HK1207032B

HK1207032B - Three-dimensional printing system and equipment assembly

Info

Publication number: HK1207032B
Application number: HK15107507.4A
Authority: HK
Inventors: J.于; T．J．布拉德伯里; T．J．贝贝; J．伊斯克拉; H．L．苏尔普勒南; T．G．韦斯特
Original assignee: 阿普雷奇亚制药有限责任公司
Priority date: 2012-09-05
Filing date: 2013-08-30
Publication date: 2018-09-07

Description

Three-dimensional printing system and equipment assembly

Technical Field

The present invention relates to a manufacturing system and an equipment assembly, and the use thereof for three-dimensionally printing a prepared object by applying one or more powders and one or more liquids to the powders.

Background

Rapid prototyping describes various techniques for making a three-dimensional prototype of an object from a computer model of the object. One technique is three-dimensional printing, whereby a printer is used to make a 3-D prototype from multiple two-dimensional layers. In particular, a digital representation of a 3-D object is stored in a computer memory. The computer software divides the characterization of the object into a plurality of distinct 2-D layers. Alternatively, a series (sequential series) of instructions for each incremental layer may be directly input, for example, a series of images. The 3-D printer then creates a thin layer of bonding material for each 2-D image layer divided by the software. The layers are printed one on top of the other and bonded to each other to together form an ideal prototype.

Three-dimensional powder-and-liquid printing techniques have been used to prepare articles such as pharmaceutical dosage forms, mechanical prototypes and conceptual models, molds for casting mechanical parts, bone growth promoting implants, circuit boards, scaffolds for tissue engineering, sensitive biomedical composites, tissue growth promoting implants, dental restorations, jewelry, fluid filters, and other such articles.

Three-dimensional printing is a solid free-form fabrication/rapid prototyping technique in which a thin layer of powder is spread over a surface and selected areas of the powder are bonded together by controlled deposition ("printing") of a fluid. This basic operation is repeated layer by layer, with each new layer being formed on top of and adhering to the previously printed layer to ultimately produce a three-dimensional object within the bed of unbound powder. When the printing object is sufficiently agglomerated, the printing object may be separated from the unbound powder.

Systems and equipment components for three-dimensional printing of articles are commercially available or used by other mechanisms: massachusetts institute of technology, three-dimensional printing laboratory (Cambridge, MA), 3DP and HD3DP from company Z Corporation^TMSystem (Burlington, MA), Company Ex One Company, L.L.C. (Irwin, PA), Company Soligen (Northbridge, CA), Company Specific Surface Corporation (Franklin, MA), Company TDK Corporation (Chiba-ken, Japan), Company Therics L.L.C. (Akron, OH, now part of the Company Integra Lifesciences), Company Phoenix Analysis&Design Technologies (Tempe, AZ), Dimension of Stratasys, inc^TMSystems (Eden Prairie, MN), the company Objet Geometries (Billerica, MA or Rehovot, Israel), the company Xpress3D (Minneapolis, MN), and 3D Systems' invasion^TMSystem (Valencia, CA).

Some systems have been described in the patent literature: U.S. publication nos. 20080281019, 20080277823, 20080275181, 20080269940, 20080269939, 20080259434, 20080241404, 20080231645, 20080229961, 36 20080211132, 20080192074, 20080187711, 36; U.S. Pat. nos. 5,490,962, 5,204,055, 5,121,329, 5,127,037, 5,252,264, 5,340,656, 5,387,380, 5,490,882, 5,518,680, 5,717,599, 5,851,465, 5,869,170, 5,874,279, 5,879,489, 5,902,441, 5,934,343, 5,940,674, 6,007,318, 6,146,567, 6,165,406, 6,193,923, 6,200,508, 6,213,168, 6,336,480, 6,363,606, 6,375,874, 6,416,850; PCT International publication Nos. WO00/26026, WO98/043762, WO95/034468, WO95/011007; and european patent No.1,631,440, which, due to its construction, employs a system based on cylindrical (radial or polar) coordinates.

Three-dimensional printing systems that employ radial or polar coordinate based printing systems are disadvantageous because positioning each jetting location at a different radial position requires variations in the surface velocity of the substrate beneath each jetting location. The superficial velocity will be greatest for the ejection location furthest from the center of rotation. This can be compensated for by normalizing the print density across all ejection locations by adjusting the input image or possible drive frequency. However, these compensation methods simply result in the objects of the radial print mimicking each other rather than being true copies. The angle at which the droplets enter the powder bed will also vary with radial position, again causing subtle differences in the printed object at different locations. Alignment and staggering of multiple printheads is another disadvantage to radial printing. Although feasible, is more complex than using a cartesian system.

Disclosure of Invention

The present invention provides a manufacturing system and equipment assembly for use in preparing an article by three-dimensional printing. The system and assembly can be used for continuous, semi-continuous, or batch manufacturing with high throughput with minimal product loss, high efficiency, and high product reproducibility in the context of flexible object design.

The present invention provides a three-dimensional printing apparatus assembly comprising:

a) a three-dimensional printing build system, comprising:

a transmitter system configured to conduct a plurality of build modules;

a plurality of build modules engaged with the conveyor system, wherein the build modules are configured to receive and temporarily hold powder from the powder layering system; and

at least one construction station, comprising: 1) at least one powder layering system configured to form incremental powder layers within the build module; and 2) at least one printing system configured to apply liquid to incremental powder layers within the building blocks according to a preset pattern;

wherein the conveyor system repeatedly transports the build modules from the at least one powder layering system to the at least one printing system to form a three-dimensionally printed bed comprising one or more three-dimensionally printed articles in the build modules.

In some embodiments, the three-dimensional printing apparatus assembly further comprises at least one liquid removal system configured to receive one or more three-dimensional printed beds and to remove liquid from one or more layers of powder onto which liquid has been applied and/or from the three-dimensional printed beds.

In some embodiments, the build module comprises an incrementally height adjustable platform configured to receive and temporarily hold at least one incremental layer or a plurality of stacked incremental powder layers. In some embodiments, a build module includes a body including an upper surface having a cavity, a height adjustable build platform disposed within the cavity, a height adjuster engaged with the body and the platform, and an engagement device. In some embodiments, the plurality of build modules are removably engaged with the conveyor system. In some embodiments, the platform is configured to descend (recess) and/or ascend in one or more increments after the incremental powder layer is placed on the platform. The stage displacement may occur before or after placing a subsequent incremental layer of powder on the stage, thereby rolling or removing a portion of the powder from the already deposited layer of powder. In some embodiments, the incremental specification is predetermined. In some embodiments, the build module includes one or more sidewalls surrounding the build panel and configured to hold the powder on the height adjustable platform. In some embodiments, the build module further comprises a removable build panel disposed below an upper surface of the build module. In some embodiments, a removable build panel is disposed above the height adjustable platform and is configured to receive and support one or more incremental powder layers. In some embodiments, the removable build panel is flat, permeable, porous, textured, coated, knurled, smooth, or a combination thereof. In some embodiments, the engagement device is configured to removably engage the build module with the conveyor system.

In some embodiments, the conveyor system conducts the plurality of build modules along a planar circuitous path, a horizontal circuitous path, a vertical circuitous path, or a combination thereof. In some embodiments, the conveyor system is configured to transport the plurality of build modules along a path in a counterclockwise direction or a clockwise direction. In some embodiments, the path of the modular conveyor system is circular, elliptical, rectangular, semicircular, square, triangular, pentagonal, hexagonal, octagonal, oval, polygonal, parallelogram, quadrilateral, geometric, symmetric, asymmetric, or the equivalent of these shapes with rounded corners and/or edges. In some embodiments, a modular conveyor system includes a plurality of conveyor modules, at least one drive motor, at least one positioning controller, and a path along which a plurality of build modules are conducted. In some embodiments, a conveyor module comprises a body, one or more build module engagement devices, and a conveyor module engagement device by which a plurality of conveyor modules are configured to be engaged to form a modular conveyor. In some embodiments, the conveyor system includes a plurality of attachments configured to removably retain a plurality of build modules. In some embodiments, the attachment comprises a plurality of one or more metal links with cam followers or wheels, panels and/or bearings attached to the building modules and mounted on the rail system on which the building modules are conducted. In some embodiments, the conveyor system further comprises one or more positioning controllers. In some embodiments, the conveyor system is a continuous or discontinuous circulation system.

In some embodiments, the at least one building station is incrementally height adjustable relative to the building module, whereby the vertical space between the building module and the building station may be adjusted in one or more increments. In some embodiments, the incrementally height adjustable build station is configured to ascend in one or more increments after placement of a powder layer on a build module and before placement of a subsequent powder layer build module. In some embodiments, the height change is achieved by changing the vertical position relative to a previous position of the platform, or relative to an absolute position of the platform relative to the building block. In some embodiments, the build station is vertically fixed relative to the build module, and the build platform within the build module is vertically height adjustable relative to the build module such that the vertical distance between the build station and the build module remains the same during a print stroke or print cycle.

In some embodiments, the incremental specification is the same for each incremental layer of the build cycle, different for one or more incremental layers of the build cycle, or a combination thereof. A build cycle comprises one or more build strokes, or a plurality of build strokes, and is defined as the total number of build strokes required to form a 3DP article. A build stroke is defined as the process of forming a printed build layer (i.e., depositing a build layer of powder build material) and depositing (printing) a liquid on the build layer. Thus, the build cycle results in the formation of multiple stacked printed build-up layers bonded to each other to form a three-dimensional printed article together.

In some embodiments, the at least one powder layering system comprises at least one powder fill head. In some embodiments, the powder filling head is stationary, meaning that the powder filling head does not move longitudinally or laterally relative to the plane of the upper surface of the build module when applying incremental powder layers on the build module. In some embodiments, a powder fill head includes at least one powder fill head body, at least one powder spreader, and at least one powder level controller. In some embodiments, a powder layering system includes a powder filling head, at least one powder reservoir, and a powder feeder channel configured to transfer powder from the powder reservoir to the powder filling head. In some embodiments, the powder spreader is a cylindrical roller whose axis has or defines a radial direction of movement opposite to the linear direction of movement of the build module through the powder layering system. In some embodiments, the powder spreader is a cylindrical roller, rod, bar, panel, or straight smooth edge. In some embodiments, the powder filling head comprises a hopper or chute.

In some embodiments, the at least one printing system is configured to apply (deposit) the liquid to the powder according to a cartesian coordinate algorithm rather than a polar (radial) coordinate algorithm (cylindrical, circular, or spherical coordinate system). In some embodiments, the printing system includes at least one printhead and at least one liquid supply system configured to deposit liquid onto the incremental powder layer in the build station. The printhead may include one or more print modules, or a plurality of print modules. In some embodiments, the present invention does not include a printing system configured to apply liquid to powder according to only a polar (radial) coordinate system. In some embodiments, the present invention does not include such an apparatus assembly or method in which the powder filling head is moved laterally or transversely relative to the build module or is not stationary while depositing the incremental powder layers. In some embodiments, the present invention does not include such an apparatus assembly or method in which the printhead is moved laterally or transversely relative to the build module or is not stationary while applying liquid to the incremental powder layer.

In some embodiments, the at least one printing system is configured to apply (deposit) the liquid in a three-dimensional pattern of droplets or a plurality of two-dimensional patterns of droplets defining one or more articles. In some embodiments, the pattern comprises droplets that are equally spaced within one or more objects. In some embodiments, this pattern includes non-equidistantly spaced droplets within one or more objects. In some embodiments, this pattern includes droplets having different pitches in different regions of the article. In some embodiments, this pattern includes droplets having a tighter pitch (i.e., higher print density) in the region outside the defined object. In some embodiments, this pattern includes droplets having a looser pitch (i.e., lower print density) in the interior region of the article.

In some embodiments, more than one pattern is used. In some embodiments, more than one liquid is used. In some embodiments, the liquid comprises a pure solvent, a mixed solvent, a solution, a suspension, a colloid, an emulsion, a melt, or a combination thereof.

In some embodiments, both the print head and the powder fill head are stationary during formation of the printed incremental layers or are otherwise stationary as described herein.

In some embodiments, the apparatus assembly further comprises a bed transfer system configured to transfer the three-dimensionally printed bed one or more at a time away from the three-dimensionally printed building system. In some embodiments, the bed transfer system is configured to transfer the three-dimensionally printed bed to one or more dewatering systems and/or one or more harvesting systems. In some embodiments, the transfer system is integrated with the conveyor system, the deliquoring system, or both.

In some embodiments, the deliquoring system includes at least one dryer. In some embodiments, the deliquoring system is configured to process two or more build panels and their contents at a time. In some embodiments, the deliquoring system is configured to process two or more printed beds at a time. In some embodiments, the deliquoring system is configured to process two or more printed articles at a time.

In some embodiments, the three-dimensionally printed powder bed comprises loose (unbound) powder and one or more three-dimensionally printed articles prior to harvesting the printed article(s) from the loose powder. In some embodiments, the apparatus assembly includes one or more harvesting systems configured to separate loose powder from one or more three-dimensional printed articles. In some embodiments, the harvesting system processes a printed bed that has been processed by the deliquoring system. In some embodiments, the harvesting system comprises a bulk powder collector and a three-dimensional printed article collector. In some embodiments, the harvesting system includes a vibrating or revolving surface configured to receive a three-dimensionally printed powder bed or three-dimensionally printed article. In some embodiments, the harvesting system includes a vacuum conveyor having a screen for separating the articles from the loose powder. The vibrating surface may be porous, non-porous, corrugated, smooth or non-smooth to allow loose powder to be separated from the printed article.

In some embodiments, the apparatus assembly further comprises a dust removal system configured to remove loose particles from printed articles that have been harvested from the printed powder bed. The dusting system may include a housing defining a dusting area, one or more air jets (e.g., one or more air knives) that introduce pressurized air into the dusting area, one or more surfaces or holders in the dusting area for temporarily holding one or more printed articles being dusted, and one or more outlets through which the air and dislodged particles exit the housing or dusting area.

In some embodiments, the equipment assembly further comprises a build panel loading system configured to place one or more build panels on the height adjustable platform(s) of the one or more build modules.

In some embodiments, the apparatus assembly further comprises one or more powder recovery systems configured to collect powder from the one or more systems of the apparatus assembly and return the powder to the powder storage. The recycling system may include one or more bulk powder collectors and one or more conduits for conducting bulk powder from the one or more collectors to the powder storage. The recycling system may further include: a) one or more powder mixers for mixing the reclaimed bulk powder with the initial bulk powder; b) one or more pressurized air powder handling systems that facilitate the transfer of loose powder from one location to another; c) one or more vacuum powder handling systems that facilitate the transfer of loose powder from one location to another; d) one or more mechanical powder handling systems that transfer loose powder from one location to another; e) one or more manual powder handling systems that transfer loose powder from one location to another; or f) combinations thereof.

In some embodiments, the equipment assembly further comprises a control system comprising one or more computerized controllers, one or more computers, and one or more user interfaces for the one or more computers. In some embodiments, one or more components of the apparatus assembly are computer controlled. In some embodiments, one or more components of the three-dimensional print build system are computer controlled. In some embodiments, the conveyor system, the height adjustable platform of the build module, the at least one powder layering system, and the at least one printing system are computer controlled. In some embodiments, the apparatus assembly is configured to spread a layer of powder and deposit (print) droplets in a predetermined pattern on the layer according to instructions provided by the computerized controller. In some embodiments, the predetermined pattern is based on one or more two-dimensional image files comprising pixels. In some embodiments, the two-dimensional image file is structured such that certain pixels indicate the dispensing of a droplet, while other pixels represent dispensing without a droplet. In some embodiments, the two-dimensional image file includes pixels of different colors to indicate dispensing or non-dispensing of different liquids.

In some embodiments, the predetermined pattern for applying the liquid is the same in each incremental layer, the same in two or more incremental layers, different in one or more incremental layers, different in all incremental layers, or the predetermined pattern for applying the liquid is the same for a first set of incremental layers and the same for a second set of incremental layers but the pattern for the first set is different from the pattern for the second set.

In some embodiments, the equipment assembly further comprises one or more work surfaces, tables, racks, enclosures, and/or platforms.

The present invention also provides a three-dimensional printing apparatus assembly comprising:

a) a three-dimensional printing build system, comprising:

a conveyor system configured to conduct a plurality of build modules and comprising a positioning controller and a plurality of build module engagers;

a plurality of build modules engaged with the conveyor system, wherein the build modules are configured to receive and temporarily hold powder from the powder layering system, and wherein the build modules comprise an incrementally height adjustable platform, an optional build panel disposed above the platform, and one or more sidewalls defining a cavity within which the platform, optional build panel, can be disposed;

at least one construction station, comprising: 1) at least one powder layering system configured to form incremental powder layers within a cavity of a build module and comprising at least one powder fill head, at least one powder spreader, and at least one powder reservoir; and 2) at least one printing system configured to apply liquid to the incremental powder layers within the build module according to a predetermined pattern, and comprising at least one liquid supply system and at least one print head configured to deposit liquid on the incremental powder layers in the build module according to a predetermined pattern;

wherein the conveyor system is configured to repeatedly transport a plurality of build modules from the at least one powder layering system to the at least one printing system,

whereby the three-dimensional printing building system forms a three-dimensional printed bed comprising one or more three-dimensional printed articles and optionally loose (unbound or only partially bound) powder that has not been printed on;

b) at least one harvesting system configured to separate loose powder from one or more three-dimensionally printed articles in a three-dimensionally printed bed; and

c) optionally, at least one liquid removal system configured to remove liquid from one or more incremental powder layers on which liquid has been applied and/or from the three-dimensionally printed bed, wherein the liquid removal system is configured to process two or more build modules at a time.

Some embodiments of the invention include those wherein: 1) at least one deliquoring system is present; 2) the apparatus assembly further comprises at least one packaging system configured to package one or more three-dimensional printed articles; 3) a conveyor system configured to repeatedly transport a plurality of build modules from the at least one powder layering system to the at least one printing system in a linear manner rather than in a radial manner, thereby facilitating cartesian coordinate printing rather than radial (polar) coordinate printing; 4) the apparatus assembly further comprises a powder recovery system for recovering and optionally recycling unprinted powder; 5) the apparatus assembly further comprises a liquid detector; 6) a liquid detector detects the presence of liquid in one or more print delivery layers and/or one or more printed articles; 7) the equipment assembly further comprises a verification system; 8) the inspection system is a print powder inspection system that determines the integrity of printing in one or more printed incremental layers and/or one or more printed articles, and/or determines whether powder is properly applied in one or more incremental layers; 9) determining the integrity of the printing includes at least one of determining whether liquid has been properly applied to the one or more incremental layers according to one or more predetermined patterns and/or determining whether liquid has been properly applied to the one or more incremental layers according to a predetermined amount; 10) the inspection system is a printed article inspection system that determines whether one or more printed articles have the correct size, shape, weight, appearance, density, content, and/or color; 11) the inspection system is a liquid application inspection system that monitors the droplets applied to the powder by the print head; 12) the inspection system includes one or more cameras; and/or 13) the cameras are in each case independently selected from the group consisting of visible wavelength cameras, UV wavelength cameras, near infrared wavelength cameras, x-ray cameras and infrared wavelength cameras.

The present invention includes all combinations, sub-embodiments and aspects of the embodiments disclosed herein. Accordingly, the present invention includes embodiments and aspects specifically disclosed, broadly disclosed, or narrowly disclosed herein, as well as combinations thereof, and sub-compositions of corresponding elements of the described embodiments and aspects.

Other features, advantages and embodiments of the invention will become apparent to those skilled in the art from the following description, which refers to the examples.

Drawings

The following drawings form part of the present specification and describe exemplary embodiments of the invention as claimed. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the general principles of the invention as further described herein. Although specific embodiments are described below with particular reference to the provided figures, other embodiments are possible without departing from the spirit and scope of the invention. In view of these drawings and the description herein, those skilled in the art will be able to practice the present invention without undue experimentation.

FIG. 1 depicts a top view of an exemplary layout of the three-dimensional printing device components of the present invention.

FIG. 2A depicts a front view of an exemplary build module of the present invention.

Fig. 2B depicts a partial perspective side view of the build module of fig. 2A.

Fig. 2C depicts a front view of three sections of a segmented or modular conveyor system.

Fig. 2D depicts a top view of the three sections of fig. 2C.

FIG. 2E depicts a side view of an alternative exemplary aspirator.

FIG. 3A depicts a top view of an exemplary printing system of the present invention.

FIG. 3B depicts a side view of the exemplary printing system of FIG. 3A.

FIG. 3C depicts a front view of the exemplary printing system of FIG. 3A.

FIG. 4 depicts a bottom perspective view of an exemplary layout of print modules in a printhead of a printing system.

Fig. 5 depicts a bottom view of an alternative exemplary layout of print modules in different printheads.

Fig. 6 depicts an alternative exemplary shape of a build panel of the present invention.

FIG. 7A depicts a top view of an exemplary build panel loading system of the present invention.

FIG. 7B depicts a side view of the exemplary build panel loading system of FIG. 7A.

Fig. 8A depicts a top view of an exemplary powder cloth layer system of the present invention.

Fig. 8B depicts a side view of the exemplary powder layering system of fig. 8A.

Fig. 8C depicts a front view of the exemplary powder layering system of fig. 8A.

Fig. 9 depicts a perspective view of an exemplary powder fill head of the present invention.

FIG. 10A depicts a top view of an exemplary bed delivery system of the present invention.

FIG. 10B depicts a side view of the exemplary bed delivery system of FIG. 10A.

FIG. 10C depicts a partial top view of an alternative exemplary bed delivery system.

11A-11B depict partial cross-sectional side views of alternative embodiments of exemplary three-dimensional printing processes in a build module of the present invention.

12A-12D depict top views of exemplary layouts of the three-dimensional print build system of the present invention.

FIG. 12E depicts a side view of an exemplary layout of a three-dimensional print build system of the present invention.

Fig. 13A depicts a side view, partially in section, of an exemplary dryer or fluid removal system of the present invention.

Fig. 13B depicts a side view, partially in section, of an alternative exemplary dryer or fluid removal system of the present invention.

Fig. 14 depicts a side view of an exemplary harvesting system of the present invention.

Fig. 15 depicts a side view of an exemplary packaging system of the present invention.

Fig. 16 depicts a partial top view of an exemplary build station including a powder coating system and a printhead.

17A-17D depict top views of various embodiments of printheads and their placement.

Fig. 18 depicts a perspective view of a combination of a harvester system and a duster or dusting system component.

19A-19C together depict an exemplary logic flow diagram for operating the device components of the present invention. Fig. 19A continues to fig. 19B, fig. 19B continues to fig. 19C, and fig. 19C returns to fig. 19A.

Fig. 20 depicts an exemplary logic flow diagram for operating a powder layering system.

FIG. 21 depicts an exemplary logic flow diagram for operating a printing system.

Fig. 22 depicts an exemplary logic flow diagram for dosage form design.

Detailed Description

The present invention provides an apparatus assembly and system having utility for processing an article of manufacture via three-dimensional printing. The assemblies and systems are suitable for preparing articles at small scale/volume, medium scale/volume, and large scale/volume. The three-dimensional printing process includes: an incremental layer of powder is formed on the surface and then the liquid is printed/applied over the layer, then the steps of forming and printing are repeated a sufficient number of times to form a printed powder bed comprising one or more desired three-dimensional printed articles and loose powder. Any excess/undesired liquid remaining in the article(s) is removed and the loose powder is separated from the articles, which is then collected.

In general, a three-dimensional printing apparatus assembly or system includes various subsystems including one or more three-dimensional printing build systems, one or more harvesting systems, and optionally one or more deliquoring systems. The equipment components may include one or more three-dimensional printing build systems, one or more harvesting systems, one or more deliquoring systems, and optionally one or more other systems. In some embodiments, the apparatus assembly further comprises one or more (sub) systems selected from one or more build panel loading systems, one or more powder recovery systems, one or more control systems, one or more build modules or conveyor positioning systems, one or more conveyor drive motors, one or more bed transport systems, or a combination of these systems.

As used herein, a "three-dimensional printing build system" generally includes a conveyor system, a plurality of build modules, at least one build station, and optionally one or more other components. The function of the three-dimensional printing building system is to form one or more three-dimensional printed objects from a multi-powder bed in a building block. The plurality of build modules are engaged with a conveyor system configured to conduct the build modules along a predetermined path through one or more build stations. The build module is conducted to the powder layering system, and an incremental powder layer is formed on an upper surface of the cavity of the build module. The build module is then conducted to a printing system and liquid is applied to the incremental powder layer according to a pre-set pattern, thereby forming a partially or fully bonded powder layer (print incremental layer). The steps of conducting the build module, forming incremental powder layers, and applying liquid to the layers are considered a single build stroke of the process. The build stroke is repeated in the build module so that the printed build layer from one stroke bonds to the printed build layer from a previous or subsequent stroke. The build stroke is repeated in the build module a sufficient number of times to form a three-dimensional printed bed comprising one or more three-dimensional printed articles and loose powder, wherein the three-dimensional printed articles comprise at least two printed incremental layers. The liquid applied to the pattern may or may not be sufficiently dry in the ambient environment between build strokes; thus, a deliquoring step may be included between build strokes. However, if the liquid is not sufficiently dry between build strokes, an optional liquid removal step may be performed after completion of all build strokes (i.e., after completion of a build cycle for the desired three-dimensional printed article).

The conveyor system is configured to conduct the build module through a predetermined trip/path between build strokes during the build strokes. Substantially any system having the purpose of conveying solid material from a first location to a second location and back to the first location may be used. In some embodiments, the conveyor system is an endless linear or oscillating conveyor system. In some embodiments, the endless conveyor system conducts the build module from the first location to the second location and then back to the first location. In some embodiments, the conveyor system is an endless or iterative conveyor system that conducts the build module two or more times through the same build station(s). In some embodiments, the linear conveyor system conducts the build module from the first build station to the second build station and optionally one or more other build stations. In some embodiments, the swing system conducts one or more building modules through at least one building station in a first direction and then conducts the one or more building modules through the at least one building station in an opposite direction.

Fig. 1 depicts a top view of an exemplary three-dimensional printing device assembly (1) comprising: a conveyor (2) configured to conduct a plurality of building modules (6) engaged with the conveyor system along a predetermined path through a building area in one or more building stations, respectively, the building stations comprising: a) at least one powder layering system (3) configured to form incremental powder layers within the build module; and b) at least one printing system (4) configured to apply liquid to the incremental powder layers within the structural modelling block according to a preset pattern. The build module is configured to receive and temporarily hold powder from the powder layering system. In the circulating system depicted, the conveyor system is a continuous circulation system that repeatedly transports/circulates the build modules from the at least one powder layering system to the at least one printing system to form a three-dimensional printed bed of one or more three-dimensional printed articles comprised in the build modules. An exemplary conveyor system (2) includes at least one drive (12) and a plurality of conveyor modules (2a), thereby forming a segmented or modular conveyor system. The conveyor modules engage the respective building modules and conduct along a predetermined path in the direction of arrow a.

The equipment components in FIG. 1 are depicted as completing three-dimensional printing of a first batch of 3-D (three-dimensional) objects and beginning 3-D printing of a second batch of 3-D objects. The three-dimensional printed bed from the end of the first build cycle is located in build module (6a) and the beginning of the second batch begins with a printed build-up layer in build module (6L). The build module (6a) comprises six 3-D objects in a powder printed bed. As the build modules (6, 6a-6L) are conducted along a predetermined path, they pass through a bed transfer system (8) which transfers build panels comprising a completed three-dimensionally printed bed one or more at a time away from the three-dimensionally printed build system. The build module comprises a body (7a) and an upper surface (7c) having a cavity within which a height adjustable build platform (7b) is arranged. An empty build module (6g) optionally receives a build panel (10) as it passes through a build panel loading area of an optional build panel loading system (9). The building block (6h) is now ready to receive powder. The building module is intended to pass through at least one building station comprising at least one powder layering system (3) and at least one printing system (4).

The building block (6j) is depicted as a powder distribution area through the powder layering system (3). The build module (6k) is depicted as being located between the powder layering system (3) and the printing system (4) and in the recovery area of an optional powder recovery system (11) that picks up loose powder from the upper surface of the build module. A build module (6L), which is the first build module of the next build stroke, is depicted as passing through the print zone of the printing system (4). A control system comprising at least one or more computers and one or more user interfaces (5) may be used to control and integrate (coordinate) the operation of the various components and systems of the plant assembly (1). In some embodiments, the operation of each of the conveyor system, the height adjustable platform of the build module, the at least one powder layering system, and the at least one printing system is controlled by a control system. In some embodiments, the operation of one or more of the build panel loading system (9), the optional powder recovery system (11) and the bed transfer system is controlled by a control system.

The apparatus assembly may further comprise a bed transfer system (8) configured to transfer the three-dimensionally printed bed one or more at a time away from the three-dimensionally printed building system. The depicted exemplary bed transfer system (8) is configured to simultaneously remove two or more printed beds from corresponding build modules in a bed transfer area. In some embodiments, the bed transport system is configured to transport the three-dimensional printed bed and the respective build panels (and/or build modules) one or more at a time away from the three-dimensional printed build system.

In some embodiments, a three-dimensional printing device assembly comprises:

a) a three-dimensional printing build system, comprising:

a transmitter system configured to conduct a plurality of build modules;

at least one construction station, comprising: 1) at least one powder layering system configured to form incremental powder layers within a build block temporarily disposed in a powder dispensing region of a build station; and 2) at least one printing system configured to apply liquid according to a preset pattern to incremental powder layers within a building block temporarily arranged in a printing area of the building station;

wherein the conveyor system repeatedly transports the build modules from the powder distribution area of the at least one powder layering system to the printing area of the at least one printing system to form a three-dimensionally printed bed of one or more three-dimensionally printed articles comprised in the build modules;

b) at least one bed transfer system configured to transfer the completed three-dimensionally printed bed one or more at a time away from the build area of the three-dimensionally printed build system;

c) at least one harvesting system configured to separate loose powder from one or more three-dimensionally printed articles in a three-dimensionally printed bed;

d) at least one control system configured to control one or more systems of the plant assembly;

e) optionally, at least one deliquoring system; and

f) optionally, at least one packaging system configured to package one or more three-dimensionally printed articles.

The build module receives and retains powder deposited on the build module by the powder layering system. In some embodiments, the build module comprises a height adjustable platform disposed within a cavity in an upper surface of the build module, wherein the cavity is defined by sidewalls. The height adjustable platform in combination with the side walls form a cavity for the powder. The platform may be configured to gradually rise or fall. The powder is placed within the cavity and directly or indirectly (such as by means of a build panel) on the platform.

Fig. 2A-2B depict an exemplary build module (15), where fig. 2A is a front view and fig. 2B is a perspective side view. The building module comprises a body (16a), a cavity (16b) in an upper surface (16d) as defined by a peripheral wall (16c), and a height adjuster (19a, 19b) engaged with the height adjustable platform and configured to raise and lower a height adjustable platform (17) arranged in the cavity. The build module is depicted as having a build panel (18) disposed above the platform and an engagement (20) by which the build module engages the conveyor system. The build module may be permanently or removably engaged with the conveyor system. Although the body and the cavity of the building block are depicted as having a rectangular shape, they may be shaped as desired. The height adjuster may comprise one or more height adjusters. In some embodiments, the height adjuster is incrementally height adjustable, thereby causing the height adjustable platform to also be incrementally height adjustable. In some embodiments, the incrementally height adjustable component or system is configured to ascend in one or more increments before and/or after a layer of powder is placed on a build module, and before a subsequent layer of powder is placed on the build module.

The incremental height (and hence the incremental layer thickness) can be controlled in different ways. In some embodiments, the height adjuster is computer controlled, whereby the computer controls the raising or lowering of the height adjustment device in increments of specification and/or number of increments. The incremental gauge (vertical shift) may vary from incremental layer to incremental layer, be the same from incremental layer to incremental layer, or a combination thereof. In some embodiments, the incremental specification is the same for each incremental layer (build stroke) of a build cycle, different for one or more incremental layers of a build cycle, or a combination thereof.

The specification of the vertical increment may be related to a previous initial position of the build platform, or a height adjuster of the powder fill head, or both. For example, the platform is lowered to a first position relative to an upper surface of the build module within the cavity in a first increment. A print build layer is formed on the platform at a first location during a first build stroke. The platform is then lowered to a second position relative to where it was at the first position in a second increment. Another print build layer is formed on the platform while at the second position during the second build stroke. This process is repeated until the build cycle is complete.

The specification of the vertical increment may be related to one or more absolute positions of the platform in the cavity of the build module. For example, the build module may include a plurality of encoders distributed vertically within or adjacent to the cavity. The specification of the first vertical increment is then defined by the absolute position (absolute vertical distance) of the platform relative to the first encoder. The second vertical position is determined or defined based on an absolute vertical distance of the platform relative to the second decoder when the platform is lowered to the target second vertical position in a second increment. This type of absolute positioning can be exemplified by the following. If the target increment is 0.50mm below the upper surface of the build module, the platform is commanded to lower by 0.50 mm. If the next target increment is to be an additional 0.25mm, the platform is commanded to lower to a depth of 0.75mm below the upper surface of the build module rather than commanding the platform to lower by 0.25mm relative to the initial 0.5mm increment. This approach is generally superior to using relative movement (0.500 and then 0.250) because any minor positioning errors will be accounted for or at least not accumulated.

The build panel is configured to fit within an upper cavity of a build module and to overlap on a height adjustable platform within the cavity. The build panel receives and supports the bed of powder and/or incremental powder layer(s). In some embodiments, the removable build panel is flat, permeable, porous, textured, coated, knurled, smooth, or a combination thereof. Any regular and/or irregular geometric pattern may be used for the arrangement of perforations. The shape of the build panels can be varied as desired. FIG. 6 depicts a build panel (40a-40h) shaped as a rectangle with rounded corners (40a), octagon (40b), cross (40c), circle (40d), hexagon (40e), pentagon (40f), half rectangle/semicircle (40g, bullet-shaped profile), rectangle with one concave end and one convex end (40 h); however, any other shape may be used. The porosity (degree of perforation) of the build panel can be configured as desired to improve handling and manufacturing. The build panel (40a) includes a plurality of evenly spaced perforations. The building panel (40b) comprises a lattice type structure or mesh. The build panel (40f) includes a rough surface having a plurality of perforations. The build panel (40g) may be made of any material that is durable enough to withstand three-dimensional printing on the build panel. In some embodiments, the build panel is configured for single use or repeated use. In some embodiments, the construction panel comprises a laminate, paperboard, corrugated board, cardboard, metal, rubber, plastic, silicone, teflon (PVDF), coated metal, vinyl, nylon, polyethylene, polypropylene, thermoplastic material, or combinations thereof.

An optional build panel loading system is configured to reload build panels on the build modules engaged with the conveyor. In some embodiments, the build panel loading system is configured to place one or more build panels on the height adjustable platform(s) of one or more build modules. The build panel loading system (9) depicted in fig. 7A and 7B includes a horizontal telescoping arm (41) and pallet loading arm (44) pivotally engaged (43) with a vertical telescoping rod (42). The system (9) engages a build panel by means of a gripper comprising a vertical pallet loading arm (44). An exemplary gripper includes a sheet (46) and an actuatable member (45) that biases/presses the build panel against the sheet, thereby gripping and temporarily holding the pallet. Other grippers may also be used to engage and temporarily hold the tray. In some embodiments, the build panel loading system is a vacuum-based transfer system. A build panel system may also be absent, in which case the build panel may be manually loaded onto the build module.

The powder layering system (3) depicted in fig. 8A-8C is mounted on a support (table, frame, body, 54) and comprises at least one powder filling head (51), at least one powder reservoir (50) and at least one powder feeder channel (52) driven by a powder feed drive (53) and configured to transfer powder from the powder reservoir to the powder filling head. The powder feeder channel may comprise a drive motor and screw-type shaft, for example, an auger such as found in Schenk feeders or a shaft with helical blades/vanes. The powder layering system forms an incremental powder layer as the build module passes through a powder distribution area (55, also referred to as a layering area), for example, in the direction of arrow J (fig. 8C).

In some embodiments, the powder fill head (51) depicted in fig. 9 includes a powder fill head body (60, box), at least one powder fill head hopper (61), and at least one powder spreader (64). The hopper receives material from the powder feeder channel to form a temporary supply of powder (63) optionally agitated by a powder fill head agitator (62), which may alternatively be a powder fill head dispensing panel. In some embodiments, the hopper (61) is replaced with a chute (not shown, or distribution panel) having a channeled inner surface that distributes powder evenly across the surface width and downward onto the build modules. The powder leaves the hopper (or chute without accumulating a large amount of powder) in the direction of arrow K. In some embodiments, the powder filling head further comprises at least one powder height controller configured to control the relative distance between the powder spreader (64) and a surface beneath the powder spreader, such as a build panel, an upper surface of a build module, a height adjustable platform, or a previous layer of powder. An optional dispensing rod (or faceplate, not shown) may be placed between the outlet of the fill head body and the powder spreader (roller). The dispensing rod serves to better distribute the powder throughout the powder bed before being contacted by the powder spreader, thereby forming an incremental powder layer (65).

The powder level controller may raise or lower the powder spreader in order to increase or decrease the thickness of the powder layer placed on the platform or on a previous powder layer on the platform. For example, if the platform is lowered in a first increment and the powder height controller is raised in the same or another second increment, the deposited powder thickness will approximate the sum of the first and second increments. If the platform is lowered in a first increment and the powder height controller is lowered in a second increment, the powder thickness deposition will approximate the difference of the first increment minus the second increment. Alternatively, a powder spreader in combination with a powder level controller may cooperate to compress a layer of powder that has been previously deposited. This can be achieved by: the powder level controller and the powder spreader are lowered, and then passed over the powder layer under the lowered powder spreader to thereby compress the powder layer.

In some embodiments, the powder spreader is a cylindrical roller, the axis of which has a radial direction of motion opposite to the linear direction of motion of the building blocks passing through the powder layering system. For example, the cylinder (64) surface has a linear direction (arrow M) opposite to the direction (arrow J) in which the sub-surface build modules (10) pass under the cylinder. In some embodiments, the powder spreader is a cylindrical roller, rod, bar, panel, or straight smooth edge. Other configurations of powder fill heads may be used.

The amount or rate of powder discharged by the powder fill head may be adjusted by one or more controllers. The powder discharge feedback controller may monitor the powder accumulation at the powder spreader as the powder is discharged and diffused by the powder fill head to form an incremental powder layer. If the powder release rate is too fast, excess powder will accumulate at the powder spreader, possibly causing the powder spreader to improperly spread the powder. The feedback controller then sends a signal, thereby causing the rate at which powder is discharged by the powder fill head to decrease. Conversely, if the feedback controller senses that the powder discharge rate is too low, the feedback controller sends a signal, thereby causing the powder discharge rate to increase. The feedback controller may employ one or more visual, laser, acoustic or mechanical sensors, or a combination thereof.

Fig. 2C-2D depict a portion of a modular (segmented) conveyor system (21) comprising a plurality of conveyor modules (segments, links) (22) and respective engagement devices (23) configured to engage adjacent conveyor modules to each other. Fig. 2C is a front view, and fig. 2D is a plan view. The conveyor module comprises a body (22a), female engagement means (22d), male engagement means (22c), and one or more building module engagement means (22b) configured to removably or permanently engage a building module. In this exemplary embodiment, adjacent segments (22) are pivotally engaged by means of an engagement means (23) and a pin (22e) such that the segments can pivot about the pin (22e) axis in the direction of arrow LX. Although the engagement means (23) is depicted as a hinge type joint, other engagement members may be used.

The apparatus assembly (1) optionally comprises one or more powder recovery systems. The powder recovery system (11) depicted in fig. 1 and 2E is an optional and vacuum-based system that includes a body (11a), an aspirator rod (11c), a vacuum source (11b), and one or more air inlets (11d, 11E) configured to remove powder from one or more surfaces of the build module. In some embodiments, the powder recovery system is configured to remove loose powder from an upper surface of the build module. The powder recovery system (11) may comprise a joining member (11f) by means of which the powder recovery system is removably or permanently joined to a surface or support. Additional powder recovery systems are described herein.

Fig. 3A-3C depict an exemplary printing system (4) configured to apply liquid to powder in a printing region of the printing system. Fig. 3A is a top view, fig. 3B is a side view, and fig. 3C is a front view. In some embodiments, the liquid is applied according to a cartesian coordinate system rather than a polar coordinate system (radial, cylindrical, circular, or spherical). In some embodiments, the present invention does not include a printing system configured to apply liquid to powder according to a polar coordinate system. An exemplary printing system includes: at least one print head (28) that deposits liquid on the incremental powder layers in the build module; and at least one liquid supply system (28 b); which conducts liquid from one or more liquid reservoirs (28c) to the at least one printhead (28). In some embodiments, the printing system comprises a plurality of printheads, a plurality of liquid supply systems, a plurality of reservoirs, or combinations thereof. In some embodiments, a printing system includes a single printhead, a plurality of liquid supply systems, and a plurality of reservoirs.

The printhead of fig. 3B introduces a stream of droplets into the print zone (29) through which the build module passes. The exemplary system (4) comprises a frame or gantry (rails 27a, 27b) by means of which the print head (28) can be displaced/moved in the direction of arrow D, transverse to the direction of movement of the building blocks during printing. The displacement of the print head may be performed manually or via computer control operations. In some embodiments, the printhead is stationary when liquid is applied to the incremental powder layer, meaning that the printhead (in particular, the print module) does not move in a direction transverse to the direction of movement of the build module during printing (i.e., during application of liquid) relative to the build plane when liquid is applied to the powder layer during a print stroke. This printing approach differs from previous systems in that the print head, in particular the print module(s), moves back and forth in this direction, which is transverse to the direction of movement of the building modules during printing.

The printhead may include one or more printing modules that deposit liquid on the powder layer. The printhead (28) of fig. 3C includes four print modules that form respective print zones (29a-29 d). When the printhead includes a plurality of print modules, the arrangement/layout of the print modules may be as desired. The printhead (30) of fig. 4 includes a plurality of print modules (4) arranged in a plurality of columns, wherein each column includes a plurality of print modules. The powder may pass through the print module in the direction of arrow E such that the printing direction is transverse to the horizontal shape of the print module.

Other suitable arrangements for the print modules are depicted in fig. 5. The printhead (34) includes a single print module. The print head (35) comprises four printing modules grouped in pairs in two groups (35a, 35b) offset from each other horizontally. The printhead (33) is somewhat similar to the tool head (35) except that the print modules (35a, 35b) are wider in the horizontal direction and offset horizontally to a greater extent than the print module (33 a); also, the print modules are horizontally offset from each other. The printhead (32) includes two linear and laterally offset sets (32a, 32b) of print modules. When viewed in the direction of arrow E, the adjacent edges of the two sets overlap (each set overlapping the dashed line).

The apparent overall print resolution of the printhead can be increased by offsetting the print modules as depicted for module (33). The print modules may be offset in a staggered, interleaved, untwisted, or angled arrangement relative to the print head to increase overall print density/resolution. For example, if the print resolution of each print module is 75dpi (dots per inch), the apparent overall print resolution of the printhead (33) can be 75dpi, 150dpi, 225dpi, 300dpi, 375dpi, 450dpi, or even higher. If the print resolution of each print module is 100dpi, the apparent overall print resolution of the printhead (33) may be 100dpi, 200dpi, 300dpi, 400dpi, or even higher. In some embodiments, the print resolution of the printhead is the same as or greater than the print resolution of the print modules included in the printhead. In some implementations, the print resolution of the printhead is a multiple of the print resolution of one or more print modules included within the printhead. In some embodiments, the print resolution of the printhead is less than the print resolution of the print modules included within the printhead.

The arrangement of one or more print modules in a printhead can be modified as needed to provide desired print results. Fig. 16 depicts a portion of a printing station including a powder fill head (176) and a print head (178), below which is a build module (175) that moves in the direction of arrow Q past a powder dispensing area and a print area, respectively. A fill head arranged transverse to the direction of motion of the build module remains laterally and longitudinally stationary (relative to a plane defining the upper surface of the build module, even though the fill head may move vertically toward or away from the plane) as it places the incremental powder layer on the cavity of the build module and across the width of the cavity. The build module and incremental layers of unprinted powder are moved in the direction of arrow Q so that they pass through the print zone beneath a print module arranged transverse to the direction of motion of the build module. The printing module is maintained stationary laterally, longitudinally, and vertically with respect to a plane defining the upper surface of the build module. The printing module applies liquid onto the incremental powder layer according to a preset pattern, thereby forming an incremental printed layer (180) comprising article(s) 181. An exemplary printhead includes a single print module (179; depicted in phantom) that spans the width of the cavity of the build module.

The printhead (185) depicted in fig. 17A includes four print modules (186) disposed both laterally and longitudinally displaced (relative to the direction of motion of the printhead). The four printing modules together span the width of the cavity of the building module. The embodiment (187) of fig. 17B differs from the embodiment of fig. 17A in that the four print modules (188) are only laterally displaced but not longitudinally displaced.

In some embodiments, the one or more printheads are stationary when liquid is applied over the build-up layer, i.e., when printing. In particular, when printing, the one or more print heads may be laterally and longitudinally stationary with respect to the linear direction of movement of the building blocks (and hence the incremental powder layers). Particular embodiments include those wherein: a) printing is performed according to a cartesian coordinate algorithm; b) the build module moves during printing in a linear direction perpendicular to the displacement of the print module (and one or more printheads); c) the print head and one or more print modules are stationary while printing (when applying liquid to the incremental powder layer) and do not move in a direction that moves laterally or longitudinally relative to the direction of motion of the build module; and/or d) printing is not performed solely according to polar coordinate algorithms.

The three-dimensional printing system/assembly of the present invention employs a cartesian coordinate based printing system and algorithm. Unlike other systems that move the printhead laterally and/or longitudinally while printing, the printhead of the present invention is substantially stationary during printing. The term "lateral" is defined relative to the direction of motion of the build module beneath the printhead and means substantially perpendicular to the direction in which the build module conducts through the print zone. The term "longitudinal" is defined relative to the direction of motion of the build module beneath the print head and means substantially parallel to the direction in which the build module conducts through the print zone. Applying liquid across the width of the powder layer beneath the print head is achieved by employing one or more printing modules that individually or together span at least 75%, 80%, at least 85%, at least 90%, at least 95%, at least 97.5%, or at least 99% of the width of the powder layer. In this case, the powder layer "width" is determined in a direction transverse to the direction of movement of the building blocks below the print head, whereas the term "length" is determined in a direction parallel to the direction of movement of the building blocks below the print head. In other words, a single printhead may span the width, or multiple printheads laterally adjacent to one another may span the powder layer width.

In particular embodiments, the printhead includes a plurality of printing modules that individually, but together, span the width of the incremental powder layer and/or the cavity width of the build module. In some embodiments, the modules of one or more printing modules together span at least 50%, at least 55%, at least 75%, at least 90%, at least 95%, at least 99%, or all of the width of the cavity of the build module. In particular embodiments, the build module moves in a first direction and the printhead is stationary while liquid is applied to the incremental powder layer. In particular embodiments, printing is performed primarily or solely according to Cartesian coordinate algorithms. For example, the algorithm controls the application of droplets of printing fluid in a linear (non-radial, straight) direction relative to the conveyor, such that the printhead applies droplets in a parallel (longitudinal) or perpendicular (lateral) direction relative to the linear direction of conveyor motion. The conveyor and corresponding build modules move only in a straight linear direction beneath the print head and build tool head.

An alternative embodiment of the present invention is depicted in fig. 17C, where the printhead (189a) includes one or more print modules, or multiple print modules, that do not span the width of the incremental powder layer and/or the cavity width of the build module. This print head is either stationary when printing (when applying liquid to the incremental powder layer) or is moved laterally with respect to the direction of motion of the build module when applying liquid to the powder. The print modules of the printheads (32, 33, 35, 189a, 189b of figures 5 and 17C) are arranged so that the jets on the plurality of printheads are staggered to increase the print density across the print bed. For example, individual print modules having an intrinsic print density of 100dpi are interleaved together such that four of the printheads together provide a print density of 400 dpi.

In some embodiments, a cluster of print modules such as depicted in fig. 17D are arranged such that their overall span covers only a portion of the powder layer width, requiring multiple printheads (each containing a cluster of print modules with staggered jets) to cover the full powder layer width. For example, three print heads (189b), each having a cluster of print modules that together span only 2.5 ", would need to be positioned in a horizontally offset manner to cover the width of a bed or layer of powder that is between 5 and 7.5 inches wide.

The at least one printing system may apply the liquid onto the incremental powder layer according to any pre-set printing pattern or randomly. The pattern may be the same from incremental layer to incremental layer, or may be different for one or more incremental layers of the printed article. In general terms, two adjacent printed patterns will include at least two overlapping printed portions such that at least a portion of the print/bond powder in one printed build-up layer will bond to at least a portion of the print/bond powder of an adjacent printed build-up layer. In this manner, a plurality of stacked adjacent printed build-up layers are bonded to one another, thereby forming a three-dimensional printed article comprising a plurality of adjacent printed build-up layers having fully or partially bonded powders. Even though the three-dimensional printed article may include cuts, overhangs, cavities, holes, and other such features, at least a portion of the printed portions adjacent the printed build-up layers must be bonded to one another to form and fill the resultant volume of the article.

The printing system employs a cartesian coordinate based printing algorithm in applying liquid to the incremental powder layer. The system includes a computer and associated software including one or more print jobs. The print job includes: information relating to the thickness of the incremental layer and the predetermined pattern to be printed on the incremental layer of the printed article, and the like. The print job provides instructions to the printhead (print module (s)) layer by layer regarding the generation and placement of droplets on incremental powder layers. The print job is based on a series of two-dimensional images (slices) that together form a preset three-dimensional image (object) when stacked.

Without being held bound to a particular mechanism, the target three-dimensional object is designed, such as with a CAD program. A virtual image of the target item is virtually sliced into a plurality of stacked sheet images (referred to herein as "two-dimensional" images), where each two-dimensional image is effectively a layer of increasing thickness powder. The sum of the image slice thicknesses is equal to the total "height" of the target object. Each two-dimensional "image" is then converted into print instructions, which together define a pre-set print pattern for that image. All print order groups are joined together to form a final print order group that is used by the computer to control printing. In addition to the incremental layer thickness, the two-dimensional shape of the predetermined pattern, and the shape of the target object, the final set of print instructions also includes specifications or considerations for the following parameters: linear speed of build modules below the print head, rate of applying liquid to the incremental powder layer, length and width of the incremental powder layer, cavity size of build modules, incremental height adjustment of height adjustable platforms of the build modules, rate of loading powder into the powder fill head, rate of loading powder into the build modules to form incremental layers, rate of transferring powder from a feed reservoir to the fill head, resolution of a two-dimensional image to be printed on each incremental layer, number of liquid applications to each incremental layer, one or more specific locations to apply one or more specific liquids to an incremental layer, start and stop of liquid application with respect to each build module, number of articles to be printed, number of build modules in an equipment assembly, number of build modules to be printed, rate of downward movement of platforms of build modules, The time to start and stop the powder delivery with respect to the entire build cycle, the speed of rotation of the levelling device (rollers), and other such parameters.

The plant assembly includes a control system including one or more controllers. Without being held bound to a particular mechanism, a home switch (timing switch) positioned at a fixed point of the conveyor (fig. 1) provides a reference point in terms of the position of the "first" build module in a set of build modules. From there, the computer can determine the locations of the remaining building modules in that set by knowing the specifications of the conveyors, the spacing of the building modules, and the dimensions of the building modules. The control system may also include a proximity sensor that indicates the position of one or more building modules relative to the conveyor. The control system includes a synchronizer that facilitates synchronization of the operation of the various components of the plant assembly. By taking into account the conveyor's trajectory (linear) speed and the target thickness and width of the incremental layer, the computer can instruct the powder layering system to load powder onto the build module at a certain feed rate. The powder feed rate may be continuous after a part of the stroke or after one or two calibration strokes. Once the appropriate incremental powder layer is formed, deposition of liquid on the incremental layer may begin. The proximity sensor senses the leading edge of the build module and then sends instructions to the printing system. The computer controlling the printing system takes into account a set of print instructions (which may include the target print resolution (density) to be printed on the incremental layers, the image(s) (pattern (s)), the target rate of liquid deposition, the number of liquids to be deposited, the dimensions of the print head and print module, the trajectory speed, a set of images (patterns) to be printed to form the target 3D printed object, the target object porosity or density, or other such parameters, etc.) and the signals generated by the wheel encoder (wheelencoder), for example, to provide pulses that set the print rate at which the image file in the print instructions is consumed and the resolution at which the image file(s) is printed. After finishing layering and printing according to the printing instruction, the build cycle is completed.

As described herein, the powder system may include one or more feedback controllers that determine appropriate powder feed rates into the powder feeder and into the build module. Likewise, the printing system may include one or more feedback controllers that determine the rate at which printing fluid (liquid) is applied and/or consumed, and thus may control the liquid application rate and may also reload the liquid reservoir(s).

A deliquoring system, such as a dryer, can include one or more of a relative humidity controller, a temperature controller, and a conveyor speed controller. The system can thus adjust drying times and conditions to provide printed articles that contain a desired humidity level.

In some embodiments, one or more components of the apparatus assembly are computer controlled. The controller is in each case independently selected from a computerized controller, an electrical controller, a mechanical controller, and combinations thereof. In some embodiments, the control system includes one or more computerized controllers, one or more computers, one or more user interfaces for the one or more computers. In some embodiments, one or more components of the three-dimensional print build system are computer controlled. In some embodiments, the conveyor system, the height adjustable platform of the build module, the at least one powder layering system, and the at least one printing system are computer controlled. In some embodiments, the apparatus assembly is configured to spread the powder layer and print the droplets in a predetermined pattern according to instructions provided by the computerized controller. In some embodiments, the predetermined pattern is based on one or more two-dimensional image files comprising pixels. In some embodiments, the two-dimensional image file is structured such that certain pixels indicate the dispensing of a droplet, while other pixels represent a dispensing without a droplet. In some embodiments, the two-dimensional image file includes pixels of different colors to indicate dispensing of different liquids, or no liquid dispensing.

19A-19C depict a flowchart of the operation for an exemplary embodiment of the present invention. The process is initiated, for example, by an operator or an electrical component such as a computer. The operator initiates and checks the status of the system and assembly components, which are then synchronized, after which the system (assembly) is ready for operation. The printing fluid and powder are loaded into their respective systems as required by the product to be three-dimensionally printed. The build panel is loaded into the build module and the build cycle is initiated. The height of the printing fluid(s) and powder(s) is checked and when the desired amount is present, the conveyor operation is initiated. Moving to fig. 19B, the powder feed rate and transport speed (conveyor speed) for the build module are applied and a query is made to determine if the build module should receive powder. If so, the platform is lowered and a layer of powder is deposited on the build modules as they pass under the powder fill head. If not, the build module does not accept the powder. A query is then made to determine if the powder layer should receive a printed image. If so, a two-dimensional pattern is printed on the layer as the build module passes under the print head. If not, the build module does not accept the printing solution. A query is made to determine if all the build modules installed on the conveyor have been processed, i.e. if the build stroke is complete or if the build module should receive another layer of powder. If not, any unprocessed building blocks are processed. If all build modules have been processed, i.e., the build run is complete, a query is made to determine if the build cycle is complete. If not, one or more additional build runs are performed. If so, the build module is ready to unload the build panel as described in FIG. 19C. The completed build panel carrying the three-dimensionally printed powder bed is unloaded and transferred to a drying tray. After the build panel has been removed from the build module, another build tray is placed in the empty build module. After all build panels have been unloaded, a query is made according to FIG. 19A to determine if additional build cycles are to be performed. If not, the process ends. If so, the next build cycle process starts.

FIG. 20 depicts exemplary sub-route details of how platform-level deltas are controlled within a build stroke and build cycle. In this embodiment, the layer thickness (delta) is specified by the product definition. The cumulative thickness is calculated from the number of layers of powder that have already been deposited. The platform is lowered to the calculated thickness and a decision is made to confirm that the platform is in the correct position within a predetermined tolerance. A query is then made to determine if the platforms of all of the build modules in a particular build run have been lowered to the correct position. If not, the platform is adjusted as needed. If so, a query is made to determine if all layers of the build cycle are complete. If so, the build panel is unloaded as described herein. If not, the processing of this view is repeated for each of the build layers as needed until the build cycle is complete.

Fig. 21 describes the detailed operation of an exemplary sub-route of the printing system. The build process is initiated and the necessary amount(s) of printing fluid is loaded into memory(s). A set of image files is identified and transmitter operation begins. During operation, the level of printing fluid(s) is monitored so that the printing fluid can be replenished as needed. When a build module passes under the print head, a trigger signal is generated prompting a query to determine whether the build module will receive a print image. If not, the trigger signal is ignored. If so, a print image file is received and processed such that an image pixel column (pixels located along the axis of movement of the build module) is assigned to a particular nozzle of the printhead. Further, the image pixel rows are sent to the print head in a manner that takes into account the linear speed of the conveyor and the expected print density of the image to be printed. The printhead then delivers the printing fluid droplets to a powder layer on the build module in accordance with the printing instructions. A query is then made to determine if all of the build modules have been processed. This query may be repeated for build runs and/or build cycle levels. The process may end when the build cycle is complete. The print head can be withdrawn and cleaned if desired.

FIG. 22 depicts a flow diagram of an exemplary process for designing a dosage form and determining the layer thickness of the dosage form and an image file (two-dimensional printed pattern) for the dosage form. The process may be performed with or without a computer. A dosage form is designed having a specific three-dimensional structure and comprising a target drug dose. A target powder layer thickness is selected, and the dosage form height is divided by the target incremental powder layer thickness to provide the amount of powder layer required to prepare the dosage form. Based on the layers and their positions within the dosage form, each layer is assigned an initial two-dimensional pattern, i.e., an image file, as needed that ultimately generates a set of print instructions that are employed by the printing system to produce the corresponding print increment layer. The image file assigned to each layer may be input, or the image file assigned to each layer may be retrieved from an image library. To determine if an archived image from the image library is needed, the system queries whether all layers have been assigned image files on demand. If so, the dosage form design is complete and the process is complete. If not, the system queries whether the image required for a particular layer exists in the image library. If so, the image file is retrieved from the library and assigned to the corresponding powder layer. The system then again asks whether all layers have been assigned an image file on demand and the logic cycle continues on demand until the dosage form design is complete. If the image file is not present in the image library, a new image file is generated, optionally stored in the image library, and assigned to the corresponding layer, and the logic loop continues as necessary until the dosage form design is complete. It should be understood that one or more of the layers may not require any image files at all, meaning that certain layers are not printed during the preparation of the dosage form.

The apparatus assembly of the invention may comprise one or more bed transfer systems configured to transfer the three-dimensionally printed bed one or more at a time away from the three-dimensionally printed building system. Fig. 10A is a top view and fig. 10B is a side view of an exemplary bed transfer (unloading) system (8) comprising a frame (70), a receiving platform (76), a pallet loading platform (77), and a bed transfer mechanism (71) movably engaged with the frame and overlying a bed transfer area (75). The bed transfer mechanism (71) includes a carriage (71c) configured to be displaced in a reciprocating manner in the direction of arrow N along rails (72a, 72 b). The bed transfer mechanism also includes a container (71a) including a cavity (82) configured to receive and temporarily hold a three-dimensional printed bed (83) with an optional build panel (10). In an alternative embodiment, the container is a pusher plate or clevis (71d) that includes a receiving area configured to receive and temporarily hold a three-dimensional printed bed. The container (71a) is reciprocated in a vertical manner in the direction of the arrow P by means of a reciprocating mechanism (71b) engaged with the container (71a) and a body (71d) of the bed transmission mechanism (71). During operation, the conveyor conducts and positions the build modules (7a) beneath the containers (71a) and in the bed transfer area (75) so as to align the three-dimensional printed bed (83) and build panel with the cavities (82). The container is then lowered in the direction of arrow P by an amount sufficient to retain substantially all of the three-dimensionally printed bed and build panel within the cavity. The bed transfer mechanism (71) then slides/displaces the print bed and build panel in the direction of arrow N onto a receiving platform (76) and then onto a transport tray (74). The container is then raised in the direction of arrow P in such a way as to leave the print bed and build panel on the transport tray, and displaced in the direction of arrow N back to the initial position of superimposition with the build module. The transport tray (74) is then conducted in the direction of arrow B.

FIG. 10C depicts an alternative embodiment of a bed transport system that includes a diverter (84) and a conveyor (86). A diverter directs a build module or panel comprising a printed bed (87) from a conveyor (85) of the build system onto an adjoining conveyor (86) which optionally delivers the printed bed to a deliquoring system or other downstream processing device (not shown). The diverter may be configured to ascend and descend. In the first position the diverter does not direct the print bed away from the build system, while in the second position the diverter does so.

In some embodiments, the bed transfer system is configured to transfer the three-dimensionally printed bed to one or more deliquoring systems, one or more harvesting systems, and/or one or more packaging systems. In some embodiments, the transfer system is integrated with the conveyor system, the deliquoring system, or both.

The deliquoring system is configured to receive one or more build panels (comprising a printed bed) and remove liquid from one or more printed powder layers and/or from a three-dimensional printed bed, the liquid having been applied on the one or more printed powder layers. The deliquoring system can be one or more treatment areas in the building block through which conduction occurs. For example, the deliquoring system in fig. 1 may be a processing area above the conveyor and not include an area below the printing area. Alternatively, the deliquoring system may be another processing region not directly associated with the three-dimensional printing build system, such as a temporary holding or storage region, where the three-dimensional printed bed is placed and dried under ambient conditions. In some embodiments, the deliquoring system is one or more dryers.

Fig. 13A-13B depict an exemplary deliquoring system. Fig. 13A is a side view, partially in section, of a dryer (130) configured to remove or reduce the amount of liquid in a three-dimensional printed bed (83) or article. The dryer includes a housing (131) within which a plurality of heating elements (137) are contained, a conveyor system (138), and yet another discharge port (132). The housing comprises an inlet (133) and an outlet (134) through which the three-dimensional printed beds (or articles) and their corresponding building panels are conducted by means of a conveyor (135, 136, respectively). During operation, the print bed is conducted through the inlet (133) and carried through a predetermined path by the conveyor system (138) as the print bed is exposed to the heating element (137) which effects evaporation of liquid from the print bed. As the printed beds (or articles) exit the dryer, the printed beds include less liquid than they do when they enter the dryer. Although not depicted in fig. 13A, the dryer may include a vacuum system configured to reduce the pressure within the dryer, or an air handling system configured to increase or otherwise control the flow of air through the dryer. Although the path of the conveyor is depicted as "S-shaped" in fig. 13A, the path may be any desired path, e.g., U-shaped, Z-shaped, N-shaped, O-shaped, etc.

Fig. 13B depicts an alternative embodiment of a dryer (141) suitable as a deliquoring system. The dryer includes a housing (142) within which a plurality of heating elements (146) are contained, and a conveyor system (145). The housing comprises an inlet (143) and an outlet (144) through which the three-dimensional printed beds and their corresponding building panels are conducted by means of a conveyor. In some embodiments, the dryer includes one or more covers (147) for the inlet and/or outlet.

In some embodiments, a three-dimensionally printed bed comprises loose powder and one or more three-dimensionally printed articles. The apparatus assembly of the present invention may further comprise one or more harvesting systems configured to separate loose powder from the one or more three-dimensional printed articles. In some embodiments, the harvester processes a build panel that has been processed by the deliquoring system. In some embodiments, the harvester includes a bulk powder collection device and a three-dimensional printed item collection device. In some embodiments, the harvester includes a vibrating and/or revolving surface configured to receive the three-dimensionally printed bed. In some embodiments, the harvester includes one or more de-agglomerators.

In some embodiments, the equipment assembly further comprises one or more dusters configured to remove loose powder from the harvested item. In some embodiments, the duster comprises one or more air brushes.

An exemplary combination of harvester and duster system (150) depicted in side view in fig. 14 comprises a frame (151), a receiving platform with an air distributor (161), a bed transfer mechanism (152) movably engaged with the frame and overlying the bed transfer area, an aspirator (154), a deagglomerator (156), a duster (157), a printed article collector (158), and a powder collector (159). At least one air brush (161) is also included. The bed transfer mechanism (152) comprises a carriage configured to be displaced in a reciprocating manner along a rail (153) in the direction of arrow N. The bed transfer mechanism also includes a container (167) including a cavity (166) configured to receive and temporarily hold a three-dimensional printed bed (83) with an optional build panel (10). The container (167) is reciprocated in a vertical manner by means of a reciprocating mechanism engaged with the body of the container and bed transfer mechanism (152). During operation, the conveyor (155) conducts and positions the print bed (83), build panel (10) and transport tray (74) beneath the container (167) and in the bed transfer area so as to align the three-dimensional print bed, build panel and transport tray with the cavity (166). The container is then lowered onto the transport tray in an amount sufficient to retain substantially all of the three-dimensionally printed bed within the cavity. An aspirator (154) then aspirates the printed bed (83) via a duct (165) and porous panel in the cavity and above the bed, thereby removing a major portion of the loose powder contained within the bed while leaving one or more printed articles (160) within the cavity of the container. The bed transport mechanism (152) then slides/displaces the print bed and build panel in the direction of arrow N over one or more air brushes (161) configured to direct air flow at the printed article in the cavity to assist in releasing additional loose powder from the printed article(s). Empty build panels (10) and transport trays (74) are transported away from the bed transfer area. The powder collector (159) is configured to receive loose powder and other solid material that would otherwise be collected by the aspirator (154). The bed transfer mechanism continues to move in the direction of arrow B until it overlaps the deagglomerator (156). The aspirator is then turned off and the printed particles fall on a processing tray of a de-agglomerator configured to remove and collect agglomerates from the printed article(s) to provide a post-agglomerate printed article (162). The bed transfer mechanism (152) is then returned to its initial position in preparation for loading and processing of additional printed beds.

The de-agglomerator's processing tray vibrates (and/or spins) and conducts the printed article in the direction of arrow B toward the duster (157) while de-agglomerating the printed particles. The duster also includes a vibratory handling tray configured to remove and collect dust from the de-agglomerated printed items to provide post-dusting printed items (163). Upon completion, the printed article (164) is conducted to a printed article collector (158). The dust separator and/or deagglomerator may further comprise a solids collector for collecting loose powder and/or agglomerates.

Fig. 18 depicts an exemplary harvester system (190) and duster system (200). The harvester system includes a housing (191), a container (192), a vibrating surface (193) within the container, and an outlet (194) for the container. A porous build panel under the dry print bed (loose powder and printed article) was placed on the vibrating surface. As the surface vibrates, loose powder is removed from the printed bed. The reclaimed loose powder falls and is collected in a container, after which it is unloaded from the container through an outlet. The recovered loose powder is collected in a bin (195). The collection of loose powder may be done manually, mechanically and/or using a vacuum system.

The precipitator system (200) of fig. 18 comprises a housing (201), a container (202), a drawer (203), an enclosure (204), one or more air jets, e.g., air knives (205, not depicted), within the enclosure, an inlet (206, not depicted) for the enclosure, and an outlet (207) for the enclosure. The porous build tray with the one or more printed articles that have been harvested is placed in a drawer, which is then pushed into the enclosure via the access opening, thereby forming a substantially enclosed dusting area. The one or more air jets direct pressurized air toward the printed article(s), whereby coarse and fine loose powder that has adhered to the printed article(s) is removed from the printed article. The loose powder falls into the container and is conducted to the outlet with the air released by the air jet(s). The printed article(s) is retrieved through the drawer opening after dusting. The recovered loose powder is collected in a bin. The collection of loose powder may be done manually, mechanically, and/or with a vacuum system and/or an air handling system. The dust collector system and/or the harvester system may be placed within a larger enclosure (208) to minimize the spread of dust in the processing area.

The loose powders, agglomerates or particles collected during the build cycle, drying, harvesting, deagglomeration and/or dusting may be arranged or may be mixed to form a reclaimed bulk material which may be comminuted (optionally) and recycled back into the feed supply of the original unprinted bulk material. Such bulk material recovery systems may include one or more vacuum systems, one or more pressurized air systems, one or more non-vacuum mechanical systems, one or more manual systems, or combinations thereof for transferring bulk material from one location to another.

12A-12E depict exemplary schematic layouts of a conveyor system and build stations for a three-dimensional print build system. Fig. 2A depicts a top view of a three-dimensional print build system (105), somewhat similar to the three-dimensional print build system depicted in fig. 1. The system (105) includes an endless and iterative conveyor system (110), a first build station (111), an optional second build station (115), and a plurality of build modules. The plurality of building blocks are conducted through a first building station and optionally a second building station (if present) and then returned through the first building station in the direction of arrow a. The build station (111) includes a powder layering system (112) and a printing system (114).

Fig. 2B depicts a top view of a three-dimensional print build system (106) that includes a linear conveyor system (118), a first build station (111), a second build station (115), and a plurality of build modules. The plurality of build modules are conducted in the direction of arrow a from position X1 through the first build station to position X2 and then through the second build station to position X3. Further processing of the printed article is done downstream of the build system (106). In some embodiments, the conveyor system is a linear conveyor system that conducts the build modules from a first build station to a second build station, and optionally to a third or other build station, in a non-cyclic or non-iterative manner.

Fig. 2D depicts a top view of a linear and iterative three-dimensional printing build system (107) comprising a linear conveyor system (119), a first build station (111), an optional second build station (115), and a plurality of build modules. The plurality of build modules are conducted from position X1 through the first build station to position X2, then through the second build station (if present) to position X3, and then back in the reverse direction through the second build station (if present) and the first build station in the direction of arrow AR. A third or more other building stations may be included and, if present, the building module conducts through these building stations.

Fig. 12D depicts a top view of a rectilinear and iterative three-dimensional printing build system (108) comprising a plurality of build stations (111, 115, 126, 127), a plurality of build modules, and a build module transfer device (124, 125). The empty build module on the conveyor (120) is transported from position Z1 to position X1. The conveyor (121) then conducts the building modules continuously from position X1 to X2 to X3 and through the building stations (111, 115). Then, the building module transfer device (124) transfers the building module from the position X3 to the position X4 in the direction of the arrow AZ. The second conveyor then conducts the build modules continuously from positions X4 to X5 to X6 and through the build stations (126, 127, respectively). Then, the building block transfer device (125) transfers the building block from the position X6 to the position X1 in the direction of the arrow AY. This type of build stroke is repeated as many times as necessary until the desired printed article is formed by means of the conveyor (122) and unloaded from the print build system (108).

Fig. 12E depicts a side view of three-dimensional print build system (109), somewhat similar to the three-dimensional print build system of fig. 12D. However, in this embodiment, the conveyors (128, 129) are arranged vertically one above the other, rather than side-by-side. Moreover, the descent conveyor system (129) has no build stations specifically associated therewith.

As mentioned above, multiple build passes are required to build a three-dimensional printed article from a powder bed. Fig. 11A depicts a partial cross-sectional view of a build module (90) that includes a body (91) having an upper surface (91A) and a height adjustable platform (92) having an upper surface (92 a). The hollow arrows indicate the processing steps, while the solid black arrows indicate the direction of movement of the platform in the view. A building block (90) is depicted in a starting position at phase 0. In process steps a1 and a2, the platform is lowered, thereby forming a cavity (93) defined by an inner surface (91b) of the build module and an upper surface of the platform. Then, as depicted in stage I, a build panel (10) is placed on top of the platform. In process step B1, as depicted in stage II, a layer of powder (94) is placed into the cavity and over the build panel such that the position of the upper surface (94a) of the layer substantially matches (or is at the same height as) the position of the upper surface (91a) of the build module. In process step C1, the platform is lowered again in increments, as depicted in stage III, thereby forming a new cavity (95) over the surface of the powder layer (94). In process steps D1 and D2, as depicted in stage IV, another layer of powder is placed into the cavity and then printed on to form one or more segments of bonded powder. In process step E1, the platform is lowered again and another cavity is formed over the previous powder layer, as depicted in stage V. In process steps F1 and F2, as depicted in stage VI, another layer of powder is placed into the cavity and then printed on to form one or more segments of bonded powder. The print pattern used in process step D2 is similar to the print pattern used in process step F2. In process step G1, the platform is lowered again as depicted in stage VII. In process step H1, as depicted in stage VIII, a layer of powder is placed into the just-formed cavity above the previous layer of powder, thereby completing the formation of a printed bed comprising loose powder (97) and a plurality of printed articles (96). In process step J1, as depicted in stage IX, the container (71a) of the bed transfer apparatus is placed over the print bed such that the cavity of the container overlaps and aligns with the print bed. In process step K1, the platform is raised, as depicted in stage X, so that the build panel and the print bed are arranged into the cavity. In process step L1, the container is displaced/slid in the direction of arrow N, thereby unloading the build tray, returning to stage 0.

The print pattern for a single print cycle can vary as desired and need not be the same for each build run. FIG. 11B depicts the building block of FIG. 11A. The process steps a1, a2, B1, and C1 in fig. 11B are similar to those in fig. 11A; however, the process of fig. 11B includes process step B2, whereby a first powder layer is printed on to form a layer comprising loose powder (100) and bound powder (101). In process step D1, a powder layer is placed into the cavity and in process step D3, the layer is printed with a different print pattern than the print pattern used in process step B2 so that the cross-section of the bonded powder (102) in stage IV of fig. 11B is different from the cross-section of the bonded powder in stage IV of fig. 11A. However, the pattern of step D3 and the pattern of step B2 sufficiently overlap so that the resulting printed layers bond to each other. The platform is lowered again according to process step E1. Then, the powder is layered into the cavity in process step F1 and printed on in process step F3. Again, the printed pattern used in process step F3 is different from the printed pattern used in process steps D3 and B2, such that the cross-section of the bonded powder (103) in stage VI includes three different patterns that are different from those depicted in stage VI of fig. 11A. However, the pattern of step F3 and the pattern of step D3 sufficiently overlap so that the resulting printed layers bond to each other. The platform descends again as depicted in stage VII according to process step G1. In process step H1, a layer of powder is placed into the cavity and in process step H2, the layer is printed with a different print pattern than any of the previously printed patterns used, so that the cross-section of the bound powder (104) in the printed bed in stage VIII comprises six different patterns, different from those depicted in stage VIII of fig. 11A. However, the pattern of step H2 and the pattern of step F3 sufficiently overlap so that the resulting printed layers bond to each other. In process step J1, a porous panel is placed over the printed bed and the container of the bed transport device is placed over the panel as depicted in stage X. In process step K1, the porous panel, the printed bed and the build panel are raised into the cavity of the container. In process step L1, the container is displaced away in the direction of arrow N, leaving the build module in its initial stage 0.

Upon completion of the exemplary print cycle, the three-dimensionally printed bed may be further processed as described herein.

As an embodiment, a conveyor system having the purpose of conducting solid articles from one location to another location during manufacturing includes a modular conveyor, a non-modular conveyor, a continuous conveyor, a conveyor belt, a cam, a pallet conveyor, or a linked conveyor. Combinations thereof may be used.

Fig. 15 depicts a side view of an exemplary packaging system (170) configured to package one or more three-dimensional printed articles (164). The system comprises a hopper (171) providing three-dimensional printed articles, which are placed on a conveyor (173). The articles are conducted through a wrapping module (172) that places one or more articles into a package (174). Suitable packaging systems may employ bottles, transparent packages, tubes, boxes, and other such cases.

The various components and systems of the device assembly will include portions made of durable materials such as metal, plastic, rubber, or combinations thereof. In some embodiments, the components of the apparatus assembly include 304 or 316 stainless steel, where possible.

The powder may comprise one or more materials suitable for pharmaceutical or non-pharmaceutical use. In some embodiments, the powder comprises one or more pharmaceutical excipients, one or more pharmaceutically active agents, or a combination thereof. In some embodiments, the three-dimensionally printed article is a pharmaceutical dosage form, a medical device, a medical implant, or other such article as described.

By way of example and not limitation, exemplary types of pharmaceutical excipients that can be included in a three-dimensional printed article include chelating agents, preservatives, adsorbents, acidifying agents, alkalizing agents, antifoaming agents, buffers, colorants, electrolytes, flavorants, polishing agents, salts, stabilizers, sweeteners, muscle elasticity modifiers, anti-adherents, binders, diluents, direct compression excipients, disintegrants, glidants, lubricants, opacifiers, polishing agents, plasticizers, other pharmaceutical excipients, or combinations thereof.

By way of example and not limitation, exemplary types of non-pharmaceutical excipients that may be included in the three-dimensional printed article include ash, clay, ceramic, metal, polymer, biomaterial, plastic, inorganic material, salt, other such materials, or combinations thereof.

In some embodiments, the powder comprises one or more, two or more, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, ten or more, or more ingredients, each ingredient being independently selected in each instance. In some embodiments, the apparatus assembly includes one or more, two or more, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, ten or more, or more powder (or solid ingredient) reservoirs.

Pharmaceutically active agents generally include physiologically or pharmacologically active substances that produce one or more systemic or localized effects in animals, cells, non-humans, and humans. When an active agent is present, any such agent may be used. By way of example and not limitation, exemplary classes of active agents include insecticides, herbicides, insect killers, antioxidants, plant growth stimulants, sterilization agents, catalysts, chemical agents, food products, nutraceuticals, cosmetics, vitamins, sterilization agents, fertility stimulants, microorganisms, flavoring agents, sweeteners, detergents, and other such compositions for use in pharmaceutical, veterinary, horticultural, household, food, cooking, agricultural, cosmetic, industrial, cleaning, confectionery, and flavoring applications.

Whenever mentioned and unless otherwise indicated, the term "active agent" includes all active agent forms including neutral, ionic, salt, base, acid, natural, synthetic, diastereomeric, isomeric, optically pure, racemic, hydrate, chelated, derivative, homologous, optically active, enriched, free base, free acid, regioisomeric, amorphous, anhydrous and/or crystalline forms.

The three-dimensional print form can include one, two, or more different active agents. Specific combinations of active agents may be provided. Some compositions of active agents include: 1) a first drug from a first therapeutic class and a different second drug from the same therapeutic class; 2) a first drug from a first therapeutic class and a different second drug from a different therapeutic class; 3) a first drug having a first type of biological activity and a different second drug having about the same biological activity; 4) a first drug having a first type of biological activity and a different second drug having a different second type of biological activity. Exemplary compositions of active agents are described herein.

The active agent may be independently selected from active agents such as, in each case, antibiotic agents, antihistamine agents, decongestants, anti-inflammatory agents, antiparasitic agents, antiviral agents, local anesthetics, antifungal agents, proteolicidal agents, trichomonad-killing agents, analgesics, antiarthritic agents, antiasthmatic agents, anticoagulants, anticonvulsants, antidepressants, antidiabetic agents, antineoplastic agents, antipsychotic agents, tranquilizers, antihypertensive agents, hypnotics, sedatives, anxiolytic stimulants, antiparkinson agents, muscle relaxants, antimalarials, hormonal agents, contraceptive agents, sympathomimetic agents, hypoglycaemic agents, antihyperlipidemic agents, ophthalmic agents, electrolytes, diagnostic agents, prokinetic agents, gastric acid secretion inhibitors, antiulcer agents (anti-ulcerant agents), An anti-bloating agent, an anti-incontinence agent, a cardiovascular agent, or a combination thereof. Descriptions of useful drugs in these and other classes and lists of classes within each class may be found in Martindale, 31 th edition, entitled Extra Pharmacopoeia (pharmaceutical Press, london 1996), the disclosure of which is incorporated herein by reference in its entirety.

The above mentioned list should not be considered exhaustive and merely exemplify many embodiments considered within the scope of the invention. Many other active agents may be included in the powders of the present invention.

The liquid applied to the powder may be a solution or a suspension. The liquid may comprise an aqueous carrier, a non-aqueous carrier, an organic carrier, or a combination thereof. The aqueous carrier may be water or a buffer solution. The non-aqueous carrier can be an organic solvent, a low molecular weight polymer, an oil, a silica gel, other suitable material, an alcohol, ethanol, methanol, propanol, isopropanol, polyethylene (ethylene glycol), ethylene glycol, other such materials, or combinations thereof.

In some embodiments, the apparatus assembly comprises one or more, two or more, three or more, four or more, or more liquid reservoirs. The liquid may be coloured or achromatic. The liquid may include a pigment, a coating, a dye, a tint, an ink, or a combination thereof.

The liquid may include one or more solutes dissolved therein. The powder and/or liquid may include one or more binders.

The exemplary embodiments herein should not be considered exhaustive and merely illustrative of but a few of the many embodiments contemplated by the present invention.

As used herein, the term "about" is taken to mean a value within ± 10%, ± 5%, or ± 1% of the indicated value.

The entire disclosure of all documents cited herein is hereby incorporated by reference in its entirety.

Example 1

The following materials and procedures were used to prepare three-dimensional print forms that dissolve rapidly in saliva.

A powder comprising at least one drug carrier is loaded into a powder reservoir. A fluid comprising a liquid and at least one active component is loaded into the fluid reservoir. The apparatus assembly is operated whereby a plurality of stacked incremental layers of printing powder are sequentially formed in the build module by repeatedly passing the build module through one or more build stations. Typically, four to fifty incremental layers of printed powder are formed and bonded to each other, thereby forming a printed bed having one or more articles surrounded by or embedded in loose powder. The printed bed was dried in a dryer. The printed article is separated from the loose powder using a harvester. The printed article is then optionally dedusted using a deduster. The printed article is then optionally packaged.

The above is a detailed description of the embodiments of the present invention. It will be understood that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims. All of the embodiments disclosed and claimed herein can be made and executed without undue experimentation in light of the disclosure.

Claims

1. A three-dimensional printing device assembly comprising:

a) a three-dimensional printing build system, comprising:

a conveyor system that conducts the plurality of build modules along a circuitous path;

a plurality of build modules engaged with the conveyor system, wherein the build modules receive and temporarily hold powder from the powder layering system, and wherein the build modules comprise an incrementally height adjustable platform, a removable build panel disposed above the platform, and one or more sidewalls defining a cavity within which the platform, build panel are disposed; and

at least one construction station, comprising: 1) at least one powder layering system that forms an incremental powder layer within the cavity of the build module; and 2) at least one printing system that applies liquid to the incremental powder layers within the build module according to a predetermined pattern, and comprising at least one liquid supply system and at least one print head that deposits liquid on the incremental powder layers in the build module according to a predetermined pattern;

wherein the conveyor system repeatedly transports the build modules from the at least one powder layering system to the at least one printing system to form a three-dimensionally printed bed comprising one or more three-dimensionally printed articles in the build modules,

wherein the conveyor system comprises a plurality of attachments to removably hold said plurality of building modules, the attachments comprising a plurality of one or more links with cam followers or comprising wheels or panels or carriers or any combination thereof attached to the building modules and mounted on a track system on which the building modules are conducted.

2. The assembly of claim 1, comprising:

a) a three-dimensional printing build system, comprising:

a conveyor system comprising a positioning controller and a plurality of build module engagers;

the at least one powder layering system comprises at least one powder filling head, at least one powder spreader and at least one powder storage;

the three-dimensional printing bed body comprises loose powder which is not printed yet;

b) at least one harvesting system that separates loose powder from one or more three-dimensionally printed articles in a three-dimensionally printed bed.

3. The assembly of claim 1, wherein: a) at least one deliquoring system is present; b) the apparatus assembly further comprises at least one packaging system for packaging one or more three-dimensional printed articles; c) a conveyor system repeatedly transports the plurality of build modules from the at least one powder layering system to the at least one printing system and printing is done with cartesian coordinate based printing rather than radial or polar coordinate printing; d) the equipment assembly further includes a powder recovery system for recovering and recycling unprinted powder; e) the apparatus assembly further comprises a liquid detector; and/or the equipment assembly further comprises at least one inspection system.

4. The assembly of claim 3, wherein the assembly comprises any one or any combination of the following features: a) a liquid detector detects the presence of liquid in one or more printed incremental powder layers and/or in one or more printed articles; b) the inspection system is a printed powder inspection system that determines the integrity of printing in one or more printed incremental powder layers and/or one or more printed articles, and/or determines whether powder is properly applied in one or more incremental powder layers; c) the inspection system is a printed article inspection system that determines whether one or more printed articles have the correct gauge or shape or weight or appearance or density or content or color or any combination thereof; d) the inspection system is a liquid application inspection system that monitors the droplets applied to the powder by the print head;

e) the inspection system includes one or more cameras.

5. The assembly of claim 4, wherein:

a) determining the integrity of the printing includes at least one of determining whether liquid has been correctly applied to the one or more incremental powder layers according to one or more predetermined patterns, and/or determining whether liquid has been correctly applied to the one or more incremental powder layers according to a predetermined amount; and/or

b) The cameras are in each case independently selected from the group consisting of visible wavelength cameras, UV wavelength cameras, near infrared wavelength cameras, x-ray cameras and infrared wavelength cameras.

6. Assembly according to the preceding claim 2, further comprising a bed transfer system for transferring the build panel and the three-dimensionally printed bed one or more at a time away from the three-dimensionally printed build system, wherein the printed beds are together or not together with their respective build modules.

7. The assembly of claim 6, wherein:

a) the bed transfer system transfers the build panel and the three-dimensional printed bed to one or more dewatering systems and/or one or more harvesting systems; and/or b) the transfer system is integrated and/or operationally synchronized with the conveyor system, the dewatering system, or both the conveyor system and the dewatering system.

8. The assembly of claim 2, further comprising at least one liquid removal system that receives one or more three-dimensionally printed beds and removes liquid from one or more layers of powder to which liquid has been applied and/or from the three-dimensionally printed beds.

9. The assembly of claim 8, wherein the assembly comprises any one or any combination of the following features: a) the liquid removal system comprises at least one dryer; b) the deliquoring system processes two or more build panels and their contents at a time; c) the liquid removal system processes two or more printing beds at a time; d) the deliquoring system processes two or more printed articles at a time.

10. The assembly of claim 2, further comprising a dust removal system that removes loose particles from printed articles that have been harvested from the printed powder bed.

11. The assembly of claim 10, wherein the dust extraction system comprises: a) a housing defining a dust removal region; b) one or more air jets that introduce pressurized air into the dust removal zone; c) one or more surfaces or holders in the dusting area for temporarily holding one or more printed articles being dusted; and d) one or more outlets through which air and dislodged particles exit the housing or dusting region.

12. The assembly of claim 2, further comprising a build panel loading system that places one or more build panels on the height adjustable platform of the one or more build modules.

13. The assembly of claim 3, further comprising:

a) a three-dimensional printing build system, comprising:

b) at least one harvesting system that separates loose powder from one or more three-dimensionally printed articles in a three-dimensionally printed bed;

c) a bed transfer system for transferring the construction panel and the three-dimensional printing bed away from the three-dimensional printing construction system in one or more ways at a time;

d) at least one liquid removal system that receives one or more three-dimensionally printed beds and removes liquid from one or more layers of powder to which liquid has been applied and/or from the three-dimensionally printed beds;

e) a dusting system that removes loose particles from a printed article that has been harvested from a printed powder bed;

f) a build panel loading system that places one or more build panels on a height adjustable platform of the one or more build modules; and

g) one or more powder recovery systems that collect and return powder to a powder storage from at least one of the conveyor system, the at least one printing system, the at least one powder layering system, the at least one harvesting system, the at least one packaging system, the at least one inspection system, the bed transfer system, the at least one deliquoring system, the de-dusting system, and the build panel loading system.

14. Assembly according to the previous claim 13, wherein the recovery system comprises one or more bulk powder collectors and one or more pipes for conducting bulk powder from said one or more collectors to the powder storage.

15. The assembly of claim 14, wherein the recovery system further comprises any one or any combination of the following features: a) one or more powder mixers for mixing the reclaimed bulk powder with the initial bulk powder; b) one or more pressurized air powder handling systems that facilitate the transfer of loose powder from one location to another; c) one or more vacuum powder handling systems that facilitate the transfer of loose powder from one location to another; d) one or more mechanical powder handling systems that transfer loose powder from one location to another; e) one or more manual powder handling systems that transfer loose powder from one location to another.

16. The assembly of claim 2, further comprising a control system comprising one or more computerized controllers, one or more computers, and one or more user interfaces for the one or more computers.

17. The assembly of claim 16, wherein the assembly comprises any one or any combination of the following features: a) one or more components of the equipment assembly are controlled by a computer; b) one or more components of the three-dimensional printing build system are computer controlled; c) the conveyor system, the height adjustable platform of the build module, the at least one powder layering system, and the at least one printing system are computer controlled; d) the equipment assembly spreads the layer of powder and deposits droplets in one or more predetermined patterns on the layer according to instructions provided by the computerized controller.

18. The assembly of claim 17, wherein: a) the predetermined pattern is based on one or more two-dimensional image files comprising pixels.

19. The assembly of claim 18, wherein: a) the two-dimensional image file is structured such that certain pixels indicate the dispensing of a droplet, while other pixels represent dispensing without a droplet; and/or b) the two-dimensional image file includes pixels of different colors to indicate dispensing or non-dispensing of different liquids.

20. The assembly of claim 2, further comprising any one or any combination of the following features: a) one or more working surfaces; b) one or more tables; c) one or more gantries; d) one or more enclosures; e) one or more platforms.

21. The assembly of claim 2, wherein the assembly comprises any one or any combination of the following features: a) at least one of the build modules comprises an incremental height adjustable platform that receives and temporarily holds at least one incremental powder layer or a plurality of stacked incremental powder layers; b) at least one of the build modules comprises a body including an upper surface having a cavity, a height adjustable build platform disposed within the cavity, a height adjuster engaged with the body and the platform, and an engagement mechanism; c) a plurality of build modules removably engaged with the conveyor system; d) at least one of the build modules comprises one or more sidewalls surrounding the build panel and configured to hold powder on the height adjustable platform; e) at least one of the build modules is removably engaged with the conveyor system.

22. The assembly of claim 21, wherein: a) the platform is lowered or raised in one or more increments after the incremental powder layer is placed on the platform.

23. The assembly of claim 22, wherein the assembly comprises any one or any combination of the following features: a) the stage displacement can occur before or after placing a subsequent incremental layer of powder on the stage, thereby rolling or removing a portion of powder from an already deposited layer of powder; b) the increment specification is preset; c) a removable build panel disposed above the height adjustable platform and receiving and supporting one or more incremental powder layers; d) the removable build panel is flat, permeable, porous, textured, coated, knurled, smooth, or a combination thereof.

24. The assembly of claim 2, wherein: a) a conveyor system conducting the plurality of build modules along a planar circuitous path, a horizontal circuitous path, a vertical circuitous path, or a combination thereof; and/or b) the conveyor system transporting the plurality of build modules along a path in a counterclockwise or clockwise direction.

25. The assembly of claim 24, wherein: a) the path of the conveyor system is circular, elliptical, rectangular, semicircular, square, triangular, pentagonal, hexagonal, octagonal, oval, parallelogram, quadrilateral, symmetrical, asymmetrical, or equivalent of these shapes with rounded corners and/or edges; and/or b) the conveyor system is a continuous or discontinuous circulation system.

26. The assembly of claim 24, wherein: a) the conveyor system comprises a plurality of conveyor systems, at least one drive motor, at least one positioning controller, and a path along which the plurality of build modules are conducted; and/or b) the conveyor system further comprises one or more positioning controllers.

27. The assembly of claim 26, wherein: the conveyor system includes a body, one or more build module engagement devices, and a conveyor system engagement mechanism by which a plurality of conveyor systems are engaged to form a modular conveyor.

28. The assembly of claim 2, wherein: a) at least one of the building stations is incrementally height adjustable relative to the building module, whereby the vertical space between the building module and the building station is adjustable in one or more increments; and/or b) at least one build station is vertically fixed relative to the build module and a build platform within the build module is vertically height adjustable relative to the build module such that the vertical distance between the build station and the build module remains the same during a print stroke or print cycle.

29. The assembly of claim 28, wherein the incrementally height adjustable build station is raised in one or more increments after placement of a layer of powder on a build module and before placement of a subsequent layer of powder on a build module.

30. The assembly of claim 29, wherein the change in elevation is achieved by changing the vertical position relative to a previous position of the platform or by changing the vertical position relative to an absolute position of the platform relative to the building block.

31. The assembly of claim 2, wherein: a) the at least one powder layering system includes at least one powder feeder channel that transfers powder from the powder reservoir to the powder fill head.

32. The assembly of claim 31, wherein the assembly comprises any one or any combination of the following features: a) the at least one powder filling head is stationary, meaning that the powder filling head does not move longitudinally or transversely with respect to the plane of the upper surface of the build module when an incremental layer of powder is applied to the build module; b) the at least one powder fill head comprises at least one powder fill head body, at least one powder spreader, and at least one powder level controller; c) at least one powder filling head comprises a hopper or chute.

33. The assembly of claim 32, wherein: a) the powder spreader is a cylindrical roller, the axis of which has a radial direction of movement opposite to the linear direction of movement of the building blocks through the powder layering system; and/or b) the powder spreader is a cylindrical roller, rod, bar, panel or straight smooth edge.

34. The assembly of claim 1, wherein: a) the at least one printing system depositing liquid to the powder according to a cartesian coordinate algorithm rather than a polar coordinate algorithm; and/or b) the at least one printing system depositing liquid in a three-dimensional pattern of droplets or a plurality of two-dimensional patterns of droplets defining one or more articles.

35. The assembly of claim 34, wherein the assembly comprises any one or any combination of the following features: a) at least one printhead includes one or more print modules; b) the pattern comprises equally spaced droplets within one or more objects; b) the pattern comprises non-equidistantly spaced droplets within one or more objects; c) the pattern comprises droplets having different pitches in different regions of the article; d) the pattern comprises droplets having a higher print density in an area defining an exterior of the article; e) the pattern comprises droplets having a lower print density in an area inside the article; f) the system prints more than one pattern; g) the printing system uses more than one liquid; h) the predetermined pattern for applying the liquid is the same in each incremental powder layer, or in two or more incremental powder layers, or different in one or more incremental powder layers, or different in all the incremental powder layers, or the predetermined pattern for applying the liquid is the same for a first group of incremental powder layers and the same for a second group of incremental powder layers but the pattern for said first group is different from the pattern for said second group; i) both the print head and the powder fill head are stationary during the formation of the printed incremental powder layer.

36. The assembly of claim 2, wherein both the at least one print head and the at least one powder fill head are stationary during formation of the printed incremental powder layer.

37. The assembly of claim 2, wherein the assembly comprises any one or any combination of the following features: a) the harvesting system processes the printed bed that has been processed by the liquid removal system; b) the harvesting system comprises a loose powder collector and a three-dimensional printed object collector; c) the harvesting system includes a vibrating or revolving surface that receives a three-dimensional printed powder bed or three-dimensional printed object; d) the harvesting system includes a vacuum conveyor having a screen for separating the articles from the loose powder.

38. The assembly of claim 37, wherein the vibrating surface is porous, non-porous, corrugated, smooth, or non-smooth, and is configured to separate loose powder from the printed article.

39. The assembly of claim 2, which does not include a printing system that applies liquid to the powder solely according to a polar coordinate or radial algorithm.

40. The assembly of claim 2, wherein the assembly comprises any one or any combination of the following features: a) the assembly does not include an apparatus assembly in which liquid is applied to the powder according to a polar coordinate system; b) the assembly does not include equipment assemblies in which the printhead moves laterally or transversely relative to the build module or is not stationary when applying liquid to the incremental powder layer; c) the assembly does not include an equipment assembly in which the powder fill head moves laterally or transversely relative to the build module as incremental powder layers are deposited.

41. A method of preparing a three-dimensional printed article using a device assembly, the method comprising:

a) initiating operation of a three-dimensional printing build system, the three-dimensional printing build system comprising:

a conveyor system that conducts a plurality of build modules along a circuitous path, wherein the conveyor system comprises a plurality of attachments that removably hold the plurality of build modules, the attachments comprising a plurality of one or more links with cam followers or comprising wheels or panels or carriers or any combination thereof attached to the build modules and mounted on a track system on which the build modules are conducted;

a plurality of build modules engaged with the conveyor system, wherein the build modules receive and temporarily hold powder from the powder layering system; and

at least one construction station, comprising: 1) at least one powder layering system forming incremental powder layers within the build module; and 2) at least one printing system that applies liquid to the incremental powder layers within the building blocks according to a preset pattern;

b) repeatedly transporting the build module from the at least one powder layering system to the at least one printing system using the conveyor system to form a three-dimensionally printed bed comprising one or more three-dimensionally printed articles in the build module.

42. A three-dimensional printing device assembly comprising:

a) a three-dimensional printing build system, comprising:

a modular conveyor system;

a plurality of build modules engaged with the conveyor system;

a build panel loading area, wherein a build panel is loaded on a build module;

at least one build station comprising a build area, the build area comprising a powder dispensing area where powder is dispensed into a build module and a printing area where printing fluid is dispensed onto powder in a build module; and

a powder recovery area in which powder is removed from one or more surfaces of the build module;

b) one or more fluid removal systems; and

c) a bed transfer system comprising a bed transfer area, wherein the three-dimensional printed bed is transferred to the one or more deliquoring systems one or more at a time, remote from the three-dimensional print building system;

wherein the conveyor system conducts the plurality of build modules along a circuitous path through a build panel loading area, a build area, a printing area, a powder recovery area, and a bed transfer area; and is

Wherein the conveyor system comprises a plurality of attachments to removably hold a plurality of building modules, the attachments comprising a plurality of one or more links with cam followers or comprising wheels or panels or carriers or any combination thereof attached to the building modules and mounted on a track system on which the building modules are conducted.

43. The assembly of claim 42, further comprising one or more harvesting systems that separate loose powder from the one or more three-dimensionally printed articles in the three-dimensionally printed bed.

44. The equipment assembly of claim 43, wherein the one or more harvesting systems comprise a bulk powder collector and a three-dimensional printed article collector.

45. The equipment assembly of claim 44, further comprising one or more dust removal systems to remove loose particles from one or more three-dimensional printed articles that have been harvested by the harvesting system.

46. The apparatus assembly of claim 42, wherein the apparatus assembly does not include an apparatus assembly that dispenses printing fluid to powder according to a polar coordinate system.

47. The equipment assembly of claim 42, wherein the equipment assembly does not include equipment assemblies in which a printhead moves laterally or transversely relative to a build module when applying liquid to an incremental powder layer.

48. The apparatus assembly of claim 42, wherein the apparatus assembly does not include an apparatus assembly in which the powder fill head moves laterally or transversely or is not stationary relative to the build module when depositing the incremental powder layer.

49. The equipment assembly of claim 42, wherein the assembly comprises any one or any combination of the following features: a) at least one deliquoring system is present; b) the apparatus assembly further comprises at least one packaging system for packaging one or more three-dimensional printed articles; c) a conveyor system repeatedly transports the plurality of build modules from the at least one powder layering system to the at least one printing system and printing is done with cartesian coordinate based printing rather than radial or polar coordinate printing; d) the equipment assembly further comprises a powder recovery system for recovering unprinted powder; e) the apparatus assembly further comprises a liquid detector; f) the equipment assembly also includes at least one inspection system.

50. The equipment assembly of claim 49, wherein: the powder recovery system is also used to recycle unprinted powder.

51. A three-dimensional printing device assembly comprising:

a) a three-dimensional printing build system, comprising:

a transmitter system configured to conduct a plurality of build modules;

wherein the conveyor system comprises a plurality of attachments to removably hold a plurality of building modules, the attachments comprising a plurality of one or more links with cam followers or comprising wheels or panels or carriers or any combination thereof attached to the building modules and mounted on a track system on which the building modules are conducted and

wherein the conveyor system repeatedly transports the build modules from the at least one powder layering system to the at least one printing system to form a three-dimensionally printed bed comprising one or more three-dimensionally printed articles in the build modules; and is

The apparatus assembly does not include a printing system configured to apply liquid to the powder according to a polar coordinate algorithm.

52. A three-dimensional printing device assembly comprising:

a modular conveyor system that conducts a plurality of build modules along a circuitous path;

a plurality of build modules engaged with the conveyor system, wherein the build modules temporarily hold one or more three-dimensional printed articles and the build modules comprise an incrementally height adjustable platform, a removable build panel disposed above the platform, and one or more sidewalls defining a cavity within which the platform, build panel can be disposed; and

at least one build station that forms one or more three-dimensional printed articles on the plurality of build modules;

wherein the conveyor system repeatedly transports the build modules through the at least one build station, and

53. The assembly of claim 52, further comprising one or more of:

a) at least one packaging system for packaging one or more three-dimensionally printed articles; b) at least one inspection system for inspecting a three-dimensional printed object that has been completed or is in progress; c) at least one transfer system for transferring the three-dimensional printed object and the corresponding build panel away from the three-dimensional printing build system; d) at least one build panel loading system to load one or more build panels onto a height adjustable platform of the one or more build modules; e) at least one control system comprising one or more computerized controllers, one or more computers, and one or more user interfaces for the one or more computers; f) at least one positioning controller; g) one or more build module engagement devices; and h) at least one three-dimensional printed object collector.

54. The assembly of claim 52, wherein the assembly does not include at least one of: a) a device component for printing an object according to a polar coordinate algorithm; b) an equipment assembly including a printhead that moves laterally or transversely relative to the build module during printing; and c) an equipment assembly including a powder fill head that moves laterally or transversely relative to the build module during printing.