Invention Overview Our breakthrough innovation is an advanced, 3D-printed basalt fiber rebar system designed to revolutionize the construction industry. This invention leverages cutting-edge robotics, dual-extrusion technology, and novel resin-curing strategies to produce rebar with complex, customizable geometries and integrated deformations—features that traditional rebar manufacturing simply cannot offer. Key Components: Dual-Extrusion Robotic System: A precision robotic arm simultaneously operates two extrusion heads: Primary Extruder: Deposits a continuous, high-strength basalt fiber rope impregnated with a UV-curable resin, forming the core of the rebar. Secondary Extruder: At regular intervals (approximately every inch), deposits a smaller-diameter basalt fiber around the primary rope to create surface deformations (ribs). These ribs are engineered to enhance the mechanical bond with concrete, ensuring superior load transfer and durability. In Situ Curing Process: The system employs an integrated UV light source to partially cure the resin during deposition, “freezing” the rebar’s shape as it is built. Moreover, our innovative approach explores leveraging the exothermic heat from curing concrete—particularly in controlled precast or CO₂-enhanced environments—to finalize the curing process, potentially eliminating the need for expensive, separate thermal curing equipment. Application & Market Opportunity 1. Enhanced Structural Performance: Complex Geometries: The ability to print rebar in intricate, customized shapes (including curves and right angles) enables optimized reinforcement tailored to specific architectural and engineering challenges. Superior Bonding: Integrated deformation ribs improve the concrete bond, enhancing the overall structural integrity and longevity of buildings and infrastructure projects. 2. Sustainability & Durability: Material Advantages: Basalt fiber is inherently corrosion-resistant and environmentally friendly compared to traditional steel rebar. This translates into longer-lasting structures and lower lifecycle costs. Energy Efficiency: By utilizing the heat generated during concrete curing for resin curing, our process reduces energy consumption and streamlines production. 3. Cost-Effective, On-Demand Production: Reduced Waste: Our additive manufacturing approach minimizes material waste and allows for rapid, on-site production, addressing the increasing demand for customized, high-performance construction materials. Scalability: The system is designed for scalability, with potential applications in both precast and cast-in-place concrete, targeting a market estimated to be in the multi-billion-dollar range. 4. Market Disruption Potential: Construction Innovation: With the construction industry steadily shifting toward smarter, more efficient building methods, our 3D-printed basalt fiber rebar can be a key driver in modernizing infrastructure. Collaborative Advantage: Partnerships with leading research institutions (such as Oak Ridge National Laboratory) and industry stakeholders will accelerate development and pave the way for widespread adoption. Investment Proposition Investing in this technology represents an opportunity to be at the forefront of construction innovation. Funds will be allocated toward: Prototype Development & Testing: Establishing a working pilot system to demonstrate the technology’s performance, reliability, and economic benefits. Material Optimization: Refining resin formulations and curing processes to ensure robust performance under real-world conditions. Scale-Up & Commercialization: Developing a scalable manufacturing platform and forging strategic partnerships in the construction sector. By addressing long-standing challenges in rebar manufacturing and concrete reinforcement, our technology not only enhances structural performance and sustainability but also offers significant cost savings and efficiency gains. This positions the invention for rapid market penetration and high growth potential. We invite you to join us in transforming the future of construction with this game-changing technology.
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