Multi-Colored 3D Concrete Printing
 
Exceptional Wall and the interior accent walls are additively manufactured in two or more layers that may be cast vertically or horizontally by spray or pouring cementitious and insulating materials. Precasting enables the utilization of 3D printing to make spectacular wall panels. Robotic 3D Printing Face with Multiple Colored Concrete Exceptional Wall’s precast product line combines the use of forms with 3D printers to make detailed, multi-colored panel faces. The form determines a wall face’s texture and shape with one or more printers (dispensers) placing different colored face material in precise locations and amounts on the form. Greatest Value in Exterior Building Walls - by Far 3D printing multi-colored, cast stone face material on a form has an estimated manufacturing cost of $1.20/sf for most designs. This compares to brick and stone cladding applied to a wall costing $15 to $30/sf and will greatly increase demand for Exceptional Wall brick and stone walls. Combining forms with multiple 3D printers creates unprecedented versatility and opens the door for a vast amount of new and exciting interior and exterior multi-colored wall designs incorporating unique colors, textures and shapes that were never before economically or materially feasible.  Manufacturing Process Precast/Prefab Manufacturing Process: Panels are made by adhesively bonding multiple layers of material together with a polyurethane foam layer bonding the panel to an embedded frame. The process begins by casting a facing material or positioning siding board or other solid cladding, face down, against a form. One or more additional layers of material are bonded to the face layer, each adding special features such as impact, fire, insect and water resistance. The last layer is usually spray polyurethane foam which bonds the panel to a frame. The process simply casts self-bonding materials onto one another. Copyright 2024 by Exceptional Building Systems, Inc., all rights reserved.
Colored concrete face layer dispensed on 3D patterned form face
Computer controls location & thickness of concrete dispensed
Concrete backing layer bonds face layer together
Multi-colored brick/stone wall face costs less than $2/sf