WO2025059492A1 - Dynamic printing bed for automated additive manufacturing for forming freeform panels - Google Patents

Abstract

A reconfigurable printing bed device for additive manufacturing or three dimensional (3D) printing includes a reconfigurable printing bed defining a surface configured to receive a deposited material. The bed includes a lattice component comprising a plurality of connected cells each having an open region. The bed includes a flexible elastomeric polymer disposed with the open regions to define a flexible mat. A plurality of actuatable pins is disposed beneath the bed. Each pin is connected to a location on the reconfigurable printing bed to translate it to a predetermined position so that the reconfigurable printing bed is capable of defining a structure having at least a single curvature. Methods of additive manufacturing on such a dynamic reconfigurable printing bed are also contemplated. After passing through a 3D printing extruder, the flowable material may be deposited onto a surface of a reconfigurable printing bed where it hardens as a printed structure.

Description

DYNAMIC PRINTING BED FOR AUTOMATED ADDITIVE MANUFACTURING FOR FORMING FREEFORM PANEES

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63/538,410, filed on September 14, 2023. The entire disclosure of the above application is incorporated herein by reference.

FIELD

[0002] The present disclosure relates to a dynamic reconfigurable bed for forming curved surface panels via additive manufacturing and methods of using the same.

BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Mass customization of freeform panels or other similar structures using molds or formwork is inefficient and decreases productivity. Freeform panels or other components can be formed from static molds that can receive cast slurry materials. Manufacturing of such molds for freeform panels is time and labor intensive, costly, and wasteful.

[0005] In lieu of casting, three-dimensional (3D) printing, also referred to as additive manufacturing (AM), offers many opportunities to digitize fabrication and create complex shapes. Additive manufacturing (AM) or three-dimensional (3D) printing is a process by which material is applied in an additive, layer-by-layer formation technique. Additive manufacturing can form structures having highly complex geometries and freeform shapes and is of particular interest in the construction industry. 3D printing on a bed could potentially be used to form panel structures or parts. However, many beds cannot be manipulated into complex surface shapes and are static, or if they can be shaped, cannot be reconfigured and used again. Thus, it would be desirable to have an adaptable, flexible, and reconfigurable 3D printing bed and process for additive manufacturing/3D printing of freeform panels or parts.

SUMMARY

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. [0007] In certain aspects the present disclosure relates to a reconfigurable printing bed device for additive manufacturing. The reconfigurable printing bed device comprises a reconfigurable printing bed defining a surface configured to receive a deposited material. The reconfigurable printing bed comprises a lattice component comprising a plurality of cells that are connected to one another, where each cell defines an open region. The reconfigurable printing bed further comprises a flexible elastomeric polymer disposed with the open region of each cell of the lattice component to define a flexible mat. The reconfigurable printing bed device further comprises a plurality of actuatable pins disposed beneath the reconfigurable printing bed. Each actuatable pin is connected to a location on the reconfigurable printing bed and configured to translate the reconfigurable printing bed to a predetermined position so that the reconfigurable printing bed is capable of defining a structure having at least a single curvature.

[0008] In one aspect, the elastomeric polymer comprises siloxane.

[0009] In one aspect, the lattice component comprises a polymeric material selected from the group consisting of: thermoplastic elastomers (TPE), thermoplastic polyurethanes (TPU), thermoplastic polyolefinelastomers (TPO), thermoplastic styrene block copolymers (TPS), thermoplastic polyamides (TPA), thermoplastic copolyesters (TPC), thermoplastic vulcanates (TPV), and combinations thereof.

[0010] In one aspect, the plurality of actuatable pins are each connected to a linear actuator.

[0011] In one aspect, the reconfigurable printing bed device further comprises a plurality of wires each extending along at least one dimension of the reconfigurable printing bed. Each wire of the plurality is connected to at least one of the plurality of actuatable pins and to the reconfigurable printing bed.

[0012] In one further aspect, the plurality of wires define a grid with intersecting wires that extends across the reconfigurable printing bed.

[0013] In one further aspect, the lattice component comprises a plurality of tabs that protrude from a lower surface of the reconfigurable printing bed. Each of the tabs comprises an aperture that receives a wire of the plurality of wires.

[0014] In one further aspect, the plurality of wires are elastic and comprise a material selected from the group consisting of: fiberglass, spring steel, and combinations thereof.

[0015] In one aspect, the plurality of cells each comprises at least one wall having an edge with at least one notch formed therein.

[0016] In certain other aspects, the present disclosure relates to a method of additive manufacturing on a dynamic bed. The method optionally comprises depositing a flowable material onto a surface of a reconfigurable printing bed and allowing the material to harden on the reconfigurable printing bed to form a printed structure. The reconfigurable printing bed comprises a lattice component comprising a plurality of cells that are connected to one another, where each cell defines an open region. The reconfigurable printing bed also comprises a flexible elastomeric polymer disposed with the open region of each cell of the lattice component to define a flexible mat. A plurality of actuatable pins is disposed beneath the reconfigurable printing bed, where each actuatable pin is connected to a location on the reconfigurable printing bed and configured to translate the reconfigurable printing bed to a predetermined position capable of defining a single curvature.

[0017] In one aspect, the depositing the flowable material further comprises printing the flowable material by passing through a printer head.

[0018] In one aspect, the depositing of the flowable material occurs with an automated three-dimensional printer having a print head disposed on at least one robotic device.

[0019] In one aspect, the automated three-dimensional printer is at least partially controlled by a computer numerical control (CNC) system.

[0020] In one aspect, the flowable material comprises a material selected from the group consisting of: a cementitious material, clay, dirt, bio-materials, wood, hempcrete, polymers, and combinations thereof.

[0021] In one aspect, prior to the depositing, the method further comprises adjusting the position of one or more of the plurality of actuatable pins to shape the surface of the reconfigurable printing bed to the predetermined position, so that the printed structure conforms to the contours of the surface of the reconfigurable printing bed during the depositing.

[0022] In one aspect, the adjusting of the position of one or more of the plurality of actuatable pins is conducted via an automated process that is at least partially controlled by a computer numerical control (CNC) system.

[0023] In one aspect, the surface is doubly curved and the printed structure is doubly curved.

[0024] In one aspect, a plurality of wires extends along at least two dimensions of the reconfigurable printing bed. Each wire of the plurality is connected to at least one of the plurality of actuatable pins and to the reconfigurable printing bed. The adjusting the position of the one or more of the actuatable pins shapes the surface of the reconfigurable printing bed.

[0025] In one aspect, the printed structure is a freeform panel.

[0026] In one aspect, the printed structure comprises an insulated panel and the depositing the flowable material comprises forming a frame structure having a plurality of open regions on the surface of the reconfigurable printing bed. The method further comprises introducing an insulating material into the plurality of open regions, followed by depositing the flowable material to form a surface layer of the insulated panel.

[0027] In one aspect, the printed structure has at least one dimension that is greater than or equal to about 10 feet.

[0028] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0029] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0030] FIGS. 1A and IB show a reconfigurable printing bed device including a reconfigurable printing bed prepared in accordance with certain aspects of the present disclosure. FIG. 1A shows the assembled reconfigurable printing bed device with the reconfigurable printing bed exhibiting a doubly curved surface. FIG. IB shows an exploded view of the reconfigurable printing bed device.

[0031] FIG. 2 shows a side sectional view of a reconfigurable printing bed device including a reconfigurable printing bed prepared in accordance with certain aspects of the present disclosure.

[0032] FIG. 3 shows a perspective view of a lattice component comprising a plurality of cells for incorporation into a reconfigurable printing bed prepared in accordance with certain aspects of the present disclosure.

[0033] FIG. 4 shows a side view of a lattice component comprising a plurality of tabs for incorporation into a reconfigurable printing bed prepared in accordance with certain aspects of the present disclosure.

[0034] FIG. 5 shows a perspective view of a photograph of a bottom surface of a reconfigurable printing bed including the lattice component comprising a plurality of protruding tabs in accordance with certain aspects of the present disclosure.

[0035] FIG. 6 shows a perspective view of a bottom surface of a lattice component comprising a plurality of protruding tabs connected to a grid of elastic wires in accordance with certain aspects of the present disclosure. [0036] FIG. 7 shows a perspective view of a plurality of linearly actuatable pins connected to a grid of elastic wires in accordance with certain aspects of the present disclosure.

[0037] FIG. 8 shows an exploded view of components for a linearly actuatable pin in accordance with certain aspects of the present disclosure.

[0038] FIG. 9 shows a view of a bottom surface of a reconfigurable printing bed connected to a plurality of actuatable pins via a grid of elastic wires in accordance with certain aspects of the present disclosure.

[0039] FIG. 10 shows a perspective view of a reconfigurable printing bed device having a printed panel disposed thereon in accordance with certain aspects of the present disclosure.

[0040] FIG. 11 shows a reconfigurable printing bed device including a reconfigurable printing bed and an automated 3D printing device prepared in accordance with certain aspects of the present disclosure.

[0041] FIG. 12 shows a reconfigurable printing bed device including a computer numerical control (CNC) controlled reconfigurable printing bed demonstrating a surface profile shape/contour including a doubly curved surface in accordance with certain aspects of the present disclosure. The side views show a cross section of a lattice component (without cast silicone) in a horizontal or flat position and a second position where the shape is curved without buckling, in accordance with certain aspects of the present disclosure.

[0042] FIG. 13 shows a reconfigurable printing bed device including a reconfigurable printing bed with a multiple layered 3D printed structure disposed thereon in accordance with certain aspects of the present disclosure. The side view show a cross section of actuators shaping a surface of a reconfigurable printing bed on which the material is deposited, in accordance with certain aspects of the present disclosure.

[0043] FIG. 14 shows an additive manufacturing process for forming an insulating panel structure by using a reconfigurable printing bed in accordance with certain aspects of the present disclosure

[0044] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0045] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0046] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, elements, compositions, steps, integers, operations, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Although the open-ended term “comprising,” is to be understood as a non-restrictive term used to describe and claim various embodiments set forth herein, in certain aspects, the term may alternatively be understood to instead be a more limiting and restrictive term, such as “consisting of’ or “consisting essentially of.” Thus, for any given embodiment reciting compositions, materials, components, elements, features, integers, operations, and/or process steps, the present disclosure also specifically includes embodiments consisting of, or consisting essentially of, such recited compositions, materials, components, elements, features, integers, operations, and/or process steps. In the case of “consisting of,” the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations, and/or process steps, while in the case of “consisting essentially of,” any additional compositions, materials, components, elements, features, integers, operations, and/or process steps that materially affect the basic and novel characteristics are excluded from such an embodiment, but any compositions, materials, components, elements, features, integers, operations, and/or process steps that do not materially affect the basic and novel characteristics can be included in the embodiment.

[0047] Any method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed, unless otherwise indicated.

[0048] When a component, element, or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other component, element, or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

[0049] Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited by these terms, unless otherwise indicated. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.

[0050] Spatially or temporally relative terms, such as “before,” “after,” “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially or temporally relative terms may be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.

[0051] In the figures, the direction of an arrow, as indicated by the arrowhead, generally demonstrates the flow of information (such as data or instructions) that is of interest to the illustration. For example, when element A and element B exchange a variety of information but information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send requests for, or receipt acknowledgements of, the information to element A.

[0052] In this application, the term “module” or the term “controller” may be replaced with the term “circuit.” The term “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

[0053] The module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces that are connected to a local area network (LAN), the Internet, a wide area network (WAN), or combinations thereof. The functionality of any given module of the present disclosure may be distributed among multiple modules that are connected via interface circuits. For example, multiple modules may allow load balancing. In a further example, a server (also known as remote, or cloud) module may accomplish some functionality on behalf of a client module.

[0054] The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, data structures, and/or objects. The term shared processor circuit encompasses a single processor circuit that executes some or all code from multiple modules. The term group processor circuit encompasses a processor circuit that, in combination with additional processor circuits, executes some or all code from one or more modules. References to multiple processor circuits encompass multiple processor circuits on discrete dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term shared memory circuit encompasses a single memory circuit that stores some or all code from multiple modules. The term group memory circuit encompasses a memory circuit that, in combination with additional memories, stores some or all code from one or more modules.

[0055] The term memory circuit is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Nonlimiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

[0056] The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general purpose computer to execute one or more particular functions embodied in computer programs. Any functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.

[0057] The computer programs include processor-executable instructions that are stored on at least one non-transitory, tangible computer-readable medium. The computer programs may also include or rely on stored data. The computer programs may encompass a basic input/output system (BIOS) that interacts with hardware of the special purpose computer, device drivers that interact with particular devices of the special purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0058] The computer programs may include: (i) descriptive text to be parsed, such as HTML (hypertext markup language), XML (extensible markup language), or JSON (JavaScript Object Notation) (ii) assembly code, (iii) object code generated from source code by a compiler, (iv) source code for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. As examples only, source code may be written using syntax from languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, Javascript®, HTML5 (Hypertext Markup Language 5th revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

[0059] None of the elements recited in the claims are intended to be a means-plus- function element within the meaning of 35 U.S.C. § 112(f) unless an element is expressly recited using the phrase “means for,” or in the case of a method claim using the phrases “operation for” or “step for.”

[0060] Throughout this disclosure, the numerical values represent approximate measures or limits to ranges to encompass minor deviations from the given values and embodiments having about the value mentioned as well as those having exactly the value mentioned. Other than in the working examples provided at the end of the detailed description, all numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. For example, “about” may comprise a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in certain aspects, optionally less than or equal to 0.1%.

[0061] In addition, disclosure of ranges includes disclosure of all values and further divided ranges within the entire range, including endpoints and sub-ranges given for the ranges.

[0062] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0063] In various aspects, the present disclosure provides a reconfigurable printing bed device including a reconfigurable printing bed, which may be used for fabricating panels or other freeform structures. In certain aspects, the reconfigurable printing bed device may be used for additive manufacturing of such a panel or other structure. In certain variations, the reconfigurable printing bed may define a surface configured to receive a deposited material. The reconfigurable printing bed comprises a lattice component comprising a plurality of cells that are connected to one another and may define a lattice or cell assembly, where each cell defines an open region. The reconfigurable printing bed also comprises a flexible elastomeric polymer disposed with the open region of each cell of the lattice component to define a flexible mat. The lattice component thus defines a grid that may be cast in an elastomeric material, like siloxane/silicone, and together these form a composite surface that shares some of the properties of the elastomer and the strength of the lattice component. In this manner, the lattice component and the elastomeric polymer together define the surface that may be considered a hybrid or composite surface that receives a material to be deposited thereon. In alternative variations, a lattice component may be a sublayer disposed below the elastomeric material to define the flexible mat.

[0064] The reconfigurable printing bed also comprises a plurality of actuatable components, which may be in the form of pins, disposed beneath the reconfigurable printing bed. Each actuatable pin is connected to a location on the reconfigurable printing bed and is configured to translate the location of the reconfigurable printing bed to a predetermined position. The plurality of actuatable pins may be part of an actuator assembly, which may optionally be partially or fully automated. Each pin may be at least linearly actuatable along at least one axis or direction (for example, in a z-axis or height direction). In various aspects, the reconfigurable bed can define a variety of shapes, including a surface having no curvature (e.g., flat or horizontal surface), single curvature (ruled surface), and double curvature geometries. Thus, in certain variations, the reconfigurable bed can define a contoured surface exhibiting at least a single curvature and in certain variations, at least a double curvature. Generally, a surface having single curvature may be a synclastic surface and a surface having a double curvature has its radii in two planes, for example, having an anticlastic curvature. Thus, the reconfigurable printing bed may have a variety of predetermined shapes or contours, including defining a surface with a single curvature, optionally with a double curvature. When a material is deposited on the surface of the bed, it likewise adopts a complementary shape, for example, singly or doubly curved, for example.

[0065] In certain aspects, the reconfigurable printing bed with the plurality of actuator pins may be used in connection with an automated or robotic device, such as a computer numerical control (CNC) machine, for configuring the bed and/or additively manufacturing a panel or other structure on the bed. Such machines have automation with advanced CNC machinery and highly articulated degrees of customization in directionality. The CNC machinery may include a computer processing unit (CPU) and one or more controllers that may be operated with various modules, as appreciated by those of skill in the art. Thus, an overall additive manufacturing system may comprise a CNC or robotic controlled automated printing system.

[0066] Thus, in various aspects, the present disclosure provides a reconfigurable flexible composite membrane (3D printing bed) that can form any curved shape. In certain variations, the flexible composite membrane reconfigurable bed may be a part of a CNC machine that includes the composite flexible membrane (3D printing bed) that is connected to a grid of actuators imparting a shape into the flexible composite membrane surface. In certain variations, the present disclosure contemplates a flexible reconfigurable bed that comprises an elastic deformable material, such as a siloxane, and a cellular lattice component that is flexible and may be filled with the elastic deformable material. The lattice component provides structure to the composite surface of the mat of the reconfigurable printing bed and may be formed of thermoplastic elastomers (TPE). By way of non-limiting example, such thermoplastic elastomers (TPE) may include thermoplastic polyurethanes (TPU), thermoplastic polyolefinelastomers (TPO), thermoplastic styrene block copolymers (TPS), thermoplastic polyamides (TPA), thermoplastic copolyesters (TPC), thermoplastic vulcanates (TPV), and combinations thereof. The cellular lattice can conform to any singly-curved, or optionally any doubly-curved, surface geometry without undesired buckling and provides reconfigurability, in other words, the ability to return to its original shape without any plastic deformation, even after being subjected to continuous and repeated stretch and stress cycles.

[0067] In various aspects, the elastic material provides a smooth surface that can be printed on, where it is cast or formed over the engineered cellular lattice, to create a composite material that can conform to any freeform surface geometry without undesired buckling over the surface and provides reconfigurability. This means that the composite surface can withstand the weight of deposited material in the span between the actuator pins with no unwanted deformation to the fabricated element on the surface. In addition, the composite surface has the ability to be subjected to continuous and repeated stretch and stress cycles without any plastic deformation to the composite surface. The balance of the elastomeric layer and the lattice component as an assembly system results in a dynamic bed with a seamless, continuous, and freeform printing surface with structural rigidity to support the weight of the deposited material.

[0068] A reconfigurable printing bed device 18 according to certain variations of the present teachings is shown in FIGS. 1A-1B, 2, and 3. The reconfigurable printing bed device 18 has a reconfigurable printing bed 20 that includes an elastomeric material 22. The bed 20 further includes a lattice component 26 disposed substantially within the elastomeric material 22. In one non-limiting variation, the lattice component 26 may have a thickness of about 7 mm and after siloxane is introduced, the flexible mat/bed 20 may have an overall thickness of about 20 mm. Together, the lattice component 26 and the elastomeric material 22 define a flexible mat having a surface 24 configured to receive a material disposed thereon. In certain variations, the lattice component 26 may be substantially disposed within the elastomeric material 22 and may thus define an interior region of the flexible mat. In alternative variations, a lattice component may be a sublayer disposed below the elastomeric material to define the flexible mat. The lattice component 26 may be designed as a flexible thermoplastic material in the pattern of a grid defined by a plurality of cells 30. These structures are used for being flexible and for their shock absorptive properties. The lattice component 26 may be formed of a thermoplastic polymer, such as thermoplastic elastomers (TPE), such as thermoplastic polyurethanes (TPU), thermoplastic polyolefinelastomers (TPO), thermoplastic styrene block copolymers (TPS), thermoplastic polyamides (TPA), thermoplastic copolyesters (TPC), thermoplastic vulcanates (TPV), and the like. As best seen in FIG. 3, the lattice component 26 comprises the plurality of cells 30 that are connected to one another. Each cell 30 may have walls 32 that define a shape, such as a polygon, here shown as a hexagon, having an open central region 34. In one variation, each hexagonal cell 30 may have an area of 1 cubic centimeter (cm³). The open central region 34 may be filled with a material, such as the elastomeric material 22 that defines the composite or hybrid flexible mat. Each cell 30 has at least one wall 32 and in some cases multiple walls that are shared and common with an adjacent cell 30 of the plurality to form the interconnection between the cells. Further, select edges of the walls 32 may comprise notches 33 that define a pivot point that promotes more flexibility and reduces surface buckling. For example, the lattice component 26 may be considered to define a grid that is cast in elastomeric material 22, like silicone, and together these form a composite surface that shares some of the properties of elastomer while having the strength of the lattice component 26. However, one challenge with having such a lattice component 26 incorporated into the flexible bed is that if the edges of the lattice component 26 are straight, when the actuators move, the resulting surface will be undesirably creased or buckle. As such, the notches 33 formed in the lattice component 26 introduce weak point(s) in each edge of each cell, which act as a pivoting point when the actuators move, resulting in a continuous surface on which the material can be deposited. Thus, the side walls 32 of the hexagonal cells 30 of the cellular lattice (lattice component 26) are notched at the center point to introduce deflection points, whereas the material would crease and buckle otherwise. Thus, as shown, the naked edges (e.g., top and bottom) of the hexagonal- shaped cells 30 of the lattice component 26 infill are notched in central regions for this purpose. In certain aspects, deformation can occur in a surface normal to a direction, for example, in a Z direction (e.g., in a vertical dimension).

[0069] With renewed reference to FIGS. 1A-1B and 2, the reconfigurable printing bed device 18 further comprises a plurality of actuatable components, shown in the form of pins 34, disposed beneath the flexible mat/reconfigurable printing bed 20 (including elastomeric material 22 and the lattice component 26). Each actuatable pin 34 is connected to location on the reconfigurable printing bed 20 and configured to translate the reconfigurable printing bed 20 to a predetermined position. As noted above, each actuatable pin 34 may translate linearly in at least one direction, for example, as shown by the arrow in FIG. 2.

[0070] The plurality of actuatable pins 34 may be part of an actuator assembly 36 that may be activated to independently change the linear position of each of the pins 34. The reconfigurable printing bed 20 is thus capable of defining a structure having at least a single curvature and in other variations, at least a double curvature, as shown in FIG. 1A. As noted above, the reconfigurable printing bed device 18 may be a part of a computer numerical control (CNC) machine. Thus, each pin 34 may be disposed in one or more mounting plates or guides 38 having apertures formed therein through which the portions of the pin 34 components may translate. As shown, by way of non-limiting example, there is a first upper guide plate 38A and a second lower guide plate 38B each having a plurality of apertures that receive respective components of each pin 34. The actuator assembly 36 may further include a plurality of stepper motors 40 attached to each respective pin 34. The actuator assembly 36 may further comprise various electronics 42 as controllers for movement of each individual pin 34 via controlling the stepper motors 40 and the like. The actuator assembly 36 and reconfigurable printing bed 20 may be disposed with a frame structure 44 that may be formed of a lightweight metal, such as aluminum.

[0071] Thus, the CNC controlled reconfigurable printing bed 20 thus includes a system of linear actuators that are attached to a flexible composite membrane (reconfigurable printing bed including the elastomeric material 22 and lattice component 26) through intermediary elastic rods as part of the pin 34 system to impart a predetermined geometry to the bed 20 surface. In certain variations, the present disclosure contemplates methods of additive manufacturing or 3D printing that comprise programming the dynamic bed to a desired shape based on an input geometry that is designed in a CAD software (e.g., a freeform surface or 3D freeform panel). An automated robot, for example, a six-axis robot having a 3D printing end effector may then be directed by G-code data related to the tool path. The toolpath data is generated based on the same input surface geometry/3D panel. The robot carries an extruder that is controlled via any controller, such as a programmable logic controller (PLC) or a microcontroller, and deposits material directly onto a surface of the dynamic reconfigurable bed.

[0072] In certain aspects, the lattice component 26 may further comprise a plurality of tabs 50 that may extend beneath a lower surface 52. Each tab 50 may define an aperture 54. While the lattice component 26 is substantially embedded in the elastomeric material 22 to form the composite or hybrid flexible mat, the tabs 50 extend below and outside of the lower surface 52. See for example, FIG. 5. The array of tabs 50 extending from the reconfigurable printing bed 20 may then be attached to a plurality of rods or wires 60. More specifically, a wire 60 may be passed and threaded through the aperture 54 of tab 50. Thus, the plurality of wires 60 may each extend along at least one dimension (e.g., x or y axis) of the reconfigurable printing bed 20, where each wire 60 of the plurality is connected to at least one of the plurality of actuatable pins 34 (described in more detail below) and passed through at least one aperture 54 of one tab 50. The plurality of wires 60 may form a grid that extends in both the x and y axes, where certain wires intersect with other wires to form the grid pattern. For example, there may be a plurality of parallel and spaced apart wires having a first orientation corresponding to the x-axis and a plurality of parallel and spaced apart wires having a second orientation corresponding to the y- axis, which generally cross one another (or as described further below, may in fact be connected at an intersection point at the tip of each actuatable pin 34). In certain variations, the wires 60 are elastic and may be formed, for example, of fiberglass or spring steel. See also, FIG. 9 which shows a view from beneath the reconfigurable printing bed where the actuatable pins 34 are connected to a grid of wires 60 and to the reconfigurable printing bed 20. [0073] FIG. 7 shows connection regions 62 between actuatable pins 34 and the plurality of wires. Each pin 34 defines a tip 64 that may have a conical shape or be pointed. The tip 64 may include a first opening 66 that extends therethrough at a first height. The tip 64 may also include a second opening 68 in a different orientation (rotated by 90°) that extends therethrough at a second height below the first height of the first opening 66. In this manner, the first opening 66 may receive a first wire 70 having a first orientation (e.g., along the x-axis shown in FIG. 7). The second opening 68 may receive a second wire 72 having a second orientation (e.g., along the y-axis). As shown, a plurality of second wires 72 may be threaded through a plurality of second openings 68 in distinct spaced apart locations/elevations in tips 64. In this manner, the actuator pins 34 are connected to the wires 60 oriented at 90° distinct orientations to one another that define a grid.

[0074] Thus, the plurality of pins 34 are arranged in an array and designed to attach to the reconfigurable printing bed and locally manipulate its shape based on the position of the pins. As discussed just above, the pins 34 are tubular and contain a solid conical end with openings (first and second openings 66, 68) at the tip 64 to retain the elastic wires/rods 60 in a perpendicular orientation. As best seen in FIGS. 2, 7, and 8, the linearly actuatable pin 34 includes a tubular sleeve 74 having a solid pointed conical end or tip 64. The tubular sleeve 74 of the pin 34 has an opening 76 that can receive a lead screw 82 which retracts into the length of the pin 34. A nut 84 may be disposed and affixed by mechanical fasteners 85 at a lower end of the tubular sleeve near the opening 76, for example onto the second lower guide plate 38B. Thus, with the remainder of the pin 34 being hollow, the lead screw 82 is housed in the opening 76 of the tubular sleeve 74 that retracts into the length of the pin 34. The lead screw 82 moves the entire pin 34 up and down using a coinciding lead screw nut 84 that can pass within the tubular sleeve 74. Moreover, the tubular sleeve 74 of the pin 34 has a horizontal profile such that, when placed into an opening of matching geometry in the first upper guide plate 38 A it prevents unwanted rotation. For example, a cross sectional shape of the tubular sleeve 74 of pin 34 may be multifaceted with edges, so that it fits into an opening 88 of collar 90 having a complementary shape. The pins 34 are inserted through such an opening 88 in the collar 90, ensuring that for their full range of vertical motion, the rotational force applied to the threaded rod is translated into vertical movement only. An actuator stepper motor 40 may be attached to a rod 80 to move the lead screw 82 in a vertical direction. A lead screw guide 86 may be disposed above the motor 40 and may have a limit switch and the rod 80 may move therethrough. As such, only vertical or linear movement of the pin 34 is allowed. [0075] In certain variations, the dynamic reconfigurable printing bed may comprise a cast elastic deformable material (e.g., silicon/siloxane) sheet with a flexible cellular lattice infill (e.g., formed of thermoplastic). The naked edges (top and bottom) of the hexagonal cells of the lattice infill are notched to form a pivot point that promotes more flexibility and reduces surface buckling. The infill is placed within the silicone cast but has tabs that extend outside of the silicone. These tabs connect to the elastic rods or wire, which serves as an intermediary to the membrane and the pins.

[0076] In this manner, the present disclosure contemplates a reconfigurable flexible composite membrane (3D printing bed) that can take any curved shape, and in certain variations, any doubly curved shape. Thus, the inventive technology pertains to a CNC machine comprising a reconfigurable printing bed (3D printing bed) that is connected to a grid of actuators that control a shape or conformation of its surface on which material will be printed. The reconfigurable printing bed may have an elastic deformable material with a cellular lattice interior. The elastic material provides a smooth surface that stretches uniformly for 3D printing material. The cellular lattice can conform to a curved surface geometry, such as a doubly-curved surface geometry, without undesired buckling and the ability to return to its original shape without any plastic deformation, even after being subjected to continuous and repeated stretch and stress cycles. The balance of the two layers as a composite system results in a dynamic bed with a seamless, continuous, and freeform printing surface with structural rigidity to support the weight of the deposited material. Additively manufactured structures formed on such a reconfigurable printing bed capable of forming a surface having at least a single curvature are shown at least in part in FIGS. 10, 11, 12, and 13, and in certain variations, such a surface exhibits a double curvature. In certain aspects, the printed structure may comprise a variety of distinct layers.

[0077] The reconfigurable printing bed may be attached to and manipulated by a series of pins controlled by linear actuators.

[0078] The present disclosure further contemplates an additive manufacturing/3D printing process using such a reconfigurable printing bed. At the outset, the reconfigurable printing bed may be manipulated to be in a predetermined position by controlling the actuators and associated actuator pins. The predetermined position of the reconfigurable printing bed permits the material printed on its surface to conform to the shape. In certain variations, the 3D printing process uses a six-axis industrial robot in tandem with an extruder end effector. For example, an automated printing system as shown in FIG. 11 may be part of a robotic device, such as a computer numerical control (CNC) machine, with a tiltable head that can form additively manufactured panels or structures. Such machines have automation with advanced CNC machinery and highly articulated degrees of customization in directionality. The CNC machinery may include a computer processing unit (CPU) and one or more controllers that may be operated with various modules, as appreciated by those of skill in the art. Thus, an overall additive manufacturing system may comprise a CNC or robotic controlled automated print system that includes the automated extruder/end effector, which deposits a printable material onto the reconfigurable printing bed, optionally in multiple layers, to form a monolithic solid structure. In certain aspects, the monolithic solid formed comprises at least one horizontal panel, which may be a freeform panel. The printed layers can be variable in thickness (e.g., height of each respective deposited layer), as controlled by the change in height between layers. Software has been developed (custom built software tool) that automatically generates the fabrication data (trajectory of the robot(tool path) and material deposition rates) of any given freeform panel design (designed with CAD software). The robot motion and extruder deposition are controlled by a programmable logic controller.

[0079] In one variation, the reconfigurable printing bed is formed of a flexible mat manufactured by casting silicone over a flexible lattice component comprising a plurality of cells. The lattice component may be at least partially disposed within the flexible mat. The reconfigurable printing bed is designed to support the load of deposited material, by way of nonlimiting example, supporting the weight of 20 feet by 20 feet concrete panels, while still being flexible and providing smooth interpolation between the actuator tips. The flexible lattice layer may be placed inside the silicone during the casting process and thus considered to be an infill. This infill is designed to both provide rigidity to the surface without compromising flexibility, and to attach the composite membrane to the actuator’s pins. As discussed above, the infill may be formed of a flexible thermoplastic material in the pattern of a grid of cells. These structures are used for their flexible and shock absorptive properties. The side walls of the hexagonal cells of the cellular lattice infill may be notched to introduce deflection points in the cellular lattice that permit the lattice component to deform without faceting, thus minimizing any creasing and/or buckling to achieve a smooth, homogeneous, and continuous surface. The infill lattice layer extends outside of the flexible mat with a series of tabs having openings that attach to a grid of elastic rods or wires that are themselves connected to the actuator pins.

[0080] FIG. 12 shows a reconfigurable printing bed device including a computer numerical control (CNC) controlled reconfigurable printing bed demonstrating a surface profile shape/contour including a doubly curved surface in accordance with certain aspects of the present disclosure. The side views in FIG. 12 show a cross section of a lattice component (without the cast silicone shown) to demonstrate a horizontal flat position and a position where the surface is curved and free of buckling. The notches in the upper and lower edges of the lattice structure serve as weak points that are introduced to the geometry in order to achieve curvature while eliminating creased/faceted moments. Notably, without these weak points, any curved surfaces adopted by the bed would be faceted so the bed would not be able to achieve the expected geometry and would not have a smooth surface. In this manner, the lattice component helps to facilitate a smooth surface of the reconfigurable printing bed.

[0081] FIG. 13 shows a reconfigurable printing bed device including a reconfigurable printing bed with a multiple layered 3D printed structure disposed thereon in accordance with certain aspects of the present disclosure. Further, the side view of the profile of the reconfigurable printing bed shows how the plurality or wires or elastic rods are connected to the bed and thus impart a predetermined shape to the printing surface. As shown, the actuators can thus impart a desired geometry to the surface. When material is deposited on the surface, it thus has a complementary shape to the geometry /contoured surface profile.

[0082] In various aspects, the present disclosure provides methods of forming planar structures, such as free form panels, by using additively manufactured or three dimensionally printed (3D) printed materials. Additive manufacturing (AM) also commonly referred to as three-dimensional (3D) printing, is a process by which material is applied in an additive, layer-by-layer formation technique. Such methods of additive manufacturing or 3D printing on a dynamic reconfigurable printing bed can produce large scale free form panels from various printable materials, including concrete, clay, wood, and the like. In certain variations, such a method of additive manufacturing on a dynamic bed may comprise depositing a flowable material after passing through a printer onto a surface of a reconfigurable printing bed and allowing the material to harden on the reconfigurable printing bed to form a printed structure. Notably, the depositing may include printing, extruding, or spraying of a material in an additive manufacturing process. The reconfigurable printing bed comprises a flexible mat comprising an elastomeric polymer and having a surface configured to receive a material disposed thereon. The reconfigurable printing bed also includes a lattice component disposed within the flexible mat, where the lattice component comprises a plurality of cells that are connected, as described above. A plurality of actuatable pins is disposed beneath the reconfigurable printing bed. Each actuatable pin is connected to a location on the reconfigurable printing bed and configured to translate the reconfigurable printing bed to a predetermined position capable of defining a single curvature, and in certain variations, a double curvature. [0083] In certain aspects, the depositing of the flowable material occurs with an automated three-dimensional printer having a print head (e.g., a 3D printing end effector/extruder) disposed on at least one robotic device. In certain variations, the process of 3D printing on the CNC controlled reconfigurable or dynamic printing bed involves using any apparatus (e.g., an automated or robotic device) with 3 axes or more that includes a 3D printing toolhead. An apparatus with only 3 axes can print the freeform surface in planar approach while an apparatus with greater than 3 axes allows for tilting the toolhead to always be perpendicular to the surface of the reconfigurable printing bed at any given point while printing. This ability allows for more precise material deposition. The automated three-dimensional printer may be at least partially controlled by a computer numerical control (CNC) system. In alternative variations, the printer may have an automated spray head that sprays a flowable/sprayable material at the target surface.

[0084] The printable or flowable material may comprise a material selected from the group consisting of: a cementitious material, clay, dirt, bio-materials, wood, hempcrete, polymers, and combinations thereof. However, the printable material can be any slurry material that is extrudable or sprayable on the bed. The materials may include a cementitious-based material like concrete, clay, hemp, such as hempcrete, earth-based, dirt, bio-material, a polymer/plastic, or any printable material. In certain variations, the printable material may be a so-called “hempcrete,” that comprises particles derived from the hemp plant mixed with a cementitious or pozzolanic binder material, such as a calcium oxide (lime)-binder and water. The printable material may be a composite material that includes a binder and a reinforcement phase. For example, the binder may be a polymer and the reinforcement phase may be a reinforcing particle or fiber, such as carbon fibers or wood-based or cellulose-containing fibers.

[0085] In certain other aspects, the methods may further comprise adjusting the position of one or more of the plurality of actuatable pins, for example, by linearly translating one or more of the pins, to shape the surface of the reconfigurable printing bed to the predetermined position. In this manner, after depositing the flowable material from the 3D printer head onto the shaped or contoured surface having the predetermined position, the printed structure conforms to the contours of the surface of the reconfigurable printing bed during the depositing. In certain aspects, the adjusting of the position of one or more of the plurality of actuatable pins is conducted via an automated process that is at least partially controlled by a computer numerical control (CNC) system, as described above. The surface of the reconfigurable printing bed may be shaped to have a curved shape (e.g., doubly curved), so that the printed structure likewise has a complementary curved shape. As noted above, the printed structure may be a freeform panel and may have at least one dimension of greater than or equal to about 5 feet, optionally greater than or equal to about 10 feet, optionally greater than or equal to about 15 feet, and in certain variations, optionally greater than or equal to about 20 feet. In certain variations, the printed structure may have two dimensions (e.g., length and width) within these ranges of dimensions.

[0086] In certain aspects, the reconfigurable printing bed is connected to a plurality of wires or rods, as described above, where the wires extends along at least two dimensions of the reconfigurable printing bed and where each wire of the plurality is connected to at least one of the plurality of actuatable pins and to the reconfigurable printing bed, so that adjusting the position of the one or more of the actuatable pins shapes the surface of the reconfigurable printing bed. In this manner, the movements of one or more of the actuatable pins can be controlled by CNC driven actuators and thus deform the dynamic 3D printing bed. As described above, the actuators are linked to the reconfigurable printing bed via an array of vertically actuated pins that connect to a grid of elastic rods or wires, which are in turn connected to the reconfigurable printing bed. See for example, FIGS. 12 and 13.

[0087] This dynamic and reconfigurable printing bed system is tailored for the production of freeform building panels across many scales (e.g., as large as 20 feet by 20 feet or larger). One embodiment is for forming freeform architectural facade components in concrete or clay (terracotta). However, 3D printing material can be expanded to any slurry material that is extrudable or sprayable on the bed. Three-dimensional freeform concrete panels, as well as clay panels that underwent firing to achieve a terracotta finish, have been formed. Some of these panels were printed as a single layer only, while others were printed with multiple layers printed on top of each other (see FIG. 13) to provide structural rigidity for larger spans and a unique texture finish. Moreover, coupling the 3D printing with CNC dynamic bed provided by the present disclosure allows the creation of lightweight freeform panels. 3D printing deposits material only where needed, producing thousands of unique lightweight panels with hollow interiors and customized surface patterns for enhanced building performance from the same reconfigurable dynamic 3D printing bed.

[0088] In other aspects, the present disclosure contemplates forming insulated structures, such as insulated panels via additive manufacturing with the reconfigurable printing bed device having the inventive reconfigurable printing bed. By way of example, FIG. 14 shows one such process where an additive manufacturing process 100 forms an insulated panel structure by using a reconfigurable printing bed 110 in accordance with certain aspects of the present disclosure. In step 102, the reconfigurable printing bed 110 is shaped in the manner described above, so that a printing surface 112 has a contoured or curved geometry. As shown, an initial printed structure 114 is deposited onto the printing surface 112 to define a frame of a panel having a plurality of hollow cavities 116. Next, in step 102, an insulating material, such as an insulating foam 120 may be deposited into the cavities 116. The deposition may be conducted by the same automated device 122 that deposited the frame structure 114 or may be deposited by other processes. Where necessary, a surface 124 of the insulating foam 120 may be subjected to a finishing process, such as milling or machining to smooth the material to match a curvature of the panel.

[0089] In step 104, an insulated panel 130 is formed by depositing via printing a surface layer 132 over the frame 114 and insulating foam material 120. The insulated panel 130 may be removed from the reconfigurable printing bed 110.

[0090] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

CLAIMS What is claimed is:

1. A reconfigurable printing bed device for additive manufacturing, the reconfigurable printing bed device comprising: a reconfigurable printing bed defining a surface configured to receive a deposited material, the reconfigurable printing bed comprising: a lattice component comprising a plurality of cells that are connected to one another, where each cell defines an open region; a flexible elastomeric polymer disposed with the open region of each cell of the lattice component to define a flexible mat; and a plurality of actuatable pins disposed beneath the reconfigurable printing bed, wherein each actuatable pin is connected to a location on the reconfigurable printing bed and configured to translate the reconfigurable printing bed to a predetermined position so that the reconfigurable printing bed is capable of defining a structure having at least a single curvature.

2. The reconfigurable printing bed device of claim 1, wherein the elastomeric polymer comprises siloxane.

3. The reconfigurable printing bed device of claim 1, wherein the lattice component comprises a polymeric material selected from the group consisting of: thermoplastic elastomers (TPE), thermoplastic polyurethanes (TPU), thermoplastic polyolefinelastomers (TPO), thermoplastic styrene block copolymers (TPS), thermoplastic polyamides (TPA), thermoplastic copolyesters (TPC), thermoplastic vulcanates (TPV), and combinations thereof.

4. The reconfigurable printing bed of claim 1, wherein the plurality of actuatable pins are each connected to a linear actuator.

5. The reconfigurable printing bed device of claim 1, further comprising a plurality of wires each extending along at least one dimension of the reconfigurable printing bed, wherein each wire of the plurality is connected to at least one of the plurality of actuatable pins and to the reconfigurable printing bed.

6. The reconfigurable printing bed device of claim 5, wherein the plurality of wires define a grid with intersecting wires that extends across the reconfigurable printing bed.

7. The reconfigurable printing bed device of claim 5, wherein the lattice component comprises a plurality of tabs that protrude from a lower surface of the reconfigurable printing bed, each of the tabs comprising an aperture that receives a wire of the plurality of wires.

8. The reconfigurable printing bed device of claim 5, wherein the plurality of wires are elastic and comprise a material selected from the group consisting of: fiberglass, spring steel, and combinations thereof.

9. The reconfigurable printing bed device of claim 1, wherein the plurality of cells each comprises at least one wall having an edge with at least one notch formed therein.

10. A method of additive manufacturing on a dynamic bed, the method comprising: depositing a flowable material onto a surface of a reconfigurable printing bed and allowing the material to harden on the reconfigurable printing bed to form a printed structure, wherein the reconfigurable printing bed comprising: a lattice component comprising a plurality of cells that are connected to one another, where each cell defines an open region; a flexible elastomeric polymer disposed with the open region of each cell of the lattice component to define a flexible mat; and a plurality of actuatable pins disposed beneath the reconfigurable printing bed, wherein each actuatable pin is connected to a location on the reconfigurable printing bed and configured to translate the reconfigurable printing bed to a predetermined position capable of defining a single curvature.

11. The method of claim 10, wherein the depositing the flowable material further comprises printing the flowable material by passing through a printer head.

12. The method of claim 10, wherein the depositing of the flowable material occurs with an automated three-dimensional printer having a print head disposed on at least one robotic device.

13. The method of claim 10, wherein the automated three-dimensional printer is at least partially controlled by a computer numerical control (CNC) system.

14. The method of claim 10, wherein the flowable material comprises a material selected from the group consisting of: a cementitious material, clay, dirt, bio-materials, wood, hempcrete, polymers, and combinations thereof.

15. The method of claim 10 prior to the depositing, further comprising adjusting the position of one or more of the plurality of actuatable pins to shape the surface of the reconfigurable printing bed to the predetermined position, so that the printed structure conforms to the contours of the surface of the reconfigurable printing bed during the depositing.

16. The method of claim 15, wherein the adjusting of the position of one or more of the plurality of actuatable pins is conducted via an automated process that is at least partially controlled by a computer numerical control (CNC) system.

17. The method of claim 15, wherein the surface is doubly curved and the printed structure is doubly curved.

18. The method of claim 15, wherein a plurality of wires each extend along at least two dimensions of the reconfigurable printing bed, wherein each wire of the plurality is connected to at least one of the plurality of actuatable pins and to the reconfigurable printing bed, so that adjusting the position of the one or more of the actuatable pins shapes the surface of the reconfigurable printing bed.

19. The method of claim 10, wherein the printed structure is a freeform panel.

20. The method of claim 10, wherein the printed structure comprises an insulated panel and the depositing the flowable material comprises forming a frame structure having a plurality of open regions on the surface of the reconfigurable printing bed and the method further comprises introducing an insulating material into the plurality of open regions, followed by depositing the flowable material to form a surface layer of the insulated panel.

21. The method of claim 10, wherein the printed structure has at least one dimension that is greater than or equal to about 10 feet.