公开(公告)号：US11999104B2

公开(公告)日：2024-06-04

申请号：US17219866

申请日：2021-03-31

Applicant: Mighty Buildings, Inc.

Inventor： Denis Indyk ,  Igor Bolgov ,  Aleksei Dubov

IPC: B29C64/209 ,  B29C64/118 ,  B29C64/241 ,  B29C64/277 ,  B29C64/321 ,  B29C64/393 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

CPC classification number: B29C64/209 ,  B29C64/118 ,  B29C64/241 ,  B29C64/277 ,  B29C64/321 ,  B29C64/393 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: A 3D printing system can include an extruding system, a curing system, a positioning system, and a feedback system. The extruding system can include a feed pipe coupled to a printing material source and a nozzle having a longitudinal axis along which printing material is extruded. The nozzle can extrude printing material at a printing angle between the longitudinal axis and the top surface of a layer of printing material being printed. The curing system can include light or other curing components configured to cure the printed material after extrusion. The positioning system can include a platform that supports the extruding system and a platform rotating subsystem that rotates the platform during the printing process to adjust the printing angle. The feedback system can include a processor and sensors to detect the location of the nozzle with respect to the 3D printed object or other objects in the printing area during the printing process.

公开(公告)号：US11891465B2

公开(公告)日：2024-02-06

申请号：US17017669

申请日：2020-09-10

Applicant: Mighty Buildings, Inc.

Inventor： Denis Indyk ,  Aleksandr Trushin ,  Anna Trushina ,  Aleksei Dubov ,  Dmitry Starodubtsev ,  Slava Solonitsyn

IPC: C08F22/20 ,  E04B1/35 ,  E04B1/16 ,  B33Y70/00 ,  B29B13/10 ,  B29C64/314 ,  B33Y40/10

CPC classification number: C08F22/20 ,  B29B13/10 ,  B29C64/314 ,  B33Y40/10 ,  B33Y70/00 ,  E04B1/16 ,  E04B1/3505

Abstract: A photopolymerized prepolymer manufacturing system can create material suitable for 3D printing buildings or building components. The system can include a conveyor, a prepolymerization chamber, and one or more processors. The prepolymerization chamber can have multiple prepolymerization stations arranged in sequence and can convert untreated material into photopolymerized prepolymer material as the conveyor moves the prepolymer past the prepolymerization chamber. The processor(s) can control operations of the conveyor, the prepolymerization chamber, or both, to alter operations in response to a detected system event. Each polymerization station can include a light source, such as an LED array, that irradiates material. Each light source can be in a lid of the prepolymerization station. When operation of one polymerization station is halted, such as for maintenance, then the system can increase the light source intensity of the remaining polymerization stations, slow the conveyor speed, or both.

公开(公告)号：US11559946B2

公开(公告)日：2023-01-24

申请号：US16774931

申请日：2020-01-28

Applicant: Mighty Buildings, Inc.

Inventor： Vasily Korshikov ,  Anna Trushina ,  Dmitrii Starodubtsev ,  Slava Solonitsyn ,  Igor Kovalev ,  Anna Ivanova ,  Aleksei Dubov

IPC: B29C64/106 ,  B29C64/314 ,  B29C64/329 ,  B33Y30/00 ,  B29C64/393 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y40/10 ,  B29C64/209 ,  B33Y70/10 ,  B29K105/00 ,  B29K509/02

Abstract: A method of printing a 3D printing a photopolymer composite material includes providing a resin premix material including an acrylate monomer or an acrylate oligomer, an inorganic hydrate, a reinforcing filler, a co-initiator, and an ultraviolet (UV) initiator. A thermal initiator is mixed with the resin premix to form a photopolymer composite resin. The photopolymer composite resin is repeatedly extruded and dual-cured by a 3D printing system to create a photopolymer composite material. The 3D printing system includes a control system, a mixing system, a feeding system in fluid communication with the mixing system, a light curing module controlled by the control system, and a printing head controlled by the control system.

公开(公告)号：US20220098335A1

公开(公告)日：2022-03-31

申请号：US17549862

申请日：2021-12-13

Applicant: Mighty Buildings, Inc.

Inventor： Vasily Korshikov ,  Anna Trushina ,  Dmitry Starodubtsev ,  Slava Solonitsyn ,  Igor Kovalev ,  Aleksei Dubov ,  Anna Ivanova

IPC: C08F20/32 ,  C08F2/50 ,  C08K3/38 ,  C08K5/5397 ,  C08K5/14 ,  C08K3/20

Abstract: A formulation for a photopolymer composite material for a 3D printing system includes an acrylate monomer or an acrylate oligomer, an inorganic hydrate, a reinforcing filler, a co-initiator, a thermal initiator, and an ultraviolet (UV) initiator. In the formulation the acrylate monomer or the acrylate oligomer may be between about 10.0-30.0 w % of the formulation. The thermal initiator may be between about 0.001-0.05 w %, the co-initiator may be between about 0.001-0.05 w %, and the UV initiator may be between about 0.001-0.2 w % of the formulation. A method of generating a formulation of a photopolymer composite material for use in a 3D printing system includes using an acrylate monomer or an acrylate oligomer, an inorganic hydrate, a reinforcing filler, a co-initiator, a thermal initiator, and an ultraviolet (UV) initiator.

公开(公告)号：US20210277648A1

公开(公告)日：2021-09-09

申请号：US16810657

申请日：2020-03-05

Applicant: Mighty Buildings, Inc.

Inventor： Aleksei Dubov ,  Anna Ivanova

IPC: E04B1/14 ,  B33Y80/00 ,  E04B5/00 ,  E04C2/20 ,  E04B1/74 ,  E04C1/39 ,  E04B1/94 ,  E04C2/36

Abstract: A residential or commercial building, structure, or building component can include an exterior member, interior member, and plurality of cross-members spatially disposed therebetween. Each of the exterior member, interior member, cross-members can be formed from a multi-layered stack of polymeric material made by a layered three-dimensional printing process, and all can be monolithically integrated. An exterior surface region of the exterior member can have an integrally formed surface finish. Overlying finishing or connective layers can be added. The exterior and interior members can be configured in a parallel arrangement to form a rectangular or curve shaped building block. A fill material can be disposed into openings between the exterior and interior members, and an interior surface region at the interior member can include a cavity configured for an electrical box, plumbing, or a sensing device.

公开(公告)号：US20210078254A1

公开(公告)日：2021-03-18

申请号：US16860021

申请日：2020-04-27

Applicant: Mighty Buildings, Inc.

Inventor： Denis Indyk ,  Aleksei Dubov ,  Slava Solonitsyn ,  Anna Trushina ,  Dmitry Starodubtsev

IPC: B29C64/277 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/106 ,  B29C64/209 ,  B29C64/241

Abstract: An optical curing system for a large scale 3D printing system may include a light source housing, a light source, a mounting bracket, a light beam focusing subsystem, and a power source. The light source may be coupled to the light source housing. The mounting bracket may secure the light source housing to a rotary system on the 3D printer. The light beam focusing subsystem is attached to the light source housing. The power source may power the light source during its operation.

公开(公告)号：US11940339B2

公开(公告)日：2024-03-26

申请号：US17129884

申请日：2020-12-21

Applicant: Mighty Buildings, Inc.

Inventor： Aleksei Dubov

IPC: G01L1/20 ,  G01L1/22 ,  G01L5/16

CPC classification number: G01L1/205 ,  G01L1/22 ,  G01L5/16

Abstract: Structural health monitoring systems for building structures created by additive processes can include at least an orientation sensing subsystem, a strain sensing subsystem, and a local processor. Orientation sensors can collect data from a first set of strategic locations and strain gauges can collect data from a second set of strategic locations on a 3D-printed building component. The sensors can be embedded during or after the 3D-printing process. A simulation engine can determine the strategic locations by modeling 3D geometry and material properties and simulating results from the application of various loads to determine the likely structural failure locations of the building component. The local processor can receive sensor data, filter the data, format the data for analysis, store the data, and forward the formatted data to a remotely located processing system for analysis. Additional system components can include an environmental subsystem and tensometers to collect humidity, temperature, and material deformation data.

公开(公告)号：US11667080B2

公开(公告)日：2023-06-06

申请号：US16397655

申请日：2019-04-29

Applicant: Mighty Buildings, Inc.

Inventor： Denis Indyk ,  Alexander Trushin ,  Anna Trushina ,  Aleksei Dubov ,  Dmitry Starodubtsev ,  Slava Solonitsyn

IPC: B29C64/321 ,  C08F2/48 ,  C08F20/18 ,  B29C64/135 ,  B29C64/264 ,  B29C64/314 ,  B29C64/357 ,  B65G15/40 ,  B29C64/393 ,  B33Y40/10 ,  B65G17/12 ,  B33Y70/00 ,  B33Y10/00 ,  B33Y50/02

CPC classification number: B29C64/321 ,  B29C64/135 ,  B29C64/264 ,  B29C64/314 ,  B29C64/357 ,  B29C64/393 ,  B33Y40/10 ,  B65G15/40 ,  B65G17/12 ,  C08F2/48 ,  C08F20/18 ,  B33Y10/00 ,  B33Y50/02 ,  B33Y70/00 ,  B65G2207/46

Abstract: A system for obtaining a photopolymerized prepolymer for use as a component of a material suitable for manufacturing buildings or building components by 3D printing processes. The system contains a flexible closed loop conveyor stretched between a precursor loading station and a prepolymerization material receiver from which the product is unloaded to a construction 3D printing machine. The conveyor carries a plurality of flexible trays capable of looping around the pulleys of the closed loop conveyor. The trays are shallow troughs that have open tops and carry dosed portions of the precursor, which is photopolymerized on its way from the loading station to the unloading station by sequentially passing under light sources of two photopolymerization stations. When the trays pass through the unloading position, they are turned upside-down and allow the precured material to fall into a receiver.

公开(公告)号：US20220314561A1

公开(公告)日：2022-10-06

申请号：US17219863

申请日：2021-03-31

Applicant: Mighty Buildings, Inc.

Inventor： Sergey Khirpunov ,  Evgeniy Kuznetsov ,  Igor Obach ,  Aleksei Dubov ,  Anna Ivanova

IPC: B29C71/04 ,  B29C64/209 ,  B29C64/393 ,  B29C64/282 ,  B29C64/106 ,  B29C64/241 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/20 ,  B33Y50/02

Abstract: A 3D printing system can include an extruding system, curing system and feedback system. The extruding system can include a feed pipe coupled to a printing material source and a nozzle that extrudes a printed material. The feedback system can include a processor and sensors and can detect the temperature and location of the curing system during the printing process. The curing system cures the printed material after extrusion and includes curing sources coupled to a mounting arrangement, which can be a curved surface. The curing sources can each be directed toward a focal region located proximate the nozzle outlet and can combine to emit a combined curing energy to the focal region. The curing sources can be LEDs and the curing energy can be UV light. The curing system can rotate about an axis during printing and curing to facilitate rapid movement and printing of complex 3D objects.

公开(公告)号：US20220196491A1

公开(公告)日：2022-06-23

申请号：US17129884

申请日：2020-12-21

Applicant: Mighty Buildings, Inc.

Inventor： Aleksei Dubov

IPC: G01L1/20 ,  G01L5/00 ,  G01L1/22 ,  E04B1/35

Abstract: Structural health monitoring systems for building structures created by additive processes can include at least an orientation sensing subsystem, a strain sensing subsystem, and a local processor. Orientation sensors can collect data from a first set of strategic locations and strain gauges can collect data from a second set of strategic locations on a 3D-printed building component. The sensors can be embedded during or after the 3D-printing process. A simulation engine can determine the strategic locations by modeling 3D geometry and material properties and simulating results from the application of various loads to determine the likely structural failure locations of the building component. The local processor can receive sensor data, filter the data, format the data for analysis, store the data, and forward the formatted data to a remotely located processing system for analysis. Additional system components can include an environmental subsystem and tensometers to collect humidity, temperature, and material deformation data.