[0001] This application claims the benefit of U.S. Provisional Application No. 63/325,488, filed March 30, 2022, and entitled SYSTEM AND METHOD FOR THE 3- DIMENSIONAL PRINTING OF STRUCTURES.

BACKGROUND

[0002] This disclosure, and the exemplary embodiments described herein, describe methods and systems for 3-dimensional printing technologies and more specifically to the 3-dimensional printing of structures. However, it is to be understood that the scope of this disclosure is not limited to such application.

[0003] 3-dimensional (3D) printing, or additive manufacturing, is the construction of a 3D object from a computer-aided design (CAD) or another 3D model. 3D printing may apply to various processes wherein material is deposited, joined, or solidified under computer control to create the 3D object. In general, 3D printable models are created using CAD programs, via a 3D scanner, or using photogrammetry software. Once a suitable file type (such as an STL file) is generated, the file is processed by a slice which converts the models into a series of thin layers. These layers become individual steps in the additive manufacturing printing process.

[0004] Traditionally, 3D printing used polymers for printing. However, methods have been developed which allow for the utilization of metals, ceramics, and other materials. The primary differences between the various known processes are in the way layers are deposited and in the materials that are used. 3D printing has many applications in the manufacturing and medical industries.

BRIEF DESCRIPTION

[0005] This summary is provided to introduce a variety of concepts in a simplified form that is disclosed further in the detailed description of the embodiments. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter. [0006] Embodiments described herein relate to a 3D-printed structure, including a structure comprising a plurality of sides including: a bottom, a top, a left side and a right side, each constructed using a 3D printing process. According to an exemplary embodiment of this disclosure, the structure is monolithically 3D printed by an additive process which results in a structure resting on a platform and oriented with the top as the most upper surface. The completed structure is then rotated onto the bottom external surface to provide a properly oriented structure. A front side/wall and rear side/wall, which are not 3D printed, are constructed and/or added using various construction techniques which attach the front and rear sides to the 3D printed structure. Some of the features associated with the front and rear sides may include, but are not limited to, windows, doors, electrical fixtures, etc.

[0007] The embodiments disclosed, and variants thereof, provide an efficient and cost-effective means of producing a habitable structure using, in some embodiments, recycled polymers, i.e. recycled plastic. The structure can be 3D-printed at a remote location and shipped to the consumer while reducing the amount of on-site fabrication, preparation, and labor.

[0008] In accordance with one exemplary embodiment of the present disclosure, disclosed is a 3D-printed structure comprising: a structure comprising a plurality of sides including a bottom, a top, a left wall and a right wall each constructed using a 3D printing process, wherein the 3D printing process additively deposits material in a continuous bead to generate the plurality of sides by 1 ) initially depositing the material to form a monolithic and continuous rear end surface associated with each of the bottom, the top, the left wall and the right wall and thereafter 2) the 3D printing process additively depositing material in a continuous bead to build up the initially deposited material to further construct the bottom, the top, the left wall and the right wall to complete the 3-D printing of the structure, the 3-D printing process finally depositing the material to form a monolithic and continuous front end surface associated with each of the bottom, the top, the left wall and the right wall, wherein the 3-D printed structure is rotated to rest on the bottom upon completion of the 3D printing process.

[0009] In accordance with another exemplary embodiment of the present disclosure, disclosed is a method of constructing a 3D-printed structure including a plurality of sides including a bottom, a top, a left wall and a right wall, the method comprising: a 3D printing process additively depositing material in a continuous bead to generate the plurality of sides by 1 ) initially depositing the material to form a monolithic and continuous rear end surface associated with each of the bottom, the top, the left wall and the right wall, and thereafter 2) the 3D printing process additively depositing material in a continuous bead to build up the initially deposited material to further construct the bottom, the top, the left wall and the right wall to complete the 3-D printing of the structure, the 3-D printing process finally depositing the material to form a monolithic and continuous front end surface associated with each of the bottom, the top, the left wall and the right wall, wherein the 3-D printed structure is rotated to rest on the bottom upon completion of the 3D printing process..

[0010] In accordance with another exemplary embodiment of the present disclosure, disclosed is A six sided enclosed habitable structure comprising: a 3-D printed structure including a plurality of sides including a bottom, a top, a left wall and a right wall each constructed using a 3D printing process, wherein the 3D printing process additively deposits material in a continuous bead to generate the plurality of sides by 1 ) initially depositing the material to form a monolithic and continuous rear end surface associated with each of the bottom, the top, the left wall and the right wall and thereafter 2) the 3D printing process additively depositing material in a continuous bead to build up the initially deposited material to further construct the bottom, the top, the left wall and the right wall to complete the 3-D printing of the structure, the 3-D printing process finally depositing the material to form a monolithic and continuous front end surface associated with each of the bottom, the top, the left wall and the right wall, wherein the 3-D printed structure is rotated to rest on the bottom upon completion of the 3D printing process; and a front wall and a rear wall added to the 3D-printed structure after completion of the 3D-printing process, the front wall and rear wall operatively attached to the 3-D printed structure and the front wall and rear wall enclosing the 3-D printed structure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a more complete understanding of the present disclosure, reference is now made to the following descriptions taken in conjunction with the accompanying drawings.

[0012] FIG. 1 illustrates a perspective view of an enclosed habitable structure including a 3D-printed structure according to an exemplary embodiment of this disclosure, the 3D-printed structure.

[0013] FIG. 2 illustrates a perspective view of another enclosed habitable structure including a 2 3D-printed structures according to an exemplary embodiment of this disclosure, this structure including 2 3D-printed modules attached to enlarge the overall size of the enclosed habitable structure.

[0014] FIG. 3 illustrates a perspective view of a completed 3D-printed structure during a 3D printing process, according to an exemplary embodiment of this disclosure.

[0015] FIG. 4 illustrates a cross-section of the sidewall of the 3D-printed structure, according to an exemplary embodiment of this disclosure.

DETAILED DESCRIPTION

[0016] This disclosure and exemplary embodiments described herein provide method and systems for generating a 3D-printed structure, the structure comprising a plurality of sides including: a bottom, a top, a left side and a right side, each constructed using a 3D printing process. According to an exemplary embodiment of this disclosure, the structure is monolithically 3D printed by an additive process which results in a 4 sided structure resting on a platform and oriented with the top side as the most upper surface. The completed structure is then rotated onto the bottom external surface to provide a properly oriented structure. A front side/wall and rear side/wall, which are not 3D printed, are constructed and/or added using various construction techniques which attach the front and rear sides to the 3D printed structure. Some of the features associated with the front and rear sides may include, but are not limited to, windows, doors, electrical fixtures, etc. [0017] The specific details of the single embodiment or variety of embodiments described herein are set forth in this application. Any specific details of the embodiments are used for demonstration purposes only, and no unnecessary limitation or inferences are to be understood therefrom.

[0018] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of components related to the system. Accordingly, the device components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0019] In general, the embodiments described herein relate to a process for the 3- Dimensional (3D) printing of a structure. The structure is designed to be occupiable and/or habitable by at least one person and may include thermal insulation, and the ability for the inclusion of building utilities, while creating a means for interior and exterior customization. The structure is constructed of a 3D-printable material such as a polymer and/or recycled polymer and is printed on its side such that the structure is printed in a single monolithic print, thus reducing the time needed for production and simplifying the manufacturing process.

[0020] In some embodiments, the deposited material is comprised of recycled plastic or a glycol-modified polyethylene terephthalate (PETG) and is glass fiber filled.

[0021] With reference to FIG. 1, shown is an enclosed habitable structure including a 3D-printed structure according to an exemplary embodiment of this disclosure, the 3D- printed structure. The enclosed habitable structure 100 includes a bottom 101 , top 103, left wall 105 and right wall 107. A front side/wall/window 109 and a rear side/wall/window 111 are added after the completion of the 3D-printing of the bottom 101 , top 103, left wall 105 and right wall 107 as described herein. In the illustrated embodiments, the bottom 101 , top 103, left wall 105, and right wall 107 are 3D printed and form a self-supporting structure. Each surface of the bottom 101 , top 103, left wall 105 and right wall 107 (collectively referred to as sidewall(s)) is capable of receiving a decorative finish, such as dry wall, paneling, etc., to allow the consumer to customize the appearance of the interior surface 113 or exterior surface 115 of the structure 100.

[0022] With reference to FIG. 2, illustrate another, second exemplary embodiment of an enclosed habitable structure including a 3D-printed structure, wherein the habitable structure 100 in FIG. 2 is larger than the habitable structure 100 in FIG. 1. This relatively enlarged and enclosed habitable structure includes two modular enclosed habitable structures 100 which are joined. Each habitable structure 100 includes a bottom 101 , top 103, left wall 105 and right wall 107. The front habitable structure 100A includes a front side/wall/window 109 and front habitable structure 100B includes a rear side/wall/window 111 which are added after the completion of the 3D-printing of the bottom 101, top 103, left wall 105 and right wall 107 as described herein. Each surface of the bottom 101 , top 103, left wall 105 and right wall 107 is capable of receiving a decorative finish, such as dry wall, paneling, etc., to allow the consumer to customize the appearance of the interior surface 113 or exterior surface 115 of the structure 100.

[0023] In some embodiments, the front wall 109 and rear wall 111 may be constructed of a transparent material and are not 3D printed. Alternatively, the front wall 109 and rear wall 111 may be constructed of a combination of materials including, but not limited to, cement board, wood framing, drywall, paneling, widow(s), door(s), etc.

[0024] The 3D printing process is performed such that the structure 100 is 3D printed on its side. In such, the rear wall 111 or front wall 109 is positioned as the base (see FIG. 3). Once the 3D printing process is complete, the 3D-printed structure is 100 is rotated such that the bottom 101 becomes the base of the structure 100. In addition, once the 3D printing process is completed, the structure 100 undergoes various prefabrication and other processes. These prefabrication processes may include installing doors, windows, internal MEP, insulation, flooring, wall finishing, ceiling cladding, and the application of protective exterior finishing. [0025] Prior to delivery, the structures foundation and utilities may be completed. The foundation ensures the structure has a suitable base to be positioned on, while utilities ensure the structure is habitable.

[0026] One skilled in the arts will readily understand that the size, dimensions, shape, and features of the structure may be modified without deterring from the embodiments described herein.

[0027] With reference to FIG. 3, illustrated is another perspective view of a completed 3D-printed structure during a 3D printing process, according to an exemplary embodiment of this disclosure, and FIG. 4 illustrates a cross-section of a top/bottom/ sidewall 400 of the structure. While the cross-section shown specifically shows the details of a top portion of the 3-D printed structure, the cross-section details are associated with all sides (top/bottom/left/right) of the 3D-printed structure.

[0028] As shown, during the 3D-printing process, a continuous exterior print bead 421 and a continuous interior print bead 422 are deposited to form the structure. Furthermore, continuous interior print bead 422 is printed to generate a plurality of channels extending between the continuous exterior print bead 421 and the continuous interior print bead 422. The cavities 403 resulting from these channels provide space for insulation, wire routing, plumbing, etc. In addition, as shown, the interior face of the continuous interior bead 422 is relatively linear/flat to provide an anchoring surface for wall/ceiling/floor substrate attachment, as well as other interior wall/ceiling/floor covering material.

[0029] When completed, the sides 400 include an interior surface 113 and an exterior surface 115. The interior 401 space between the interior surface 113 and an exterior surface 115 includes insulation 403. One or more light assemblies 405 and electrical wiring 407 are positioned such that the light assemblies 405 protrude through the interior surface 113 and substrate 409 thereof. The exterior surface 115 may include an ultraviolet light (UV) protective layer 411.

[0030] Various details of the disclosed 3-dimensional printed structure and system and method for the 3-dimensional printing of structures are now provided. [0031] According to an exemplary embodiment of this disclosure, a 3D-printed structure and associated printing system and method includes a structure comprising a plurality of sides including a bottom, a top, a left wall and a right wall each constructed using a 3D printing process. The 3D printing process additively deposits material in a continuous bead to generate the plurality of sides by

1 ) initially depositing the material to form a monolithic and continuous rear end surface associated with each of the bottom, the top, the left wall and the right wall, and thereafter

2) the 3D printing process additively depositing material in a continuous bead to build up the initially deposited material to further construct the bottom, the top, the left wall and the right wall to complete the 3-D printing of the structure, the 3-D printing process finally depositing the material to form a monolithic and continuous front end surface associated with each of the bottom, the top, the left wall and the right wall, wherein the 3-D printed structure is rotated to rest on the bottom upon completion of the 3D printing process.

[0032] According to an exemplary embodiment, the deposited material is recycled plastic and the 3D-printing process includes the use of a 3-axis robotic arm operatively associated with the positioning of an extruder to additively deposit the material.

[0033] According to another exemplary embodiment, the 3D-printing process includes the use of an anchored 3-axis robotic arm operatively associated with the positioning of an extruder to additively deposit the material, and a rotating platform to position the 3-D printed structure for additively depositing the material.

[0034] According to another exemplary embodiment, the 3-D-printed structure includes a continuous exterior print bead and a continuous interior print bead, and the continuous interior print bead is printed to generate a plurality of channels extending between the continuous exterior print bead and the continuous interior print bead.

[0035] According to another exemplary embodiment, a front wall and a rear wall are independently added to the 3D-printed structure after completion of the 3D-printing process, the front wall and rear wall operatively attached to the 3-D printed structure and the front wall and rear wall enclosing the 3-D printed structure. [0036] According to another exemplary embodiment, the plurality of sides are 3D- printed as a complete monolithic structure.

[0037] According to another exemplary embodiment, each of the plurality of sides includes an interior surface and an exterior surface, and the interior surface and the exterior surface are separated by insulation.

[0038] According to another exemplary embodiment, the interior surface includes at least one of the following: a wall covering, a flooring, a wall finishing, and a ceiling cladding.

[0039] According to another exemplary embodiment, the exterior surface includes a UV protective layer.

[0040] It should be understood, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, as apparent from the discussion herein, it is appreciated that throughout the description, discussions utilizing terms such as "processing" or "computing" or "calculating" or "determining" or "displaying" or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices. [0041] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

[0042] The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.