3D printed construction element and a system, a method for manufacturing the 3D printed construction element

Patent metadata

Field	Value
Publication number	US-12331518-B1
Application number	US-202418800579-A
Country	US
Kind code	B1
Filing date	Aug 12, 2024
Priority date	Aug 12, 2024
Publication date	Jun 17, 2025
Grant date	Jun 17, 2025

Abstract

The present disclosure is directed to a construction element produced by additive manufacturing, an additive manufacturing system for producing the construction element and a method for manufacturing the construction element. The construction element includes an outer layer. The outer layer is configured to define or form an enclosure. The construction element further includes an inner matrix. The inner matrix is formed within the enclosure. The outer layer and the inner matrix are formed integrally, by depositing successive layers using an additive manufacturing system. The inner matrix is defined by a first layup and a second layup. The first layup is laid along a first direction and across the enclosure. The second layup is laid juxtaposing the first layup. The first layup and the second layup define a plurality of air pockets in the inner matrix. Further, a filler material is infused into at least some air pockets of the plurality of air pockets.

First claim

The invention claimed is:

1. An additive manufacturing system for producing a construction element, the system comprising:
an extruder configured to extrude material layer-by-layer for producing the construction element;
a sensor module connectable to the extruder, the sensor module being configured to detect one or more predetermined parameters of the construction element;
a mechanism engageable with the extruder, the mechanism configured to introduce reinforcement into the construction element and adapted to regulate predetermined characteristics of each layer of the construction element; and
a control unit communicatively coupled to the extruder, the sensor module and the mechanism, the control unit configured to:
regulate movement of the extruder, based on signals corresponding to the one or more predetermined parameters received from the sensor module; and
operate the mechanism, selectively, to regulate introduction of reinforcement into the construction element and to regulate one or more of the predetermined characteristics of the construction element, and
wherein the mechanism comprises an injector configured to infuse a filler material into at least some air pockets of a plurality of air pockets defined in the construction element.

2. The additive manufacturing system according to claim 1 , wherein the mechanism comprises:
a spool unit configured to selectively introduce a reinforcement member into the construction element; and
a swing arm coupled to the spool unit, the swing arm being configured to swing relative to at least one of the extruder and the spool unit, the swing arm comprises:
a first rotary element, a second rotary element, and an actuator,
wherein, the swing arm is configured to selectively engage one of the first rotary element or the second rotary element with layers of the construction element, to regulate the predetermined characteristics of the construction element.

3. The additive manufacturing system according to claim 2 , wherein the control unit is configured to operate the mechanism by:
operating the spool unit to introduce the reinforcement member into a layer of the construction element; and
operating the actuator associated with the swing arm to selectively engage one of the first rotary element or the second rotary element with the layer of the construction element, wherein operation of the spool unit and the swing arm is configured to regulate the predetermined characteristics of each layer of the construction element.

4. The additive manufacturing system according to claim 2 , wherein the first rotary element, upon engagement with each layer of the construction element, is configured to traverse over each layer to alter characteristics of a surface each layer.

5. The additive manufacturing system according to claim 4 , wherein the first rotary element is a herringbone gear, and wherein the first rotary element upon traversing over each layer of the construction element, imprints herringbone pattern on the surface of each layer.

6. The additive manufacturing system according to claim 2 , wherein the second rotary element is a flattening wheel, and wherein the second rotary element upon traversing over each layer of the construction element, flattens a surface of each layer.

7. The additive manufacturing system according to 1 , wherein the predetermined characteristics comprise surface roughness, flatness, depth, height, width, uniformity, or shape of layers being formed during discharging of the material from the extruder.

Assignees

• Univ United Arab Emirates

Inventors

• Ahmed Waleed
• Al Marzouqi Ali
• Zaneldin Essam
• Almazrouei Noura
• Elhassan Amged
• Aziz Muthanna

Classifications

• B28B13/0295

  Treating the surface of the fed layer, e.g. removing material or equalization of the surface · CPC title

• B28B17/0072

  Product control or inspection · CPC title

• B28B23/0062

  forcing the elements into the cast material, e.g. hooks into cast concrete · CPC title

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title