3D-Printed Wall Blocks With Integrated Installation Channels

Solution Overview

Problem

Conventional construction methods for buildings, particularly small or medium-sized structures, are labor-intensive, time-consuming, and generate unnecessary dust, debris, and noise due to the installation of cable ducts and pipe coverings, with inefficient resource utilization.

Innovation Solution

An additive manufacturing process for constructing walls using multifunctional building blocks that incorporate installation channels, allowing for the integration of service ducts and infrastructure during the design phase, reducing the need for post-construction modifications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional construction methods are used to build walls and install infrastructure separately, then structural stability is achieved, but labor intensity and construction time increase significantly

Engineering Contradiction:

Improveconstruction efficiencyVSAvoidlabor intensity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent combines wall construction and infrastructure installation into a single integrated process. Building blocks are manufactured with pre-formed installation channels that accommodate cables, pipes, and conduits during the additive manufacturing process itself, eliminating the need for separate post-construction installation work and significantly improving construction efficiency while reducing labor intensity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The installation channels are prepared in advance during the manufacturing of building blocks before the wall is constructed. This preliminary action allows infrastructure elements to be seamlessly integrated into the wall structure during assembly, rather than requiring time-consuming modifications after the wall is built

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If cable ducts and pipe coverings are installed after wall construction, then structural integrity is maintained, but dust, debris, and noise are generated

Engineering Contradiction:

Improveconstruction pollutionVSAvoidresource efficiency

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The installation channels are prepared in advance during the manufacturing of building blocks before the wall is constructed. This preliminary action allows infrastructure elements to be seamlessly integrated into the wall structure during assembly, rather than requiring time-consuming modifications after the wall is built

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent combines wall construction and infrastructure installation into a single integrated process. Building blocks are manufactured with pre-formed installation channels that accommodate cables, pipes, and conduits during the additive manufacturing process itself, eliminating the need for separate post-construction installation work and significantly improving construction efficiency while reducing labor intensity

Inventive Principle:

Principle #5Merging (Combining)

3Loss of substance

If installation channels are created by milling into finished walls, then structural stability is preserved, but material resources are wasted

Engineering Contradiction:

Improvematerial wasteVSAvoidinstallation precision

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The installation channels are prepared in advance during the manufacturing of building blocks before the wall is constructed. This preliminary action allows infrastructure elements to be seamlessly integrated into the wall structure during assembly, rather than requiring time-consuming modifications after the wall is built

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent combines wall construction and infrastructure installation into a single integrated process. Building blocks are manufactured with pre-formed installation channels that accommodate cables, pipes, and conduits during the additive manufacturing process itself, eliminating the need for separate post-construction installation work and significantly improving construction efficiency while reducing labor intensity

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4703107A2Method for producing a wall, construction element for constructing a wall, construction element set, and building blank

Publication Date: 2026.03.04 BAM BUNDESANSTALT FUER MATERIALFORSCHUNG UND

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AI summary

Method (1000) for manufacturing a wall (200, 300, 3000a), comprising: computer-aided design (1010) of the wall (200, 300, 300a), wherein the wall (200, 300, 300a) has an installation channel (1); computer-aided disassembly (1020) of the constructed wall (200, 300, 300a) into building elements (100, 110, 120, 130, 140, 150, 160), wherein a plurality of adjacent building elements (100, 110, 120, 130, 140, 150, 160) comprise at least one section of the installation channel (1); Computer-aided creation (1030) of a control data set for controlling an additive manufacturing device (500) configured to individually provide the plurality of components (100, 110, 120, 130, 140, 150, 160) from at least one building material; additive manufacturing (1040) of the plurality of components (100, 110, 120, 130, 140, 150, 160) for the wall (200, 300, 300a) using the additive manufacturing device (500) with the control data set;and typically erecting the wall (1100) by an orderly joining of the multitude of manufactured building elements (100, 110, 120, 130, 140, 150, 160) comprising forming a bond (200, 300, 300a) of the building elements 100, 110, 120, 130, 140, 150, 160).;