Method for Casting a Construction Element

Abstract

The present invention relates to a method for casting building material to form a construction element using a computer-controlled apparatus. The method comprises the steps of: moving the material deposition head and selectively depositing material, to fabricate a formwork; pouring building material in contact with at least a portion of the formwork; at least partially curing the building material, thereby forming the construction element; and removing at least a portion of the formwork from the construction element.

1 . A method for casting building material to form a construction element using a computer-controlled apparatus, the apparatus having a material deposition head in communication with a reservoir of formwork material and being movable within a build volume responsive to computer instructions, the method comprising the steps of:
 receiving, by the apparatus, computer instructions relating to a form work geometry;   moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a formwork corresponding with the formwork geometry;   pouring building material in contact with at least a portion of the formwork;   at least partially curing the building material in contact with the formwork, thereby forming the construction element; and   removing at least a portion of the formwork from the construction element.   
     
     
         2 . A method for casting building material to form a construction element according to  claim 1 , wherein the step of removing the formwork comprises heating the construction element and the formwork to a temperature above the melting point of the formwork material, thereby melting the at least a portion of the formwork. 
     
     
         3 . A method for casting building material to form a construction element according to  claim 2 , comprising the further step of collecting and recirculating the melted formwork material to the reservoir. 
     
     
         4 . A method for casting building material to form a construction element according to  claim 2 , wherein the temperature is less than 70° C. 
     
     
         5 . A method for casting building material to form a construction element according to  claim 2 , wherein the formwork material is a wax compound. 
     
     
         6 . A method for casting building material to form a construction element according to  claim 1 , wherein the step of removing the formwork comprises spraying the formwork with a liquid, thereby dissolving the at least a portion of the formwork. 
     
     
         7 . A method for casting building material to form a construction element according to  claim 1 , wherein the step of removing the formwork comprises at least partially submerging the construction element and the at least a portion of the formwork in a liquid, thereby dissolving the at least a portion of the formwork. 
     
     
         8 . A method for casting building material to form a construction element according to  claim 1 , further comprising the step of selectively applying one or more materials to affect a surface finish of the construction element to the formwork, in specific locations. 
     
     
         9 . A method for casting building material to form a construction element according to  claim 8 , wherein the material used to affect the surface finish of the construction element is at least one of an acid, a pigment, paint, or masking. 
     
     
         10 . A method for casting building material to form a construction element according to  claim 1 , further comprising the steps of:
 before pouring the building material, selectively applying a retarder to the formwork, in specific locations; and   after the at least a portion of the formwork is removed from the construction element, removing uncured building material from the construction element by mechanical means.   
     
     
         11 . A method for casting building material to form a construction element according to  claim 1 , wherein the apparatus further has a milling head movable within the build volume responsive to computer instructions, and the method further comprises the step of, before pouring the building material, selectively milling, by the apparatus, the formwork in specific locations. 
     
     
         12 . A method for casting building material to form a construction element according to  claim 1 , wherein the step of moving the material deposition head to fabricate the formwork comprises the further substep of moving the material deposition head to fabricate a scaffold structure at least partially enclosed by a shell, the scaffold structure and shell thereby forming the formwork. 
     
     
         13 . A method for casting building material to form a construction element according to  claim 12 , wherein the scaffold structure comprises a network of interconnected braces. 
     
     
         14 . A method for casting building material to form a construction element according to  claim 12 , wherein the scaffold structure defines at least one conduit, allowing a fluid to pass through the formwork. 
     
     
         15 . A method for casting building material to form a construction element according to  claim 1 , wherein the step of moving the material deposition head to fabricate the formwork, comprises the further substep of selectively heating or cooling at least a portion of the build volume. 
     
     
         16 . A method for casting building material to form a construction element according to  claim 1 , further comprising the step of:
 before pouring the building material, selectively applying one or more portions of composite material to the formwork, in specific locations;   thereby after the at least a portion of the formwork is removed from the construction element, the one or more portions of composite material are secured to the construction element.   
     
     
         17 . A method for casting building material to form a construction element according to  claim 16 , further comprising the step of:
 after selectively applying one or more portions of composite material selectively to the formwork, at least partially curing the one or more layers of composite material.   
     
     
         18 . A method for casting building material to form a construction element using a computer-controlled apparatus, the apparatus having a material deposition head in communication with a reservoir of formwork material and being movable within a build volume responsive to computer instructions, the method comprising the steps of:
 receiving, by the apparatus, computer instructions relating to a first form work geometry;   moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a first formwork corresponding with the formwork geometry;   selectively applying one or more portions of composite material to the first formwork, in specific locations, to form a homogenous layer of composite material;   curing the layer of composite material to form a composite element;   removing the first formwork from the composite element;   pouring a first building material in contact with at least a portion of the composite element; and   curing the first building material in contact with the composite element, thereby forming a first construction element.   
     
     
         19 . A method for casting building material to form a construction element according to  claim 18  comprising the further steps of:
 arranging a second formwork proximal to the first construction element; 
 pouring a second building material in contact with at least a portion of the first construction element and the second formwork; 
 curing the second building material in contact with the first construction element and the second formwork, thereby forming a second construction element joined to the first construction element; and 
 removing the second formwork from both construction elements. 
 
     
     
         20 . A method for casting building material to form a construction element according to  claim 19 , wherein the first and second building materials have a substantially identical composition. 
     
     
         21 . A method for casting building material to form a construction element according to  claim 16  wherein the one or more portions of composite material are selectively applied to the formwork by a computer-controlled composite lay-up head movable responsive to computer instructions. 
     
     
         22 . A method for casting building material to form a construction element according to  claim 16  wherein the composite material is a preimpregnated tape. 
     
     
         23 . A method for casting building material to form a construction element using a computer-controlled apparatus, the apparatus having a material deposition head in communication with a reservoir of formwork material and being movable within a build volume responsive to computer instructions, the method comprising the steps of:
 receiving, by the apparatus, computer instructions relating to a first formwork geometry;   moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a first formwork corresponding with the first formwork geometry;   selectively applying one or more portions of composite material to the first formwork, in specific locations;   curing the one or more portions of composite material to form one or more first composite elements;   receiving, by the apparatus, computer instructions relating to a second formwork geometry;   moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a second formwork corresponding with the second formwork geometry, the second formwork at least partially in contact with the first formwork or the one or more first composite elements;   selectively applying one or more portions of composite material to the second formwork, in specific locations;   curing the one or more portions of composite material to form one or more second composite elements;   pouring building material in contact with at least a portion of the first and second formworks;   curing the building material in contact with the first and second formworks, thereby forming a construction element; and   removing the first and second formworks from the construction element.   
     
     
         24 . A method for casting building material to form a construction element according to  claim 18  wherein the one or more portions of composite material are selectively applied to the formwork by a computer-controlled composite lay-up head movable responsive to computer instructions. 
     
     
         25 . A method for casting building material to form a construction element according to  claim 18  wherein the composite material is a preimpregnated tape.