US 12,077,958 B1
Wall system with novel structures and method of construction thereof
Adam Hoch, San Jose, CA (US); Brian Hillman, Camino, CA (US); Jonathan Reiland, Phoenix, AZ (US); Nicholas Simon, Norco, CA (US); Paul Clark, Gilbert, AZ (US); Philip Mutarelli, Fremont, CA (US); and Russell Varone, Phoenix, AZ (US)
Assigned to Diamond Age 3D, Inc., Phoenix, AZ (US)
Filed by Diamond Age 3D, Inc., Phoenix, AZ (US)
Filed on Dec. 8, 2022, as Appl. No. 18/063,421.
Application 18/063,421 is a continuation of application No. 17/326,153, filed on May 20, 2021, granted, now 11,536,019.
This patent is subject to a terminal disclaimer.
Int. Cl. E04B 1/35 (2006.01); E04B 1/16 (2006.01); E04B 1/41 (2006.01); E04B 1/76 (2006.01)
CPC E04B 1/3505 (2013.01) [E04B 1/16 (2013.01); E04B 1/4185 (2013.01); E04B 1/7604 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method for constructing a three-dimensional (3D) printer-printable wall system, the method comprising the steps of:
forming a concrete foundation on a substrate, wherein the concrete foundation embeds a plurality of reinforcements;
printing a first inner wythe horizontal layer and a first outer wythe horizontal layer using a construction material mixture from a 3D printer, wherein the first inner wythe horizontal layer and the first outer wythe horizontal layer are separated by an interstitial space;
printing additional inner wythe horizontal layers upward on top of the first inner wythe horizontal layer to form a composite inner wythe;
printing additional outer wythe horizontal layers upward on top of the first outer wythe horizontal layer to form a composite outer wythe;
placing at least one wall tie between the composite inner wythe and the composite outer wythe, across the interstitial space;
installing a sill cap on top of the composite inner wythe and the composite outer wythe; and
inserting an anchor mechanism into the sill cap.