Method for manufacturing a 3D printed construction element
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.
1 . A method for manufacturing a construction element, the method comprising:
operating, by a control unit, an extruder to extrude an outer layer the outer layer defining an enclosure;
operating, by the control unit, the extruder to extrude an inner matrix within the enclosure, the outer layer and the inner matrix formed by depositing successive layers using an additive manufacturing system and regulating by the control unit and during the depositing of the successive layers, predetermined characteristics of each layer of the construction element, defining the inner matrix by:
a first layup laid along a first direction and across the enclosure; and
a second layup laid juxtaposing the first layup, wherein, the first layup and the second layup define a plurality of air pockets in the inner matrix; and
operating, by the control unit, an injector to infuse a filler material into at least some of the plurality of air pockets, the filler material being different from a material of the outer layer and a material of the inner matrix, further comprising detecting, by a sensor module coupled to the extruder, one or more predetermined parameters of the construction element, and regulating, by the control unit, movement of the extruder based on signals corresponding to the detected parameters, and further comprising, upon detecting a protrusion or unevenness on a printed layer, engaging a flattening wheel to traverse the printed layer to restore flatness before resuming extrusion.
2 . The method according to claim 1 , further comprising defining one or more cavities in the inner matrix, the one or more cavities defined between the outer layer and one or more inner layers of the construction element.
3 . The method according to claim 2 , further comprising inserting an insert into the one or more cavities, and wherein the insert is made of an insulating material.
4 . The method of claim 1 , wherein regulating the predetermined characteristics comprises operating, by the control unit, a mechanism engageable with the extruder, the mechanism including a rotary element configured to traverse over each layer to alter surface characteristics.
5 . The method of claim 4 , wherein the rotary element is a herringbone gear configured to imprint a herringbone pattern on the surface of each layer to enhance interlayer bonding.
6 . The method of claim 4 , wherein the rotary element is a flattening wheel configured to flatten the surface of each layer.
7 . The method of claim 1 , wherein the construction element is configured such that the plurality of air pockets are adapted to facilitate circulation of warm or cold air for heating or cooling purposes.
8 . The method of claim 1 , wherein the first layup and the second layup crisscross each other at an angle in a range of 40 degrees to 50 degrees.
9 . The method of claim 1 , wherein the plurality of air pockets constitutes at least 50 percent of a volume of space within the enclosure.
10 . The method of claim 1 , wherein the filler material comprises at least one of a foam, a synthetic foam, compressed plastic waste, or compressed natural fibres.
11 . The method of claim 3 , wherein the insulating material of the insert comprises at least one of compressed plastic waste and compressed natural fibres.
12 . The method of claim 1 , wherein the predetermined characteristics comprise at least one of surface roughness, flatness, depth, height, width, uniformity, and shape.
13 . The method of claim 1 , further comprising introducing, by the control unit, a reinforcement member into at least one layer of the construction element during the depositing of the successive layers.
14 . The method of claim 13 , wherein the reinforcement member is a pin made from at least one of a metallic material or a polymeric material and is inserted into a layer at an angle of 75 degrees to 105 degrees relative to a surface of the layer.
15 . The method of claim 10 , wherein the compressed natural fibres include at least one of dried and milled palm trunk wood, dried palm leaves, date palm tree leaves, crushed date pit, and wood, and are compressed using binders including okra powder and water.