Three-dimensional printing system and equipment assembly

• US 9,517,591 B2
• Filed: 02/18/2016
• Issued: 12/13/2016
• Est. Priority Date: 09/05/2012
• Status: Active Grant

• Current Assignee: Aprecia Pharmaceuticals Company
• Original Assignee: Aprecia Pharmaceuticals Company
• Inventors: Yoo, Jaedeok, Bradbury, Thomas J., Bebb, Thomas J., Iskra, James, Surprenant, Henry L., West, Thomas G.
• Primary Examiner(s): Sultana, Nahida
• Application Number:
  US15/046,714
• Publication Number:
  US 20160193787A1
• Time in Patent Office: 299 Days
• Field of Search: 264/308, 264/113, 264/401, 425/375, 425/174.4, 425/193
• US Class Current: 1/1
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/176 Sequentially
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential

Abstract

A three-dimensional printing system and equipment assembly for the manufacture of three-dimensionally printed articles is provided. The equipment assembly includes a three-dimensional printing build system, an optional liquid removal system and an optional harvester system. The build system includes a conveyor, plural build modules and at least one build station having a powder-layering system and a printing system. The equipment assembly can be used to manufacture pharmaceutical, medical, and non-pharmaceutical/non-medical objects. It can be used to prepare single or multiple articles.

Claims

1. A three-dimensional printing equipment assembly comprising:

a) a three-dimensional printing build system comprising;

a conveyor system adapted to conduct plural build modules along a circuitous path;

plural build modules engaged with the conveyor system, wherein the plural build modules are adapted to receive and temporarily retain powder from a powder layering system, and wherein the plural build modules comprise respective incrementally height adjustable platforms, respective removable build plates disposed above the incrementally height adjustable platforms, and respective one or more sidewalls defining respective cavities within which the incrementally height adjustable platforms and the removable build plates are disposed; and

at least one build station comprising;

     1) at least one powder layering system adapted to form incremental powder layers within the plural build modules; and

     2) at least one printing system adapted to apply a liquid according to a predetermined pattern to incremental powder layers within the plural build modules and comprising at least one liquid feed system and at least one print head adapted to deposit liquid according to a predetermined pattern onto the incremental powder layers;

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

2. The assembly of claim 1, wherein:

the conveyor system comprises positioning-controller and engagements for the plural build modules;

the at least one powder layering system comprises at least one powder fill head, at least one powder spreader and at least one powder reservoir; and

the at least one printing system comprises at least one liquid feed system and at least one print head;

and the equipment assembly further comprises;

at least one harvesting system adapted to separate loose powder from one or more three-dimensionally printed articles in the three-dimensionally printed beds.

3. The assembly of claim 1, wherein:

a) the equipment assembly further comprises at least one liquid removal system adapted to remove liquid from one or more incremental powder layers onto which the liquid has been applied or from the three-dimensionally printed beds, wherein the liquid removal system is adapted to process two or more build modules at a time;

b) the equipment assembly further comprises at least one packaging system adapted to package one or more three-dimensionally printed articles;

c) the conveyor system is adapted to repeatedly transport the plural build modules;

from the at least one powder layering system to the at least one printing system, and the printing is done using Cartesian coordinate-based printing and not a radial or polar coordinate printing;

d) the equipment assembly further comprises a powder recovery system for recovering, and optionally recycling, unprinted powder;

e) the equipment assembly further comprises a liquid detector;

or f) the equipment assembly further comprises at least one inspection system.

4. The assembly of claim 3, wherein:

a) the liquid detector detects the presence of liquid in one or more printed incremental layers or in one or more printed articles;

b) the at least one inspection system is a printed powder inspection system that determines the integrity of printing in one or more printed incremental layers or one or more printed articles or determines whether or not powder was applied in one or more incremental layers;

c) the at least one inspection system is a printed article inspection system that determines whether or not one or more printed articles have the correct size, shape, weight, appearance, density, content or color;

d) the at least one inspection system is a liquid application inspection system that monitors droplets of liquid applied by the print head to powder;

or e) the at least one inspection system comprises one or more cameras.

5. The assembly of claim 4, wherein:

a) determining the integrity of printing comprises at least one of determining whether or not liquid has been correctly applied to one or more incremental layers according to one or more predetermined patterns, or determining whether or not liquid has been correctly applied to one or more incremental layers according to a predetermined amount;

or b) the one or more cameras is independently selected at each occurrence from the group consisting of a visible wavelength camera, an UV wavelength camera, a near infrared wavelength camera, an x-ray camera and an infrared wavelength camera.

6. The assembly of claim 1 further comprising a bed transfer system adapted to transfer the removable build plates and respective three-dimensionally printed beds, one or more at a time, away from the plural build modules and respective incrementally height adjustable platforms.

7. The assembly of claim 6, wherein:

a) the bed transfer system is adapted to transfer the removable build plates and respective three-dimensionally printed beds to one or more liquid removal systems or one or more harvesting systems;

or b) the transfer system is integrated or synchronized with the conveyor system, the liquid removal system or both.

8. The assembly of claim 1 further comprising at least one liquid removal system adapted to receive the one or more three-dimensionally printed beds and to remove liquid from one or more powder layers onto which the liquid has been applied or from the three-dimensionally printed bed.

9. The assembly of claim 8, wherein:

a) the at least one liquid removal system comprises at least one dryer;

b) the at least one liquid removal system is adapted to process two or more removable build plates and respective three-dimensionally printed beds at a time;

c) the at least one liquid removal system is adapted to process two or more three-dimensionally printed beds at a time;

or d) the at least one liquid removal system is adapted to process two or more three-dimensionally printed articles at a time.

10. The assembly of claim 1 further comprising a dedusting system adapted to remove loose particles from three-dimensionally printed articles that have been harvested from respective three-dimensionally printed powder beds.

11. The assembly of claim 10, wherein the dedusting system comprises:

a) a housing defining a dedusting region;

b) one or more air jets that direct pressurized air into the dedusting region;

c) one or more surfaces or retainers in the dedusting region for temporarily retaining one or more three-dimensionally printed articles being dedusted; and

d) one or more outlets through which air and removed particles exit the housing or dedusting region.

12. The assembly of claim 1 further comprising a removable build plate loading system for loading the removable build plates onto the respective height adjustable platforms.

13. The assembly of claim 1 further comprising one or more powder recovery systems adapted to collect powder from one or more systems of the equipment assembly and return it to a powder reservoir.

14. The assembly of claim 13, wherein the one or more powder recovery systems comprises one or more loose powder collectors and one or more conduits for conducting loose powder from the one or more collectors to a powder reservoir.

15. The assembly of claim 14, where the one or more powder recovery systems further comprises:

a) one or more powder mixers for mixing recovered loose powder with virgin loose powder;

b) one or more pressurized air powder handling systems that facilitate transfer of loose powder from one location to another;

c) one or more vacuum powder handling systems that facilitate 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;

or e) one or more manual powder handling systems that transfer loose powder from one location to another.

16. The assembly of claim 1 further comprising a control system comprising one or more computerized controllers, one or more computers, and one or more user interfaces for one or more computers.

17. The assembly of claim 16, wherein the control system controls one or more of the three-dimensional printing build system, the conveyor system, the height adjustable platforms of the build modules, the at least one build station, the at least one powder layering system, or the at least one printing system.

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 files are structured such that certain pixels indicate dispensing of droplets, and other pixels represent no dispensing of droplets;

or b) the two-dimensional image files include different colors of pixels to indicate dispensing of different liquids, or no dispensing of liquid.

20. The assembly of claim 1 further comprising:

a) one or more working surfaces;

b) one or more tables;

c), one or more gantries;

d) one or more enclosures;

or e) one or more platforms.

21. The assembly of claim 1, wherein the plural build modules are removably engaged with the conveyor system.

22. The assembly of claim 21, wherein the height adjustable platforms are adapted to move vertically by one or more increments after placement of respective incremental powder layers thereon.

23. The assembly of claim 22, wherein:

a) the vertical movement occurs prior to placement of a subsequent incremental layer of powder thereon, thereby press-rolling or removing a portion of powder from a powder layer that has already been laid down;

b) the size of an increment is predetermined;

c) the removable build plates are flat, porous, perforated, textured, coated, knurled, smooth or a combination thereof;

or d) the vertical movement occurs after placement of a subsequent incremental layer of powder thereon, thereby press-rolling or removing a portion of powder from a powder layer that has already been laid down.

24. The assembly of claim 1, wherein:

a) the conveyor system conducts the plural build modules along a planar circuitous path, a horizontal circuitous path, a vertical circuitous path, or a combination thereof;

b) the conveyor system is adapted to transport the plural build modules along a path in a counterclockwise direction;

or c) the conveyor system is adapted to transport the plural build modules along a path in a clockwise direction.

25. The assembly of claim 24, wherein:

a) the path of the conveyor system is circular, ellipsoidal, rectangular, semicircular, square, triangular, pentagonal, hexagonal, octagon, oval, polygonal, parallelogram, quadrilateral, geometric, symmetrical, asymmetrical, or equivalents thereof with rounded corners or edges;

or b) the conveyor system is a continuous loop system.

26. The assembly of claim 1, wherein:

a) the conveyor system comprises plural conveyor modules, at least one drive motor, at least one positioning controller, and a path along which the plural build modules are conducted;

b) the conveyor system comprises plural attachments adapted to removably retain the plural build modules; and

c) the conveyor system further comprises one or more positioning-controllers.

27. The assembly of claim 26, wherein:

a) the plural conveyor modules respectively comprise a body, one or more build module engagement means, and conveyor module engagement mechanism by way of which the plural conveyor modules are adapted to engage to form a modular conveyor; and

b) the plural attachments of the conveyor comprise plural one or more metal links with cam followers, or comprises wheels, plates, bearings or a combination thereof attached to a build module and mounted on a rail system upon which the build module is conducted.

28. The assembly of claim 1, wherein the at least one build station is an incrementally height adjustable build station, which is incrementally height adjustable with respect to the plural build modules, whereby the vertical space between the plural build module and the incrementally height adjustable build station can be adjusted by one or more increments.

29. The assembly of claim 28, wherein the incrementally height adjustable build station is adapted to raise by one or more increments after placement of a layer of powder on the plural build modules and prior to placement of a subsequent layer of powder the plural build modules.

30. The assembly of claim 29, wherein the raise is achieved by changing vertical position with respect to a prior position of the height adjustable platform or with respect to an absolute position of the height adjustable platform relative to the plural build modules.

31. The assembly of claim 1, wherein:

a) the at least one powder layering system comprises at least one powder fill head;

or b) the at least one powder layering system comprises at least one powder fill head, at least one powder reservoir and at least one powder feeder tube adapted to transfer powder from the powder reservoir to the powder fill head.

32. The assembly of claim 31, wherein:

a) the at least one powder fill head is stationary, meaning it does not move either longitudinally or transversely with respect to the plane of the upper surface of the plural build modules, when applying an incremental layer of powder onto the plural build modules;

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-height controller;

or c) the at least one powder fill head comprises a hopper or chute.

33. The assembly of claim 32, wherein:

a) the at least one powder spreader is a cylindrical roller the axis of which has or defines a radial direction of motion opposite the linear direction of motion of a build module through the powder layering system;

or b) the at least one powder spreader is a cylindrical roller, bar, rod, plate or straight smooth edge.

34. The assembly of claim 1, wherein:

a) the at least one printing system is adapted to deposit liquid to the powder according to a Cartesian coordinate algorithm instead of a polar coordinate algorithm;

b) the at least one printing system comprises at least one print head adapted to deposit liquid onto incremental powder layers and at least one liquid feed system;

or c) the at least one printing system is adapted to deposit liquid as a three-dimensional pattern of droplets or as plural two-dimensional patterns of droplets defining one or more articles.

35. The assembly of claim 34, wherein:

a) the at least one print head comprises one or more print modules or plural print modules;

b) the pattern of droplets comprises droplets placed at equal spacing within one or more articles;

b) the pattern of droplets comprises droplets placed at unequal spacing within one or more articles;

c) the pattern of droplets comprises droplets with different spacing within different regions of an article;

d) the pattern of droplets comprises droplets with higher print density in a region defining the exterior of an article;

e) the pattern of droplets comprises droplets with lower print density in a region interior to an article;

f) the at least one printing system is adapted to print more than one pattern of droplets;

g) the at least one printing system is adapted to use more than one liquid;

h) the pattern of droplets is the same in each incremental layer, is the same in two or more incremental layers, is different in one or more incremental layers, is different in all incremental layers, or is the same for a first group of incremental layer and the same for a second group of incremental layers but the pattern for the first group is different than the pattern for the second group;

or i) both the at least one print head and the at least one powder fill head are stationary during formation of a printed incremental layer.

36. The assembly of claim 1 further comprising one or more harvesting systems adapted to separate loose powder from the one or more three-dimensionally printed articles.

37. The assembly of claim 36, wherein:

a) the one or more harvesting systems processes printed beds already processed by the at least one liquid removal system;

b) the one or more harvesting systems comprises loose powder collector and three-dimensionally printed article collector;

c) the one or more harvesting systems comprises a vibrating or orbiting surface adapted to receive the three-dimensionally printed powder bed or the three-dimensionally printed articles;

or d) the one or more harvesting systems comprises a vacuum conveyor with a screen to separate articles from loose powder.

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

39. The equipment assembly of claim 1, wherein the at least one printing system applies liquid according to a Cartesian coordinate system and not according to a polar coordinate system.

40. The equipment assembly of claim 2, wherein the at least one print head remains stationary, while applying liquid to incremental powder layers.

41. The equipment assembly of claim 2, wherein the at least one powder fill head remains stationary, while depositing the incremental powder layers.

42. A three-dimensional printing equipment assembly comprising:

a) a three-dimensional printing build system comprising;

a modular conveyor system;

plural build modules engaged with the conveyor system, and comprising respective height adjustable platforms;

a build plate loading system comprising a build plate loading region, wherein removable build plates are loaded onto the plural build modules;

at least one build station comprising a build region comprising a powder dispensing region, wherein powder is dispensed onto the removable build plates, and a printing region, wherein printing fluid is dispensed onto the powder on the removable build plates, thereby forming three-dimensionally printed beds comprising one or more three-dimensionally printed articles; and

a powder recovery region, wherein powder is removed from one or more surfaces of the plural build modules; and

b) one or more liquid removal systems; and

c) a bed transfer system comprising a bed transfer region wherein the three-dimensionally printed beds and respective removable build plates are transferred, one or more at a time, away from the plural build modules and respective height adjustable platforms to the one or more liquid removal systems;

wherein the conveyor system conducts the plural build modules along a circuitous path through the build plate loading region, build region, printing region, powder recovery region and bed transfer region.

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

44. The equipment assembly of claim 43, wherein the one or more harvesting systems comprises loose powder collector and three-dimensionally printed article collector.

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

46. The equipment assembly of claim 42, wherein the printing fluid is dispensed onto the powder according to a Cartesian coordinate system and not according to a polar coordinate system.

47. The equipment assembly of claim 42, wherein the at least one build station comprises at least one printing head in the printing region that remains stationary, with respect to the plural build modules, while dispensing liquid onto the powder.

48. The equipment assembly of claim 42, wherein the at least one build station comprises at least one powder fill head in the powder dispensing region that remains stationary, with respect to the plural build modules, while depositing the powder.

49. The equipment assembly of claim 42, wherein:

a) the equipment assembly further comprises at least one packaging system adapted to package one or more three-dimensionally printed articles;

b) the conveyor system is adapted to repeatedly transport the plural build modules from the powder dispensing region to the printing region, and the printing is done using Cartesian coordinate-based printing and not a radial or polar coordinate printing;

c) the equipment assembly further comprises a powder recovery system for recovering, and optionally recycling, unprinted powder;

d) the equipment assembly further comprises a liquid detector;

or e) the equipment assembly further comprises at least one inspection system.