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Abstract

A method for producing free form three-dimensional architectural objects by placing construction materials in a matrix of sequential layers or laminations along with fill materials intended for later removal. A digital model specifies the composition of various areas of each lamination so that appropriate materials result in corresponding areas of the finished objects. The relatively void-free laminations inherently provide support to placed material in all directions save the direction in which successive laminations progress. Support in the direction laminations form comes from accelerations, usually the acceleration due to gravity. The uniformity of support obviates the need for large-scale tensile strengths in the pattern of the objects under construction during the placement process. The method supplies the ultimate required object tensile strengths, via a process called activation, in large volumes of the matrix often involving the entire matrix volume. Since activation occurs after matrix deposition, the activation does not add a time requirement proportional to the total piece count of the placed construction materials but proceeds at its characteristic pace in parallel across the entire volume to which activation is applied. In the embodiment producing ferrocement objects, laminar automatic placement of unactivated cementitous materials naturally supports the forming objects within the matrix, whatever their geometries, without activation. The usual practice of the art contrasts with the present invention by requiring application of wet (activated) cementitious material to a reinforcement structure that must support the weight of the wet material in addition to its own weight during construction or employ costly custom supplemental support means until the structure cures enough to become self-supporting. Wet application of material to an intricate reinforcement network in situ severely challenges any automation and the manual labor alternative becomes extremely costly except in locations with an oversupply of laborers.

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First Claim