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.

The rack assembly of one 3D construction printer comprises two rows of vertical supporting posts anchored from the ground. Within each row of vertical supporting posts, between two neighboring vertical supporting posts, longitudinal beams are provided and extended along the length direction of the rack assembly, the longitudinal beams are configured to provide support and allow a cart carrying a 3D construction printer to move. On a top of the rack assembly, ring frame is provided, and on each of the longitudinal ends of the rows of vertical supporting beams, a cantilever extension end, being suspended, is connected to said rectangular ring frame. Further on the upper surface of a bottom longitudinal beam of the rectangular ring frame, guiding rails are provided in order for the cart carrying a crane to move along the longitudinal direction of the ring frame.

A robotised construction system is provided that includes a cartesian robot that can be automatically lifted as the construction is becoming higher, that is provided with a system of robotic supply of the materials and of the electric and electronic installations and that is provided with specific fabrication tools which work some by the contribution of layers of fluid construction materials. In a cement-based usage in which the cement is setting and having been deposited, by projection of these same materials and others by forming and placing construction elements in a determined position.

The invention relates to a system (10) comprising at least one first device (20) movable in a controlled manner and at least one second device (27), which is arranged on said at least one first device, for applying material. In order to produce complex structures in a simple manner, according to the invention, the at least one first device (20) movable in a controlled manner is formed by an aircraft (20) provided with at least one rotor (21), which aircraft comprises at least one container (231; 232) for storing the material.

The present invention relates to methods and apparatuses for an automated reinforced concrete construction system for onsite slip-form molding and casting a variety of cementitious mixes in a cast in place leave in place externally moldable flexible reinforced containment sleeve providing a wide variety of interchangeable full-scale molding configurations simultaneously optimizing a wide variety of cementitious mix curing characteristics, further having optional internal reinforcement net(s), for layer wise interlocking additive printed brick deposition providing improved slip-form mold casting of a wide variety of reinforced concrete structures; the present invention further includes a variety of operating platforms suitable for on and offsite constriction as disclosed herein.

Provided is a level-by level construction methodology integrating architectural and structural work for use in the construction of a multi-level building utilizing a movable protection system that can be mounted to a multi-level building during its construction.

A sprayed-in-place framed wall is disclosed, comprised of a cementitious face and backing layers and a polyurethane foam insulation layer that bonds the cementitious layers to a separate wall frame. Stationary walls are constructed by spraying the materials against one-sided, vertical wall forms positioned around an erected, exterior wall frame. The cementitious materials are restrained by stays. The wall forms may have indentations to enable the resulting wall face to have protrusions such as moulding, bands, quoins and cornices, which may be a different color that the surrounding flat wall face.

A sprayed-in-place framed wall is disclosed, comprised of a cementitious face and backing layers and a polyurethane foam insulation layer that bonds the cementitious layers to a separate wall frame. Stationary walls are constructed by spraying the materials against one-sided, vertical wall forms positioned around an erected, exterior wall frame. The cementitious materials are restrained by stays. The wall forms may have indentations to enable the resulting wall face to have protrusions such as moulding, bands, quoins and cornices, which may be a different color that the surrounding flat wall face.

A method for forming a building includes obtaining a mould, spraying a first spray material onto the outside of the mould so that it sets generally in the shape of the mould to provide a core. The core has side walls, and end wall integral with the side walls and a roof integral with both the side walls and end wall. A second spray material different to the first spray material is sprayed onto the inner and outer surfaces of the core to give it a rigid skin.

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.