SYSTEM AND METHOD FOR 3D CONSTRUCTION PRINTING

• Main Authors: HAYES JACOBSON, Susan M, BATCHELDER, J. Samuel, CRUMP, S. Scott
• Format: Patent
• Language: English; French; German
• Published: 28.12.2022
• Subjects: ADDITIVE MANUFACTURING TECHNOLOGY; ADDITIVE MANUFACTURING, i.e. MANUFACTURING OFTHREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVEAGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING,STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING; BRAIDING; BUILDING; BUILDING IMPLEMENTS OR OTHER BUILDING AIDS, OR THEIRUSE; CEILINGS; FIXED CONSTRUCTIONS; FLOORS; FORMS; GENERAL BUILDING CONSTRUCTIONS; HANDLING BUILDING MATERIALS ON THE SITE; INSULATION OR OTHER PROTECTION OF BUILDINGS; KNITTING; LACE-MAKING; NON-WOVEN FABRICS; PERFORMING OPERATIONS; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTINGBUILDINGS; ROOFS; SCAFFOLDING; SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURESCONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR; SHAPING OR JOINING OF PLASTICS; SHUTTERING; TEXTILES; TRANSPORTING; TRIMMINGS; WALLS, e.g. PARTITIONS; WORKING CEMENT, CLAY, OR STONE; WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL

A large-scale additive manufacturing system for printing a structure includes an extrusion system and a knitting system. The extrusion system includes a nozzle configured to receive a supply of structural material and to selectively dispense the structural material in flowable form, and a first gantry configured to move the nozzle along toolpaths defined according to a structure to be printed such that structural material may be dispensed along the toolpaths to print a series of structural layers, wherein the series of structural layers bond together to form all or a portion of the structure. The knitting system includes a tow feeder configured to feed a supply of tow material to a location proximate a current course of loops extending above an upper surface of a current structural layer or extending above a base surface in regions where no structural layer has been printed, and a hooking device configured to engage the tow material and bring it through the current course of loops to form a subsequent course of loops interwoven with the current course of loops. A controller is configured to operate the knitting system to form additional subsequent courses of loops each interwoven with a current course of loops after each of the series of structural layers are printed, wherein the interwoven courses of loops create a reinforcement network of knitted loops embedded in the structure, and wherein the series of structural layers are tied together.