Abstract: A modular hybrid building panel system configured to form an envelope for an entire building or a portion thereof can include a plurality of hybrid building panels, a plurality of panel connectors, and a plurality of anchoring components. Each hybrid building panel can include at least a structural insulated panel coupled with a customizable 3D-printed exterior cladding. The plurality of panel connectors can be coupled to the plurality of hybrid building panels and can be configured to couple the plurality of hybrid building panels to each other horizontally, vertically, or both. The plurality of anchoring components can be coupled to the plurality of hybrid building panels and can be configured to couple the plurality of hybrid building panels to one or more separate building components.

Abstract: A 3D-printed integrated panel, assembly, or other building element configured to form part of an overall building can include 3D-printed panels, connectors, and load transfer components. 3D-printed panels can be integrally formed by 3D printing technology using a photocurable composite material. A 3D-printed panel can include an outer frame shell defining a geometric shape having interior and exterior outer surfaces, side edges therebetween, and an infill structure therewithin, the infill structure forming internal cavities within the outer frame shell. Connectors can couple 3D-printed panels to each other and/or to separate building components of the overall building. Load transfer components can be coupled to and transfer loads across 3D-printed panels. Waterproofing elements can be coupled to 3D-printed panels, and thermal insulation material can be disposed within the internal cavities. The panel, assembly, or other building element can comply with building construction standards.

Abstract: A 3D-printed integrated building panel system configured to form a portion of an overall building can include 3D-printed building panels, connectors, and one or more load transfer components. Each 3D-printed building panel can be formed by 3D printing technology using a photocurable composite material, and at least a portion of the 3D-printed building panels can be integrally formed. The connectors can be coupled to one or more of the 3D-printed building panels and can couple the 3D-printed building panels to each other and/or to one or more separate building components of the overall building. The load transfer component(s) can be coupled to at least a portion of the 3D-printed building panels and can transfer loads across the 3D-printed building panels. The load transfer component(s) can be configured to form at least a portion of an overall super structure for the overall building.

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.

Abstract: A composition for a 3D printing construction material includes an acrylate oligomer, an acrylate monomer, a UV photoinitiator, a flame retardant, fillers, and additives. In the composition, the acrylate oligomer may be between about 0-30.0 wt % of the composition. The acrylate monomer may be between about 0-30.0 wt % of the composition. The UV photoinitiator may be between about 0.02-1.0 wt % of the composition. The flame retardant may be between about 2.0-20.0 wt % of the composition. The fillers may be between about 20.0-80.0 wt % of the composition. The additives may be between about 0-3.0 wt % of the composition. A method for manufacturing a composition for a 3D printing construction material includes combining an acrylate oligomer, an acrylate monomer, an Uaphotoinitiator, a flame retardant, fillers, and additives.

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.

Abstract: A 3D printing apparatus can include a base composite material channel configured to pass a base composite material therethrough, a fiber strand channel configured to pass a fiber strand therethrough, and a fiber feeding component configured to feed the fiber strand through the fiber channel. The fiber strand can be separate from the base composite material before entering the 3D printing apparatus, and the fiber feeding component can facilitate combining of the fiber strand with the base composite material to form a layer of a 3D printed building component with the fiber strand within the base composite material. An impregnation material channel may be included to pass an impregnation liquid or material to impregnate the fiber strand while the fiber strand is within the 3D printing apparatus.

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.

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.

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.

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.

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.

Abstract: A composition for a 3D printing construction material includes an acrylate oligomer, an acrylate monomer, a UV photoinitiator, a flame retardant, fillers, and additives. In the composition, the acrylate oligomer may be between about 0-30.0 wt % of the composition. The acrylate monomer may be between about 0-30.0 wt % of the composition. The UV photoinitiator may be between about 0.02-1.0 wt % of the composition. The flame retardant may be between about 2.0-20.0 wt % of the composition. The fillers may be between about 20.0-80.0 wt % of the composition. The additives may be between about 0-3.0 wt % of the composition. A method for manufacturing a composition for a 3D printing construction material includes combining an acrylate oligomer, an acrylate monomer, an Uaphotoinitiator, a flame retardant, fillers, and additives.

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.

Abstract: A 3D printing apparatus can include a base composite material channel configured to pass a base composite material therethrough, a fiber strand channel configured to pass a fiber strand therethrough, and a fiber feeding component configured to feed the fiber strand through the fiber channel. The fiber strand can be separate from the base composite material before entering the 3D printing apparatus, and the fiber feeding component can facilitate combining of the fiber strand with the base composite material to form a layer of a 3D printed building component with the fiber strand within the base composite material. An impregnation material channel may be included to pass an impregnation liquid or material to impregnate the fiber strand while the fiber strand is within the 3D printing apparatus.

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.

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.

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.

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.

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.