Additive manufacturing of buildings and other structures
First Claim
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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.
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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.
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Citations
42 Claims
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1. A process for fabricating a structure, the process comprising:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 40)
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7. A process for fabricating a structure, the process comprising:
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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. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A process for fabricating a structure, the process comprising:
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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. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 41)
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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:
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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. - View Dependent Claims (42)
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Specification