Method for Casting a Construction Element

A method for casting building material to form a construction element using a computer-controlled apparatus, the apparatus having a material deposition head in communication with a reservoir of formwork material and being movable within a build volume responsive to computer instructions, the method comprising the steps of:

• receiving, by the apparatus, computer instructions relating to a first form work geometry;
• moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a first formwork corresponding with the formwork geometry;
• selectively applying one or more portions of composite material to the first formwork, in specific locations, to form a homogenous layer of composite material;
• curing the layer of composite material to form a composite element;
• removing the first formwork from the composite element;
• pouring a first building material in contact with at least a portion of the composite element;
• and
• curing the first building material in contact with the composite element, thereby forming a first construction element.

A method for casting building material to form a construction element using a computer-controlled apparatus, the apparatus having a material deposition head in communication with a reservoir of formwork material and being movable within a build volume responsive to computer instructions, the method comprising the steps of:

• receiving, by the apparatus, computer instructions relating to a first formwork geometry;
• moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a first formwork corresponding with the first formwork geometry;
• selectively applying one or more portions of composite material to the first formwork, in specific locations;
• curing the one or more portions of composite material to form one or more first composite elements;
• receiving, by the apparatus, computer instructions relating to a second formwork geometry;
• moving the material deposition head within the build volume and selectively depositing formwork material in specific locations, to fabricate a second formwork corresponding with the second formwork geometry, the second formwork at least partially in contact with the first formwork or the one or more first composite elements;
• selectively applying one or more portions of composite material to the second formwork, in specific locations;
• curing the one or more portions of composite material to form one or more second composite elements;
• pouring building material in contact with at least a portion of the first and second formworks;
• curing the building material in contact with the first and second formworks, thereby forming a construction element;
• and
• removing the first and second formworks from the construction element.