strength, directly resolving the time-strength contradiction.
Solution Approach 2:
The invention uses composite materials (photopolymer resin with filler particles) that combine the benefits of rapid curing with structural integrity. The composite formulation enables both fast setting and adequate compressive strength, resolving the contradiction between speed and strength.
2Strength
If concrete is used for load-bearing walls, then structural integrity is achieved, but manual reinforcement is required increasing complexity
Solution Approach 1:
The patent replaces the mechanical reinforcement system (steel rebar embedded in concrete) with a monolithic photopolymer structure that achieves structural integrity through material properties and geometric design. This substitution eliminates the need for manual reinforcement installation, reducing complexity while maintaining strength.
Solution Approach 2:
The photopolymer material and printing process inherently provide structural integrity without requiring separate reinforcement steps. The material self-cures and self-supports during printing, eliminating the need for external reinforcement systems and manual intervention.
3Extent of automation
If on-site 3D printing is used, then construction automation is improved, but setup and calibration time increases
Solution Approach 1:
The patent employs preliminary action by pre-calibrating the printing system during manufacturing and pre-positioning support structures before printing begins. This preliminary preparation reduces on-site setup time and enables faster automation deployment, resolving the contradiction between automation benefit and setup overhead.
4Reliability
If traditional construction materials are used, then structural performance is achieved, but construction time and costs increase
Solution Approach 1:
The invention changes the fundamental material parameter from slow-curing concrete to rapid-curing photopolymer, reducing construction time from months to days while maintaining structural performance. This parameter change directly resolves the productivity-reliability contradiction.
Solution Approach 2:
The photopolymer printing process enables continuous deposition and curing without the interruptions required by concrete (curing waits, reinforcement installation stops). This continuous printing action dramatically increases productivity while maintaining structural integrity through uninterrupted layer bonding.
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 reduces construction time and costs, allows for the creation of complex geometries and multi-story structures, and meets performance requirements for structural integrity, thermal efficiency, and waterproofing, while eliminating the need for manual reinforcement and long curing times.
Implementation Method 1
The use of photocurable composite materials for 3D printing, which hardens under UV light
Data Source
AI summary
A 3D-printed integrated building panel system configured to form a portion of an overall building can include 3D-printed building panels, connectors, and one or more load transfer components. Each 3D-printed building panel can be formed by 3D printing technology using a photocurable composite material, and at least a portion of the 3D-printed building panels can be integrally formed. The connectors can be coupled to one or more of the 3D-printed building panels and can couple the 3D-printed building panels to each other and/or to one or more separate building components of the overall building. The load transfer component(s) can be coupled to at least a portion of the 3D-printed building panels and can transfer loads across the 3D-printed building panels. The load transfer component(s) can be configured to form at least a portion of an overall super structure for the overall building.