Additive manufacturing of buildings and other structures

• US 10,695,973 B2
• Filed: 03/21/2019
• Issued: 06/30/2020
• Est. Priority Date: 10/30/2013
• Status: Active Grant

• Current Assignee: Branch Technology, Inc.
• Original Assignee: Branch Technology, Inc.
• Inventors: Boyd, IV, R. Platt
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US16/360,237
• Publication Number:
  US 20190217527A1
• Time in Patent Office: 467 Days
• Field of Search: 264 31, 264 34, 264 35, 264 401, 264 406, 264 407, 264255, 264256, 264308
• CPC Class Codes: B23K 2101/02 Honeycomb structures
• CPC Class Codes: B23K 2101/045 Hollow panels
• CPC Class Codes: B23K 26/00 Working by laser beam, e.g. welding, cutting or boring
• CPC Class Codes: B25J 11/00 Manipulators not otherwise provided for
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B28B 1/008 made from two or more materials having different characteristics or properties casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00
• CPC Class Codes: B28B 11/001 Applying decorations on shaped articles, e.g. by painting
• CPC Class Codes: B28B 17/0081 Process control
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 67/00 Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29D 99/0017 with filled hollow ridges
• CPC Class Codes: B29D 99/0021 provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
• CPC Class Codes: B29D 99/0089 Producing honeycomb structures consisting of porous ceramic ware C04B38/0006
• CPC Class Codes: B29L 2031/60 : Multitubular or multicompartmented articles, e.g. honeycomb
• CPC Class Codes: B29L 2031/601 : Multi-tubular articles, i.e. composed of a plurality of tubes hollow-walled B29L2024/00
• CPC Class Codes: B29L 2031/602 : composed of several elementary tubular elements
• CPC Class Codes: B29L 2031/608 : Honeycomb structures
• CPC Class Codes: B29L 2031/776 : Walls, e.g. building panels
• CPC Class Codes: B32B 1/00 : Layered products having a non-planar shape
• CPC Class Codes: B32B 13/00 : Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
• CPC Class Codes: B32B 2262/02 : Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/101 : Glass fibres
• CPC Class Codes: B32B 2262/105 : Ceramic fibres
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/304 : Insulating
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/00 : Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: B63B 71/00 : Designing vessels; Predicting their performance
• CPC Class Codes: E04B 1/3505 : characterised by the in situ moulding of large parts of a structure E04B1/3511, E04B1/3516, E04B1/3522, E04B1/3533, E04B1/3544, E04B1/355 take precedence
• CPC Class Codes: E04C 5/07 : Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal metal elements with non-structural coatings E04C5/01
• CPC Class Codes: E04G 21/0418 : with distribution hose
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like

Abstract

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create “scaffolding” or “skeletons” of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

Claims

1. A process for fabricating a structure, the process comprising:

extruding a three-dimensional cellular matrix using a multi-axis extrusion system;

the multi-axis extrusion system comprising an extruder head and a multi-axis movement device configured to move the extruder head along at least one multi-directional, three-dimensional sequential pathway while extruding a plurality of segments of the matrix and sequentially joining at least some of the segments to one another at a plurality of joints with the segments being self-supporting between the joints during extrusion;

wherein the multi-axis extrusion system extrudes the plurality of segments and forms the plurality of joints into a space frame configuration for the cellular matrix comprising at least one of a plurality of hexahedron cells and a plurality of tetrahedron cells;

wherein the at least one pathway defines an additive process in which segments of the cellular matrix are extruded to connect to previously extruded segments of the cellular matrix.

2. The process of claim 1, wherein the multi-axis extrusion system extrudes at least one of a thermoplastic or thermoset plastic material.

3. The process of claim 2, wherein the extruded thermoplastic or thermoset plastic material further comprises fiber reinforcements.

4. The process of claim 1, wherein the multi-axis extrusion system locates some of the joints in an interior portion of the cellular matrix.

5. The process of claim 4, wherein at least some of the joints located in the interior portion of the cellular matrix are located at intersections of at least three extruded segments extending from the joint in at least three different directions.

6. The process of claim 1, wherein the multi-axis extrusion system extrudes the plurality of segments and forms the plurality of joints into a space frame configuration for the cellular matrix comprising hexahedron cells that include extruded segments extending diagonally between two non-adjacent joints of a side of the hexahedron cell.

40. The process of claim 1, wherein the extrusion system extrudes some of the segments along parts of the pathway that are non-horizontal.

7. A process for fabricating a structure, the process comprising:

extruding a three-dimensional cellular matrix using a multi-axis extrusion system;

the multi-axis extrusion system comprising an extruder head and a multi-axis robotic arm configured to move the extruder head along at least one multi-directional, three-dimensional sequential pathway while extruding a plurality of segments of the matrix and sequentially joining at least some of the segments to one another at a plurality of joints;

wherein the multi-axis extrusion system extrudes the plurality of segments and forms the plurality of joints in a space frame configuration for the cellular matrix;

wherein the at least one pathway defines an additive process in which segments of the cellular matrix are extruded to connect to previously extruded segments of the cellular matrix;

wherein the extruded segments are self-supporting between joints during the fabrication process.

8. The process of claim 7, wherein the multi-axis extrusion system extrudes a three-dimensional cellular matrix comprising a plurality of cells that are not uniform in geometry throughout the entire cellular matrix.

9. The process of claim 8, wherein the multi-axis extrusion system forms cells in a first region of the matrix with a first geometry and forms cells in a second region of the matrix with a second geometry that is different from the first geometry.

10. The process of claim 9, wherein the first region is configured to withstand a higher stress than the second region.

11. The process of claim 7, further comprising introducing a filler material into at least a portion of the cellular matrix.

12. The process of claim 11, further comprising covering an outer face of the cellular matrix with a finish layer.

13. The process of claim 12, further comprising attaching decorative elements to the structure.

14. The process of claim 7, wherein the cellular matrix is self-supporting during the extrusion process.

15. The process of claim 7, further comprising introducing a first type of filler material into one portion of the cellular matrix and introducing a second type of filler material into another portion of the cellular matrix, the first and second types of filler material being different materials.

16. The process of claim 7, wherein the multi-axis extrusion system further comprises at least one controller configured to control the movement of the extruder head along the at least one sequential pathway.

17. The process of claim 16, wherein the at least one sequential pathway is derived from acellular matrix pattern applied to a design for the structure to be fabricated.

18. The process of claim 17, wherein the cellular matrix pattern at least partially fills a three-dimensional geometry of the design for the structure to be fabricated.

19. The process of claim 16, wherein the at least one pathway is a plurality of sequential pathways.

20. The process of claim 16, wherein the controller changes at least one operational parameter during extrusion of the plurality of segments.

21. The process of claim 20, wherein the at least one operational parameter comprises at least one of a motion speed parameter, an extrusion speed parameter, an extrusion temperature parameter, and a coolant flow parameter.

22. The process of claim 21, wherein the controller changes the at least one operational parameter based on a pre-programmed change.

23. The process of claim 21, wherein the controller changes the at least one operational parameter in response to a sensed condition of a portion of the extruded three-dimensional cellular matrix.

24. The process of claim 20, wherein the controller is configured to adjust a solidity characteristic of material extruded by the extruder head during extrusion of the plurality of segments.

25. The process of claim 7, wherein the multi-axis extrusion system extrudes the plurality of segments and forms the plurality of joints into a space frame configuration for the cellular matrix comprising at least one of a plurality of hexahedron cells and a plurality of tetrahedron cells.

26. The process of claim 25, wherein the multi-axis extrusion system extrudes the plurality of segments and forms the plurality of joints into a space frame configuration for the cellular matrix comprising hexahedron cells that include extruded segments extending diagonally between two non-adjacent joints of a side of the hexahedron cell.

27. A process for fabricating a structure, the process comprising:

extruding a three-dimensional cellular matrix using a multi-axis extrusion system;

the multi-axis extrusion system comprising;

(i) an extruder head, (ii) a multi-axis movement device configured to move the extruder head along at least one multi-directional, three-dimensional pathway to extrude a plurality of segments of the matrix and join at least some of the segments to one another at a plurality of joints, with the extruded segments being self-supporting between the joints, and (iii) at least one controller configured to control the extruder head and the multi-axis movement device;

wherein, during extrusion of the three-dimensional cellular matrix, the controller receives feedback on a condition of a portion of the cellular matrix and adjusts one or more parameters of at least one of the extruder head and the multi-axis movement device in response to the feedback.

28. The process of claim 27, wherein, during extrusion of the three-dimensional cellular matrix, the controller receives feedback from at least one sensor on a condition of at least one joint of the cellular matrix.

29. The process of claim 27, wherein, during extrusion of the three-dimensional cellular matrix, the controller receives feedback on an actual condition of the portion of the cellular matrix relative to a designed condition of the portion of the cellular matrix.

30. The process of claim 27, wherein the controller is configured to adjust at least one of an extrusion speed and a coolant flow in response to the feedback.

31. The process of claim 27, wherein the controller is configured to adjust a solidity characteristic of material extruded by the extruder head in response to the feedback.

32. The process of claim 27, wherein the extruder head heats a material prior to extrusion, wherein the process further comprises flowing a coolant at least partially along a pathway of the heated material.

33. The process of claim 32, wherein at least a portion of the coolant flow along the pathway of the heated material is within an extrusion nozzle of the extruder head.

34. The process of claim 33, wherein the coolant also flows along the heated material after extrusion from the nozzle.

35. The process of claim 34, wherein the coolant flow outside of the nozzle is aligned with an extrusion direction of the heated material.

36. The process of claim 34, wherein the coolant flow outside of the nozzle is parallel to an extrusion direction of the heated material.

37. The process of claim 32, wherein flowing the coolant comprises flowing the coolant along a recirculating pathway.

38. The process of claim 32, wherein flowing the coolant comprises flowing the coolant along a non-recirculating pathway.

41. The process of claim 27, wherein the extrusion system extrudes some of the segments along parts of the pathway that are non-horizontal.

39. A process for frabricating a cellular matrix, the matrix comprising a plurality of cells, the cells comprising segments connected at joints, the joints located at corners of the cells, some of the joints located in an interior area of the cellular matrix, the process using an extruder nozzle mounted on a multi-axis robotic armature, the process comprising:

using the multi-axis robotic armature, moving the extruder nozzle along a sequential pathway while extruding the segments of the cellular matrix such that during fabrication the extruded segments of the cellular matrix are self-supporting between the joints;

wherein the process extrudes the plurality of segments and forms the plurality of joints into a space frame configuration for the cellular matrix comprising at leat one of a plurality of hexahedron cells and a plurality of tetrehedron cells.

42. The proces of claim 39, wherein the extruder nozzle extrudes some of the segments along parts of the pathway that are non-horizontal.