Patent Description:
The present invention relates to frames for windows or doors and methods for making such frames.

Windows, doors, skylights and structural components made from materials such as aluminum, alloys thereof, steel and plastics are known. For example, window and door assemblies may be made from aluminum alloy extrusions. Windows manufactured with aluminum frame and thermal break components are also known. For example, manufacturers use pour-and-debridge and crimped polyamide strips to make aluminum windows with thermal breaks. The pour-and-debridge type window uses liquid polyurethane poured in the pocket of an aluminum extrusion. After the polyurethane solidifies, the aluminum backing of the pocket is cut away. The process involves four different operations: polyurethane mixing, lancing the aluminum extrusion, abrasion conditioning of the aluminum extrusion and cutting the backing of the thermal break. The crimped polyamide method uses polyamide (or other polymer) strips that are crimped at both ends into the internal and external aluminum extrusions of the window frame. In this case, the manufacturing process requires three different operations: knurling the aluminum extrusions, inserting the polyamide and crimping the aluminum extrusions. Windows that use pour-and-debridge thermal breaks may have a general U factor of about <NUM> Btu/h ft<NUM> F and windows that use crimped polyamide may have a general U factor of about <NUM> Btu/h ft<NUM> F. This corresponds to about an R3 thermal resistance. Both of these technologies require a significant number of manufacturing steps and expensive manufacturing equipment. Typically lengths of material are formed, such as plastic or aluminum extrusions, cut and mitered to size, machined to permit the use of fasteners and joined from multiple pieces. Alternative methods, apparatus and manufactures for producing windows, doors and other structural and architectural components remain desirable.

An architectural manufacture is disclosed in https://www. com/window-companies-utilize-3d-printing-technology/. <FIG> of <CIT> shows a 3D-printer for making an architectural manufacture.

The present invention provides an architectural manufacture according to claim <NUM>.

In another embodiment, the deposits are in the form of least one of dots, lines or ribbons.

In another embodiment, the architectural manufacture is monolithic.

In another embodiment, the deposits are spatially distributed to form areas of greater and lesser mechanical strength.

In another embodiment, the areas of greater mechanical strength have thicker or denser structural walls.

In another embodiment, the areas of greater mechanical strength have a rib on a surface thereof.

In another embodiment, the rib is internal to the manufacture.

In another embodiment, the manufacture has a corner and the rib is at the corner.

In another embodiment, the manufacture has hollows therein.

In another embodiment, the hollows are defined by exterior members and internal members.

In another embodiment, the exterior members include a plurality of exterior walls and the internal members include a network of structural elements.

In another embodiment, the network of structural elements includes a plurality of pyramids.

In another embodiment, the manufacture has a plurality of internal hollow cells.

In another embodiment, the architectural manufacture is composite, having a plurality of different materials for forming associated sub-portions.

In another embodiment, the different materials have different thermal properties.

In another embodiment, the different materials have different mechanical properties.

In another embodiment, at least one sub-portion is made of a metal and at least one sub-portion is made of plastic.

In another embodiment, at least one sub-portion is not made by additive manufacturing.

In another embodiment, at least one sub-portion is an extrusion.

In another embodiment, a first portion is an outer cladding on a second portion.

In another embodiment, a first portion is an interior reinforcement structure.

In another embodiment, the interior reinforcement structure is at least one of a a spine, a beam, or a grid.

In another embodiment, a second portion includes a foam material.

In another embodiment, further including an adhesive to join a first sub-portion to a second sub-portion.

In another embodiment, the frame surrounds a glazing panel.

In another embodiment, the frame has a monolithically formed first sub-portion with a recess for receiving the glazing panel and a second portion extending over the glazing panel and attached to the first portion capturing the glazing panel there between.

In another embodiment, the frame has at least one of integral glass setting blocks or integral anchoring clips.

In another embodiment, the outer cladding is a clip-on cap.

In another embodiment,the outer cladding is a cap with a portion thereof imbedded in the second portion.

In another embodiment, a surface texture of the manufacture simulates wood grain.

In another embodiment, an exterior surface of the manufacture is coated.

The present invention also provides a method for making an architectural manufacture according to claim <NUM>.

In another embodiment, the step of digitally scanning is 3D scanning.

In another embodiment, further including the step of altering the design data in light of the finite element analysis to improve shape optimization.

In another embodiment, a final dimension of the architectural manufacture is achieved by post processing.

In another embodiment, the post processing is by material removal.

In another embodiment, the plurality of deposits of material include a first ribbon of material and a second ribbon of material, the second ribbon of material printed over the first ribbon of material generally parallel and laterally shifted relative to the first ribbon of material.

The present invention also provides an apparatus for making an architectural manufacture according to claim <NUM>.

In another embodiment, further including a hardening device for rendering the material non-flowable.

In another embodiment, further including a plurality of print heads capable of simultaneously depositing material.

In another embodiment, the plurality of print heads are capable of moving independently or in conjunction.

In another embodiment, the apparatus is mobile and capable of being transported to a work site.

For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.

The present disclosure reveals a novel manufacturing technology that allows manufacture of high performance windows via simple, economic and ecological manufacturing processes. The present disclosure recognizes that the manufacture of architectural products may be done via additive processes in contrast to the more traditional subtractive manufacturing techniques of cutting, drilling, joining, etc. The additive manufacturing (AM) processes contemplated by the present application include 3D printing, selective laser sintering (SLS), selective laser melting (SLM) and stereo lithography. The present disclosure also contemplates the options of utilizing data obtained from computer aided design (CAD) and computer aided manufacturing (CAM) models, as well as data obtained from 3D scanning and finite element analysis (FEA) to drive and/or direct the AM process employed for manufacturing the architectural manufacture, e.g., a window or door. Aspects of the present disclosure include architectural manufactures, such as windows and doors having a composite construction with variations in composition structure, density and distribution of materials within the body of the manufacture. These variations may be driven by the thermal and structural requirements of the manufacture. The manufactures may utilize an outer layer or inner framework upon which or around which is deposited an additively manufactured portion to form the final product. For example, one or more outer surfaces of the manufacture may be made from an aluminum extrusion and a core is made from a high density foam with low thermal conductivity and good structural properties. In another alternative a reinforcement, such as an extruded aluminum spine, may provide structural rigidity to a manufacture that is produced by coating the framework with one of more layers of foam and plastic that provides thermal insulation and/or an aesthetic outer shape and finish. Adhesives and sealants may be selectively applied by AM to join preformed panels, such as glazing panels to the manufacture produced by AM or to adhere an exterior shell to a core made by AM.

An aspect of the present disclosure is a reduction in lead times for the production of custom architectural products through automated additive manufacturing that may be driven by automatically obtained digital data or models, e.g., those garnered by a 3D scanning device or from a CAD/CAM file produced by an operators entering the exact dimensional requirements for a given application and those dimensions being used to direct the additive manufacturing process. The additive manufacturing process in accordance with the present disclosure is adaptable to be used with existing structural members, such as an extruded aluminum cladding, support structures, such as metal plates of or hinge structures that are embedded in a matrix of 3D printed material(s). In one embodiment, a hinge structure, e.g., a half hinge extending from the manufacture, may be made via 3D AM. The use of additive manufacturing techniques in accordance with the present disclosure avoids the waste associated with subtractive manufacturing methods. The ease with which a given design may be implemented may optionally be used to develop models that may be presented to for customer aesthetic design review and approval as a commercial order pursuit tool. It is anticipated that utilizing the additive methods of the present disclosure will allow elimination of existing conventional manufacturing steps, such as material component takeoff, waste and scrap. The system disclosed in the present application permits flexibility in providing mixed models of a given architectural product, e.g., based upon size, configuration and/or performance and improved assembly cycles over conventional cut and fabricate assembly methods. A given design may be altered "on-the-fly" in response to design changes that arise after production begins. Expedited design-to-manufacture times may lead to decreased or eliminated lead times and closure (dry-in) times for buildings. The additive manufacturing process of the present disclosure permits designs where the architectural manufacture has varying thickness, e.g., at the vertical middle of window where the maximum deflection occurs in order to minimize stress and deflection. The architectural manufacture does not have to be symmetrical and the thickness of walls defining the manufacture may vary as required for the application.

<FIG> show a casement outswing type window assembly <NUM> having a sash <NUM> held within a frame <NUM> having side jambs <NUM>, <NUM>. The sash <NUM> pivots on one or more hinges/pivots <NUM>, <NUM> (diagrammatically shown in dotted lines), allowing the sash <NUM> to be opened and closed relative to the frame <NUM>. Alternatively, the window assembly <NUM> may be a hung type window with one or more sashes <NUM> that are either slideably or hingedly mounted to a frame <NUM> to allow opening and closing. As yet another alternative, the window assembly <NUM> may feature one or more non-movable sashes <NUM>. The sash <NUM> features horizontally oriented rails <NUM>, <NUM> and vertically oriented stiles <NUM>, <NUM>. The frame <NUM> has an upper horizontal head <NUM> and a lower, horizontal sill <NUM>. The glazing <NUM>, e.g., glass or plastic is held within the sash <NUM>. It should be understood that <FIG> shows one type of window, but that there are many other types of windows to which the present disclosure may be applied, including moveable and immoveable windows used in residential and commercial applications.

<FIG> show that the rail <NUM> may be formed from a plurality of sub-parts <NUM>, <NUM>, <NUM>, <NUM>. The sub-parts <NUM>, <NUM> and <NUM> are in the form of extrusions, e.g., of aluminum. The sub-part <NUM> is a structural foam member, e.g., made from high density polymeric foam, e.g., PVC, polyurethane, etc. having structural properties (tensile strength, shear strength, etc.) suitable for this application. The sub-parts <NUM> and <NUM> are mechanically and adhesively coupled to the foam member <NUM> to form the rail <NUM>. The stiles <NUM>, <NUM> and rail <NUM> may be similarly constructed to surround and support the glazing unit <NUM>, which is, in this instance, a triple glazed unit having three spaced glass panes 50a, 50b, 50c. The window frame <NUM> may have a similar composite construction. For example, the cross-sectional view of the sill <NUM> shown in <FIG> shows a composite construction made from sub-parts <NUM>, <NUM> and <NUM>, with sub-parts <NUM> and <NUM> being extrusions, e.g., of aluminum alloy and sub-part <NUM> being a structural foam member interposed there between. The foam sub-parts <NUM> and <NUM> have a low thermal conductivity of, e.g., about <NUM> W/mK to <NUM> W/mK and function as a structural component as well as a thermal break between the aluminum extrusions <NUM>, <NUM> and <NUM>, <NUM>, respectively.

<FIG> shows a gasket <NUM> with a push-in, barbed leg <NUM> received in slot <NUM> in foam sub-part <NUM>. The barbed leg <NUM> facilitates insertion of the leg <NUM> into the slot <NUM>, but resists withdrawal due to the orientation of the barbs 62B. A contact lip <NUM> of the gasket <NUM> abuts against face 33F formed on a downwardly extending shoulder <NUM> of foam sub-part <NUM> to create a seal against air infiltration when the window assembly <NUM> is closed. It should be noted that the gasket <NUM> provides a redundant /additional seal over and above the seals provided by gaskets G1, G2 proximate the outside environment O and the inside environment I, respectively. In this embodiment, the foam sub-parts <NUM> and <NUM> participate in the sealing function of the window assembly <NUM> in addition to the structural and thermal break functions that they perform. The foam sub-part <NUM> is easily adapted to this function in that the shoulder <NUM> can be formed by machining/removing material from the foam sub-part <NUM>. Alternatively, the shoulder <NUM> can be formed during formation of the foam sub-part, e.g., by injection molding. In a similar manner, the structural foam composition of foam sub-part <NUM> lends itself to easy formation of slot <NUM> by machining the slot <NUM> or by injection molding that feature into the foam sub-part <NUM>. The foam sub-parts <NUM>, <NUM> may alternatively be cut from a larger block of foam, e.g., using a knife, saw, laser, torch, water or air jet.

In accordance with an embodiment of the present disclosure, one or more of the sub-parts <NUM>, <NUM>, <NUM>, <NUM>, etc. may be formed by 3D printing. For example, instead of being made from an aluminum extrusion, subpart <NUM> may be formed of a polymer, such as ABS, PLA, Nylon, etc. that is "printed" by a 3D printing print head. In this manner, the 3D printed subparts <NUM>, <NUM>, <NUM>, etc. may be first formed and then assembled to the other sub-parts, <NUM>, <NUM>, <NUM>, etc. to make the window assembly <NUM>. As is known, various materials may be used in different additive processes. For example, a manufacture made from aluminum metal may be formed by EBF, DMLS, EBM, SLM , SHS or SLS using an additive methodology. In another alternative, a plurality or all of the sub-parts <NUM>, <NUM>, <NUM>, <NUM>, etc. may be 3D printed contiguously.

<FIG> shows a sill <NUM> of a window assembly like window assembly <NUM> being made by an additive manufacturing process. More particularly, the sill <NUM> is shown on a table <NUM> that is optionally movable on a plurality of axes X, Y and Z as shown by coordinate system 170C. The table <NUM> may be moved by any number of mechanical, pneumatic or electrical positioning means under computer control. A first printing device <NUM> has a telescoping arm 172A with a print head 172B at one end. The print head 172B is supplied with media, such as a polymer, like ABS or PLA in liquid, powder, gel or pellet form via conduit <NUM>. In the case of thermoplastic powders or pellets, the print head may have a heating element to melt the media before it is dispensed. Electrical power and control signals are provided to the print head 172B via conduit 172E. In this manner, deposits of media, e.g., in the form of dots, lines or ribbons (not shown) may be deposited by the print head 172B on the surface <NUM> and then on the formed manufacture <NUM>, as it is built up. A second printing device <NUM> has a telescoping arm 174A with a print head 174B at one end. The print head 174B is supplied with media via conduit <NUM> and electrical power and control signals via conduit 174E. The media supplied by conduits <NUM> and <NUM> may be the same or may be different. For example, one print head 172B may be supplied with a hard plastic, such as ABS and the other print head 174B may be supplied with a foaming polymer, such as polyurethane. Materials such as fiber reinforced ABS and rubber may also be printed. The print heads 172B and 174B are movable on a plurality of axes X, Y and Z as shown by coordinate system 172C. The position of the arms 172A, 174A and the print heads 172B, 174B are determined under computer control. As with additive manufacturing generally, either the support structure (here table <NUM>), the print head(s) 172B, 174B, or both are moved as the additive manufacturing occurs to deposit the multiple "pixels" of deposited material at selected locations to form the manufacture <NUM>. This typically occurs in multiple parallel planes 170P, starting with the surface <NUM> of the table <NUM> and finishing at the upper extent 148E of the manufacture <NUM>. As is known in the field of machining and additive manufacture, print heads and supports may be moved in more than in the X, Y and Z directions, i.e., as described in the terms of art "<NUM>-axis printing" and "<NUM>-axis machining. " In addition, <NUM> axis printing and machining is also know where displacements of the tool/print head may be made in X,Y and Z directions as well as executing yaw, pitch and roll movements. Embodiments of the present disclosure may be implemented using <NUM> or <NUM> axis printing.

In the sill manufacture <NUM> shown in <FIG>, several different materials are used, more specifically, the sub-parts <NUM> and <NUM> are formed from a first polymer, such as ABS and the sub-part <NUM> is made from a foam, such as polyurethane. The foam of subpart <NUM> is built up around a matrix or support framework <NUM> that may be printed from a polymer, such as ABS. Given that the printing is directed by a computer in accordance with a design/data model, which is effectively infinitely variable, the shape and contours of any of the subparts <NUM>, <NUM> and <NUM> are highly variable. For example, the thickness of the walls of the 141W1 and 141W2 may be any selected thickness and may vary in thickness over their extent, as determined by the design, which may reflect strength or thermal requirements of the application of the architectural manufacture <NUM>. In addition to printing architectural components, like subpart <NUM>, the present disclosure contemplates printing around components that are held in a given position relative to the manufacture <NUM>, e.g., by fixturing. For example, metal plate 141P may be held in a fixture as the sub-portion <NUM> is printed around it. In this manner, metal plate 141P may be used as a mounting plate, e.g., for a hinge, handle or other device, via threaded nipples 141PN which are embedded in wall 141W2. In another example of the integration of a non-printed member with a printed portion, cladding plate 145P may be held by fixturing while wall 145W1 is printed next to it. The plate 145P may be made from a metal, such as aluminum or stainless steel and may be provided for aesthetic or functional reasons, e.g., to provide an abrasion-resistant surface. The plate 145P may have a rough surface that forms an interlocking interface with wall 145W1. In another alternative, the wall may be adhered to the subpart <NUM> after it is printed, or a layer of adhesive may be printed between the plate 145P and the wall 145W1, as the wall 145W1 is printed, to assure a strong bond there between.

The manufacture <NUM> produced may be dimensioned to interact with and assemble to components that are made by traditional methods. For example, a glazing panel <NUM> may be inserted into a door or window manufactured by additive methods.

In preparation for installation of the glazing panel <NUM>, a sealant, such as a silicone sealant, may be printed on the manufacture <NUM> and then the glazing panel assembled to the manufacture.

Since the additive manufacturing of the present disclosure allows for unlimited variation in the distribution of printed media in three-dimensional space, material saving approaches may be utilized, such as the inclusion of hollows within a given volume of the manufacture <NUM>. In one example, the given volume of printed material may resemble a plurality of hollow, adjacent cells, like a honeycomb. Internal hollows in a member can be used to save material and control heat transmissibility of the member, reducing heat transfer while preserving strength. Selected areas of a manufacture <NUM> may be provided with increased strength, either attributable to increased use of material, e.g., increasing the thickness/density of material per unit volume or changing the material composition, e.g., using a greater amount of high strength material (media) in a selected area. In one example, the corners of a window or door have a need for increased strength due to anticipated torsional loading and may be reinforced by higher material density or greater use of high strength materials.

<FIG> shows an alternative embodiment of the present disclosure in which a print head assembly <NUM> has a plurality of print units 272A-272I. The print head assembly <NUM> is positioned relative a table <NUM> that supports a manufacture <NUM> on surface <NUM> thereof. Either or both the print head assembly and/or the table <NUM> may be moveable on a plurality of axes, as illustrated by coordinate system 270C. While a table <NUM> support is depicted, a moving belt or other type of support surface could be used. Media 272M1-272M3 of one or more types may be distributed to the print head assembly <NUM> from associated reservoirs for printing the manufacture <NUM>. The media 272M1-272M3 may be channeled to the print units 272A-272I by conduits or passageways 272P within the print head assembly <NUM>. The print units 272A-272I may optionally be individually moveable relative to the print head assembly <NUM>, as shown by print unit 272E via electrical motors, such as, linear motors or stepper motors acting through pulleys and belts. The media 272M1-272M3 may be supplied under pressure, such that the print units 272A-272I act as valves that dispense the pressurized media. The print units 272A-272I may be electromagnetically controlled to regulate the duration of valve opening and the amount of media dispensed for each deposited dot/pixel, line or ribbon of media that is used to build up the manufacture <NUM>. The dispensing of the print units 272A-272I, any individuated positioning thereof, the positioning of the table <NUM> and/or the print head assembly <NUM> is all coordinated and controlled by a programmed computer <NUM>. The printing system <NUM> of <FIG> may be used to rapidly print an architectural manufacture <NUM>, in that multiple print units 272A-272I may be activated simultaneously to deposit media, e.g., on both sides 248A, 248B of the manufacture <NUM> simultaneously. While only nine print units 272A-272I are illustrated in <FIG>, any number could be used, <NUM>, <NUM> or <NUM>,<NUM> and their spatial distribution may be such as to increase the speed of printing of the manufacture <NUM>. For example, in the case of manufacture <NUM> that has a frame-like shape, multiple print units 272A-272I may be arranged in the print head assembly <NUM> roughly approximating the frame shape, such that small displacements of the print units 272A-272I and /or the table <NUM> and/or the print head assembly <NUM> can achieve rapid printing of a plane of the manufacture. One or a plurality of sources of radiation <NUM>, e.g., a UV light or laser may be used in conjunction with the printing to fix/cure the printed media, e.g., 272M1 after printing, depending upon the identity of the media and how it hardens. For media that hardens by cooling, a source <NUM> of cold air or other gas, such as carbon dioxide, may be provided to cool the printed media, e.g., 272M2, in order to allow the media to rapidly achieve a temperature that is optimal for printing the next layer and to increase the rate of printing.

<FIG> shows a system <NUM> that may be used to gather data and generate a model of the manufacture, e.g., <NUM>, <NUM> that may be used as the data reference for guiding the computer controller, e.g., <NUM> (<FIG>) to direct the process of additive manufacture. More particularly, a given architectural application, e.g. building B, has various architectural features, such as apertures A, which may be for windows, doors, skylights, etc. The aperture A shown is depicted as having a non-regular (complex) shape to illustrate that the system <NUM> may be used on an aperture A of a given shape to create a model for a manufacture <NUM>, <NUM> specifically suitable to the design requirements of the building B and aperture A. While <FIG> shows a 2D diagrammatic depiction of a building B, it is understood that all buildings would have a 3D shape and that the features, such as the aperture A, would also have three dimensions. A 3D scanner <NUM>, such as a Model Handy Scan 3D scanner available from Creaform may be used to extract the 3D shape of the aperture A from the building B and express that shape in digital form, such as a stereolithography (STL) file that may be received as input data to a CAD program, such as Inventor, available from Autodesk.

In some instances, such as when architectural features (A) are highly regular and precise, e.g., as a consequence of rigidly controlled modular design and manufacture encountered in factory manufactured modules for a high rise building or, in the instance where a high degree of variation and large tolerances are acceptable, the 3D scanner may be unnecessary and factory spec measurements or measurements taken by a tape measure may be suitable dimension data <NUM> for the architectural problem. Besides functionally defined dimensional data, aesthetic data 312A, e.g., pertaining to surface shape or profile may also be used with the dimension data <NUM> by a computer running CAD/CAM software <NUM>, such as Inventor from Autodesk to generate a 3D CAD/CAM design/model <NUM>. In accordance with an aspect of the present disclosure, the architectural problem, e.g., the aperture A to be closed, may ultimately be used to define the solution, i.e., the manufacture <NUM>, <NUM>. Further with respect to defining the "problem" to be solved, the manufacture <NUM>, <NUM> is preferably capable of withstanding the forces F, e.g., compression, wind, etc. that it will encounter when incorporated into the building B. In some instances, the manufacture <NUM>, <NUM> may contribute to the structural strength of the building B and in other instances their supporting capacity is designed to be minimal. In any case, the force or stress requirements F that will be experienced by the architectural element that is installed in aperture A are preferably determined, e.g., based upon calculations, architectural models of static and dynamic forces and/or empirical measurements. In addition to the force definition of the problem that the manufacture <NUM>, <NUM> is intended to solve, architectural elements have thermal requirements or objectives T that may also be taken into consideration in their design. This thermal objective T may be expressed as an R-value. In accordance with one embodiment, force data <NUM> and thermal requirements <NUM> associated with an architectural feature like aperture A may be used along with property data <NUM> pertaining to the physical properties of the media, e.g., 272M1-272M3 and the 3D model <NUM> to perform a finite element analysis <NUM> on the initial design (3D model) <NUM> of the manufacture <NUM>, <NUM>. If the FEA indicates that the 3D model <NUM> executed in the material having the properties reflected in the property data <NUM> is adequate to meet all force and thermal requirements, the 3D model <NUM> may be used as the reference data for executing the additive manufacture of the manufacture <NUM>, <NUM>. In the event that the 3D model <NUM> evidences shortcomings, it may be modified to yield an altered 3D model <NUM>, e.g., by a change in dimensions or materials to yield a more robust model that may be subjected to another round of finite element analysis <NUM>. The 3D model <NUM> or <NUM> may then be used by a 3D printer system <NUM>, <NUM> to generate print control signals <NUM>.

In another alternative approach, the stress intensity over the volume of a 3D CAD/CAM design/model of a manufacture <NUM>, <NUM> as shown by an FEA may be directly interpreted by a computer into design variations of corresponding magnitude to the stresses. For example, areas of the model showing stress levels exceeding material properties if printed at a constant density, may be automatically increased in density per unit volume proportionally to the level of stress indicated by the FEA. Alternatively, higher strength materials may be printed in greater proportion in areas where the FEA indicates the stress will exceed the capacity of the less strong materials. For example, if a foam member with hollows is called for in the initial model, but the FEA indicates anticipated stresses will cause the foam member to break, then the hollows may be reduced in size or a strong plastic inclusion, e.g., in the form of a reinforcement rib made from ABS may be printed in the volume which would otherwise be too weak if executed in foam material alone.

The methods of the present disclosure may be used to avoid the extrusion of profiles, e.g., in aluminum alloy, as well as the associated cutting, mitering, drilling, machining, joining and sealing same. This may lead to reductions in scrap, and production lead time. The formation of the manufacture <NUM>, <NUM> based upon the requirements of the architectural problem to be solved may result in windows and doors that fit the building B well, are strong, light and thermally efficient.

<FIG> show a 3D printed window frame <NUM> having an outer surface <NUM> with a plurality of adjacent panels 412S1- 412S10, etc. that cover a plurality of internal pyramid elements 412P. The pyramid elements 412P are defined by a plurality of beam members 412B1-412B6 forming the edges of the triangular pyramid elements 412P. The pyramids are conjoined at their corners (the convergence of the conjoined beams) allowing the transfer of stresses from one pyramid to the other. The adjacent panels 412S1 - 412S10 are also conjoined to each other and to the beams 412B1-412B6 to transfer stresses from the panels 412S1 - 412S10 to the pyramids 412P and from the pyramids 412P to the conjoined others of the adjacent panels 412S1 - 412S10. The conjoined pyramids 412P and panels may be considered a monolith due to their formation by 3D printing /additive manufacture techniques. Because additive manufacturing permits the formation of a compound network or webwork of beams within the confines of a hollow defined by the panels 412S1 - 412S10, the monolithic window frame <NUM> has a significant percentage of the volume <NUM> of the window frame that is hollow (not occupied by the material composing the beams or panels). The hollow volume <NUM> represents a weight and material savings as well as a volume with reduced thermal conductivity. The hollow <NUM> may be left hollow or filled with an inert gas, foam or other filler to reduce thermal conductivity. In the case of foam, this may optionally be printed during the additive manufacture of the window frame <NUM>.

<FIG> shows a uniform load L1 applied to one half of a window frame <NUM> (as bisected by plane P1 and with support constraints C1 applied to the other half of the frame <NUM> as revealed in a computer topology analysis.

<FIG> shows a shape optimization <NUM> of the window frame <NUM> (shown in dotted lines) of <FIG>, when subjected to the specific loading simulation L1 and support constraints C1 for the analysis shown in <FIG>. The shape optimization results in the identification of a region 512R where material should be concentrated.

<FIG> shows a shape optimization <NUM> based upon a topology analysis applied to the window frame <NUM> shown in <FIG>, showing only the internal structure, i.e., the pyramids 612P, as modified by the topology analysis.

<FIG> shows a window frame <NUM> made by additive manufacturing techniques and featuring glass setting blocks 712B and anchoring clips 712C integrally formed with the frame <NUM>. In accordance with one embodiment, the frame <NUM> may otherwise be formed in a manner similar to window frame <NUM>, having the same internal pyramid structures and exterior panels. In another optional approach, the window frame <NUM> may be formed in a manner as shown in <FIG> and described below.

<FIG> shows a window frame <NUM> made by additive manufacturing techniques and featuring glass setting blocks 812B and anchoring clips 812C integrally formed with the frame <NUM>. The window frame <NUM> has a plurality of panels/surfaces 812S1 - 812S9 that are integrally joined/printed. A plurality of strength ribs 812R are formed monolithically on the interior side of the panels 812S4 and 812S5, which are the only ones visible in <FIG>. Optionally, all panels 812S1-812S9 or any subset of same may be provided with strengthening ribs 812R. The corners 812CR1-812CR4 of the window frame <NUM>, may feature strengthening ribs 812RC1-812RC5. Of these, 812RC4 is arcuate and the remainder radially extend from the center of arc rotation of 812RC4. The internal strengthening features, e.g., ribs 812R and 812RC1-812RC5 may be designed in accordance with results of a Finite Element Analysis (FEA) that showed the weak points of the frame <NUM> that needed strengthening in light of anticipated stresses.

<FIG> show modular corner elements <NUM>, <NUM>, respectively, that may be printed using additive manufacturing techniques for forming <NUM>° and <NUM>° angles, respectively on a window frame. The modular corner elements <NUM>, <NUM> feature male sub-portions 982A-982D and 1082A-1082D which extend from base portions 982E, <NUM> E respectively. As shown in <FIG>, the male sub-portions 982A-982D may slide into mating hollow extrusions <NUM>, <NUM> to form a form assembly <NUM>. Similar modular corners <NUM> may be placed at the other ends of extrusions <NUM>, <NUM> and accept additional extrusions like <NUM>, <NUM> to form a closed frame structure <NUM>, e.g., for a window. The connection between modular corners <NUM> and extrusions <NUM>, <NUM> may optionally be secured in an assembled condition by frictional interaction, interlocking action or by an adhesive applied to the male portions 982A-982D. The modular corner <NUM> of <FIG> can be readily seen to operate in a similar way with extrusions like <NUM> and <NUM> of <FIG> to form a frame assembly with a square corner. The printed corner modules <NUM>, <NUM> can be used with existing aluminum extrusions to create custom window frames with custom/ different angles. The resultant frame assembly <NUM>, when used in a frame exposed to weather, eliminates possible water penetration at the corners, where the traditional windows have a miter cut that is sometimes penetrated by water. The modular corner <NUM>, <NUM> also simplifies a frame assembly process, eliminating complex miter cutting preparation and staking used in the traditional process of frame assembly. Traditional corner keys are also eliminated.

<FIG> show an additive manufacturing process for forming a window frame <NUM>. The window frame <NUM> has an aluminum portion 1112A and a plastic portion 1112B, e.g., made from ABS. The aluminum portion 1112A may be formed by a print head 1174A printing molten aluminum or aluminum powder that is melted and adhered to previously printed layers by electrical discharge or laser energy. The plastic portion may be printed by a print head 1174B that prints beads or ribbons of melted plastic that hardens upon cooling or plastic that is cured by radiation, such as UV radiation. The plastic portion 1112B features pyramidal elements 1112P and exterior plates <NUM> like those shown in <FIG>. As can be appreciated, window frames like <NUM> with the frame geometry shown would not likely be made by traditional extrusion processes.

<FIG> schematically depicts the fabrication of a window frame <NUM> with a glazing panel <NUM>, e.g., made from glass or a polymer. The window frame <NUM> may be made by an additive manufacturing process, e.g., 3D printing, and has two portions 1212A and 1212B, between which the glazing panel <NUM> is captured. The window frame portions 1212A, 1212B may optionally have internal features like window frames <NUM> (<FIG>) or <NUM> (<FIG>). One or both of the portions 1212A, 1212B may have a recess 1212R to receive the glazing panel <NUM> therein and keep it is a given desired orientation relative to the window frame <NUM>. The two portions 1212A and 1212B may be assembled around the glazing panel <NUM>, which is captured there between, and then fastened together by fasteners, such as screws or rivets or by an adhesive or plastic welding.

<FIG> shows a window frame <NUM> with a glazing panel <NUM>, e.g., made from glass or a polymer. The window frame <NUM> may be made by an additive manufacturing process, e.g., 3D printing, wherein a first portion 1312B is 3D printed. The glazing panel is laid on top of the first portion 1312B, which may feature a recess 1312R to receive the glazing panel <NUM>. A second portion 1312A of the window frame <NUM> is then printed directly on top of the first portion 1312B by print head <NUM>, capturing the glazing panel <NUM> within the window frame <NUM>. Since the second portion is printed on the first portion and fuses with the first portion, forming a monolith, no fasteners or adhesives are need to join the first and second portions. To indicate this monolithic formation, the demarcation between 1312A and 1312B is shown in dotted lines. One could describe the glazing <NUM> as being embedded within the window frame <NUM>.

<FIG> shows a window frame <NUM> with a glazing panel <NUM> embedded therein. In contrast to the window frame <NUM> of <FIG>, the window frame <NUM> is printed by print head <NUM> with the glazing panel <NUM> in a vertical, rather than horizontal, orientation. In one approach, a lower portion of the window frame <NUM> is printed to define a U-shape with an internal slot to receive the glazing panel <NUM>, which is slid into the slot in a vertical orientation. The remainder of the frame <NUM> can then be printed to embed the glazing panel securely in the frame <NUM>. In an alternative approach, the glazing panel <NUM> can be held by a fixture in a vertical orientation and the frame <NUM> printed around it.

<FIG> shows a plurality of window frames 1412A-1412D being printed simultaneously by a plurality of 3D print heads 1472A-1472D. The print heads 1472A-1472D may be attached to a common base 1472E, that is moved under computer control. In this manner, multiple window frames 1412A-1412D may be printed simultaneously, reducing the time for production in a manufacturing environment.

<FIG> diagrammatically shows that the 3D additive manufacturing of architectural products, like windows <NUM>, doors or other manufactures may be conducted in a manufacturing facility (plant) <NUM> distant from a jobsite JS or in a mobile manufacturing facility <NUM> positioned proximate a jobsite JS. Since the specifications of the manufacture <NUM> may be digitally determined, e.g., by a scanner at a jobsite JS, additive manufacture enables a virtual presence at the jobsite JS. This virtual presence enables manufactures <NUM> to be made with a high degree of certainty as to fit and function, such that the manufacture <NUM> may be shipped from the manufacturing facility <NUM> to the jobsite JS with a high degree of confidence in the suitability of the manufacture. Notwithstanding, as shown in <FIG>, a mobile additive manufacturing unit <NUM> installed in a container, on the bed of a truck trailer, or in the back of a box truck may be used to transport 3D manufacturing capability to a job site JS to facilitate manufacture and installation of architectural products for a building B at the jobsite JS. A mobile 3D manufacturing unit <NUM> at a job site JS can reduce transportation requirements of architectural manufactures, in that raw materials in the form of plastic pellets, metal powder or the like is compact and typically doesn't require careful handling. The 3D manufactured items <NUM> however, typically have carefully formed shapes, a greatly decreased density and increased dimensions, such that they require careful handling and are difficult to pack and ship. A mobile unit <NUM> can print the architectural manufactures, e.g., window frames <NUM>, at the jobsite JS, eliminating the need for shipping, packaging, potential breakage and liability costs. Placing a mobile additive manufacturing (3D printing) unit <NUM> at the jobsite JS allows for customization and reduction in manufacturing errors, in that a first manufactured architectural unit, e.g., a window <NUM>, can be made on-site and immediately placed on the building B to ascertain fit and function. In the event a design change is required, the digital specification guiding the additive manufacturing/3D printing process can be changed to eliminate any fit and function problems in subsequently generated units.

<FIG> show a building B with window apertures WA in which window frames/window units <NUM> are printed on-site. More specifically, printing unit <NUM> is placed within a window aperture WA and prints the window frame/ window <NUM> directly in the aperture WA, i.e., directly on the brick, block, steel beams, wooden beams, etc. that form the structure of the building B and define the window apertures WA. In this manner, the printed window frame/ window <NUM> is assured close fidelity and complementarity with the window aperture WA, leading to a weather-proof fit of the window frame /window <NUM>.

<FIG> shows a system <NUM> for providing mobile additive /3D manufacturing units <NUM> (like mobile unit <NUM> of <FIG>) and/or <NUM> (like mobile unit <NUM> of <FIG>) to multiple jobsites JS1 and JS2. As shown, the system <NUM> and the 3D manufacturing process allows mobility and a variety of manufactures/products, e.g., <NUM>, <NUM>, <NUM>, <NUM> to be printed at a plurality of jobsites JS1, JS2, etc. Mobile units dedicated to printing specific manufacturing line products (windows, doors, storefronts) can travel between jobsites JS1, JS2, and thus embody a manufacturing-on-demand system. A manufacturer may have a fleet of additive mobile units out on the field and traveling between jobsites to fulfill contractor/ customer demands. Optionally, 3D printing services mobile units <NUM> may be deployed to repair broken 3D printers at the job site JS <NUM>, JS2 and can travel between job sites JS <NUM>, JS2.

<FIG> shows a cross-section of a bead or ribbon <NUM> of printed material diagrammatically, such as a thermo plastic extruded from a printing head like <NUM> A of <FIG>. The shape and dimensions of the bead <NUM> will depend upon the shape and dimensions of the print head orifice (not shown) and may have a variety of shapes and dimensions. In the example shown, the beads may have a width of, e.g.,. <NUM> inch and a height of. <NUM> inch. The length (not shown) of the bead <NUM> may be any selected length, e.g., <NUM> inches or the length of a given architectural manufacture, such as a window or window frame.

<FIG> is a cross-sectional, diagrammatic view of a printed body <NUM> made from a plurality of beads <NUM> of printed material. As in many forms of additive manufacture, printed /extruded/ melted elements/pixels/beads are applied in flowable form to a support surface and then on top of one another, adhering to one another due to material adhesion, welding or other surface attraction. The extruded material may be applied in an elongated bead or ribbon that is dispensed from a print head that is moved as the bead is dispensed or the bead may be extruded upon a moving supporting structure, e.g., a table, that moves under the print head during extrusion to receive an elongated, continuous bead/ribbon of extrudate of a given length. In the example shown, the beads <NUM> may have, e.g., a width of. <NUM> inch and a height of. <NUM> inch and on the right side are stacked vertically in stacks <NUM> twenty three deep, resulting in a height of <NUM> inches total. The horizontal dimension of the printed body <NUM>, e.g., <NUM> inches is similarly a consequence of the number of stacks (five) in the horizontal direction and the width. <NUM> inches of each bead <NUM>. As a result, the finished cross-sectional dimensions resulting from printing beads <NUM> is initially determined by the dimensions of the beads and a given dimensional objective must be reconciled to the dimensions resulting from multiples of the bead dimensions in the vertical and horizontal directions. The same may be said of hollows <NUM> or discontinuities in the stacks <NUM>. <FIG> also illustrates design dimension lines <NUM>, <NUM> marking the design height, e.g., <NUM> inches (<NUM> inches less than the stack height) and design width, e.g., <NUM> inches (<NUM> inches greater than the width of the stack), respectively. The hollow <NUM> is also marked with a design line <NUM>, which makes the hollow <NUM> larger than the result of the stack <NUM> dimensions. In addition to dimensional considerations, the spaces <NUM> between adjacent beads <NUM>, either internal or external to the printed body <NUM>, may provide a reason for post processing. For example, external spaces <NUM> will result in an external surface of the body <NUM> that is not smooth, such that removal of material on the extensor surface of the body <NUM> may be required in order to achieve a smooth exterior surface. Internal spaces <NUM> represent a limit on surface area contact/adhesion between adjacent beads <NUM> implying less than optimal strength for a given number of beads <NUM>. Post-processing steps, such as compression to deform the beads <NUM> and press them into closer contact may be utilized to reduce internal spaces <NUM>. In another approach, the location of bead <NUM> printing may be shifted in successive rows, such an over-printed row of beads <NUM> may be shifted relative to the row of beads <NUM> upon which it is printed to reduce the volume of the intra-bead spaces <NUM>.

<FIG> shows a printed body <NUM> having the design dimensions shown in <FIG>. Given a printed body <NUM> of <FIG>, it may be post processed after cure, e.g., by machining one of more exterior surfaces, to remove material, e.g., by a milling machine, a planer, a sander or other material removing device, e.g., to reduce <NUM> inches from the body <NUM> height to reach the height of <NUM> inches and to improve surface smoothness. In another alternative, the printed beads <NUM> may be compressed downwardly by a press or stamper to reduce their height and add to their width prior to curing. This compression may be conducted upon the entire body <NUM> to distort those beads which are still compressible or after the deposition of a row of beads <NUM> and may result in reducing the volume of internal inter-bead spacing. These post-printing steps may therefore by employed to achieve a given design dimension for the printed body. As can be appreciated, the compression of the body <NUM> may be conducted in any direction to achieve a displacement in the perpendicular direction. As another alternative, a bead dimension may be tailored, e.g., by selecting a print orifice shape and dimensions that produce that that in multiples achieve a given dimensional target.

<FIG> shows a printed body <NUM> made from a plurality of horizontal rows <NUM> and vertical columns <NUM> of beads <NUM> of printed material. A facade <NUM>, e.g., made from metal, such as an aluminum extrusion, is imbedded in the body <NUM>. A pair of downwardly extending extensions <NUM>, <NUM> extend from an upper surfacing plate <NUM> and are overprinted by retainer beads 1924R, <NUM> that, when cured, adhere to the beads <NUM> below them to retain the facade <NUM> in association with the remainder of the body <NUM>.

<FIG> shows a clip-on facade <NUM> with a central portion 2038C and right and left legs 2038R, <NUM>, respectively, that embrace retain the façade <NUM> to the printed body <NUM> made from a plurality of printed beads <NUM>.

<FIG> shows a traditional, flat, printed window <NUM> having straight length and width dimensions, i.e., in two dimensions width W and length L. Of course, the window has a thickness dimension that extends perpendicularly to the length L and width W that is generally constant. The printed window <NUM> may be made in accordance with the techniques and apparatus described above, e.g., as described relative to <FIG>.

<FIG> shows a curved, printed window <NUM> wherein the window frame <NUM> and glazing panel <NUM> bulge outwardly in the depth direction in traversing the width and.

<FIG> shows an angled window unit <NUM> having a monolithic frame <NUM> printed by additive manufacturing techniques, as described above. The frame <NUM> has a firs side <NUM> disposed at an angle A relative to a second side <NUM>. The glazing surfaces <NUM> and <NUM> may be made from a single piece of material, such as glass or plastic, e.g., polycarbonate, that is bent at the angle A or two pieces joined at their conjunction by a sealant.

<FIG> shows a curved, printed window <NUM> like that of <FIG> installed into a window opening O between diverging walls W1, W2 of a structure.

<FIG> shows an angular printed window <NUM> like that of <FIG> installed into an opening o between diverging walls W1, W2 of a structure.

<FIG> show a compound window structure <NUM> having multiple glazing panels 2402A, 2402B, 2402C, 2402D, 2402E, 2402F, <NUM>, <NUM>, with a pyramidal center structure <NUM>. The frame <NUM> and all mullions <NUM> may be formed monolithically by additive manufacturing techniques described above or may be formed by additively manufacturing methods in subunits and then assembled to form the window structure <NUM>. If the length and width of the window are considered to be disposed in the x and y directions, then the pyramidal structure <NUM> extends in the z direction. The pyramidal structure <NUM> defines a hollow space <NUM>. In other embodiments, other hollow spaces may be defined by structures having other shapes, such as a triangular pyramid or a geodesic, vaulted or arched dome.

<FIG> and <FIG> show a window structure <NUM> with a muntin grill <NUM>, which may be produced by additive manufacturing methods as described above. The muntin grill may be printed monolithically with other portions of the window <NUM>, e.g., sash elements <NUM> and <NUM>. In one alternative, the glazing member <NUM> may be placed in a recess formed in the sash members, e.g., <NUM>, <NUM> and then the muntin grill is printed over the glazing panel <NUM>. In this instance, the glazing panel extends over the entire extent of the window unit <NUM> and the muntins are decorative, rather than acting as pane dividers. In <FIG> the window unit <NUM> features a muntin grill 2502F on the front of the window <NUM> and a muntin grill 2502R on the rear of the window <NUM>. The glazing unit <NUM> is double glazed, with a front portion 2508F and rear portion 2508R. An aspect of the present disclosure is that 3D printing of different materials may be conducted. The resolution of the printing may also be varied. A high resolution printed outer layer may be applied on top of prior layers to cover the prior layers and provide a given exterior coating of a selected material/ color and texture for sealing/aesthetic purposes. In one example a printed window may be provided with an exterior surface of high resolution printed material simulating a wood grain pattern or another selected textural pattern. In this respect, the overprinting of an exterior layer may be used to achieve a selected external appearance, including making a smooth surface to cover exterior spacing <NUM> (<FIG>).

<FIG> shows a window frame/sash <NUM> formed monolithically by additive manufacturing techniques as described above. The window frame <NUM> may be made from a thermoplastic polymer, such as ABS dispensed in ribbons/beads at a temperature of approximately <NUM>°F. The window frame <NUM> has an interior recess <NUM> to accommodate a glazing panel <NUM>, which is not present in this view, as indicated by the dotted reference line. The glazing panel <NUM> could be glass, plastic or composite, e.g., made from multiple panels with a vacuum or gas there between and would be placed in the recess <NUM> while it is open and prior to completion of the window <NUM>. For example, half the thickness of the window frame <NUM> could be printed defining half of the depth of the recess <NUM>, the glazing panel <NUM> may then be placed in the partially completed recess <NUM> and then the remainder of the window frame <NUM> printed, capturing the glazing panel <NUM> in the recess <NUM>. Sealants or gaskets may be placed or printed in the recess to seal the glazing panel <NUM>/ frame <NUM> interface from weather intrusion. The window <NUM> has a textured outer surface <NUM>, having a lined effect with a plurality of parallel grooves <NUM>. If desired, the window frame <NUM> may be coated with a pigmented material to provide to provide a selected color, pattern or other aesthetic effect.

It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the scope of the claimed subject matter as defined by the appended claims. The present disclosure contemplates the additive manufacture / 3D printing of what are now considered hardware elements, such as window handles, hinges, locks and other elements that are now separately manufactured and assembled to architectural manufactures, such as windows and doors. In accordance with the present disclosure, these elements can be printed either simultaneously or independently from the associated architectural product, e.g., a window or door. The present disclosure may be used to enable the manufacture of custom designed facade elements (windows, doors, etc.) using additive manufacturing/ 3D printing for any given application. Architectural manufactures made in accordance with the additive manufacturing techniques of the present disclosure may be made in a variety of shapes, e.g., frames may be made with circular and oval shapes. The joining lines and elements previously required by prior art techniques of architectural product manufacture are not necessary in the additively manufactured architectural products of the present disclosure. It should be appreciated that the internal hollows within architectural manufactures made by additive manufacturing techniques in accordance with the present disclosure may be used as warming/cooling channels and for water circulation. The additive manufacture of architectural products in accordance with the present disclosure may also be used to include energy harvesting elements, e.g., printed solar cells in the manufactures, e.g., windows and doors.

The present disclosure reveals a novel manufacturing technology that allows manufacture of high performance windows via simple, economic and ecological manufacturing processes. The present disclosure recognizes that the manufacture of architectural products may be done via additive processes in contrast to the more traditional subtractive manufacturing techniques of cutting, drilling, joining, etc. The additive manufacturing (AM) processes contemplated by the present application include 3D printing, selective laser sintering (SLS), selective laser melting (SLM), Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM), Continuous Liquid Interface Production (CLIP), Selective Heat Sintering (SHS), Directed Energy Deposition, Electron Beam Freeform Fabrication (EBF), and Stereolithography (SLA).

Claim 1:
An architectural manufacture (<NUM>; <NUM>) comprising a plurality of spatially distributed deposits of material connected one to another to form the architectural manufacture,
the deposits having been deposited in a flowable state at a plurality of 3D coordinates as controlled by a computer (<NUM>) based upon design data and having transitioned to a non-flowable state,
the architectural manufacture being a frame for at least one of a window or a door,
the architectural manufacture being capable of being installed in an opening in a building and withstanding the forces encountered when incorporated into said building.