Mighty Buildings, Inc.

Anna Trushina

Aleksei Dubov

Slava Solonitsyn

Dmitry Starodubtsev

Vasily Korshikov

Igor Kovalev

Anna Ivanova

Denis Indyk

Dmitrii Starodubtsev

Alexander Trushin

Aleksandr Trushin

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.

System for obtaining a photopolymerized prepolymer

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.

Optical curing system for 3D printing

A formulation for a photopolymer composite material for a 3D printing system includes an acrylate oligomer, an inorganic hydrate, a reinforcing filler, and an ultraviolet (UV) initiator. In the formulation the acrylate oligomer may be found in the range between about 20.0-60.0 w % of the formulation. The inorganic hydrate may be found in the range between about 20.0-50.0 w % of the formulation. The reinforcing filler may be found in the range between about 5.0-60.0 w % of the formulation, and the UV initiator may be found in the range between about 0.001-0.5 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 oligomer, an inorganic hydrate, a reinforcing filler, and an ultraviolet (UV) initiator.

3D printed material, structure and method for making the same

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.

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.

3D printing of a composite material via sequential dual-curing polymerization

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.

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Tomsk, Russia

Anna Trushina