Apparatus, system, and method for automated depowdering and extraction of three-dimensional printed parts

An apparatus mounted to a first container of a system and electronically connected to a controller, the apparatus comprising:

• an elevated frame removably secured to an open top of the first container and configured to vertically receive at least fully raised at least one three-dimensional (3D) printed layer and partially raised at least one powder layer, wherein the at least one 3D printed layer comprises one or more 3D printed parts and powder in between the one or more 3D printed parts;
• a perforated plate slidably inserted into the elevated frame, capable of longitudinally passing through the partially raised at least one powder layer and depowdering at least a portion of the partially raised at least one powder layer;
• a movable unit engaged to a front end portion of the perforated plate and adapted to move longitudinally along with the perforated plate, within the elevated frame, the movable unit comprising:
• a rotary actuator comprising a driver member;
• one or more driven members;
• and
• a connecting member transversely connecting the driver member to the one or more driven members and adapted to be positioned in front of the front end portion, wherein at least a portion of the connecting member transversely slides within the partially raised at least one powder layer;
• a lifting-lowering mechanism mechanically coupled to the elevated frame, the lifting-lowering mechanism configured to removably secure the elevated frame to the open top during the slidably insertion of the perforated plate into the elevated frame and to lift the elevated frame along with the perforated plate up to a second predefined height upon completion of the slidably insertion of the perforated plate into the elevated frame;
• a depowdering unit electronically coupled to the controller and configured to depowder the at least one powder layer, the powder in between one or more 3D printed parts, and powder adhered to the one or more 3D printed parts;
• and
• at least one gripper electronically coupled to the controller and configured to automatically extract the one or more 3D printed parts of the fully raised the at least one 3D printed layer.

A method, comprising:

• accommodating, by a first container, a plurality of extraction layers comprising at least one three-dimensional (3D) printed layer and at least one powder layer alternatively arranged with the at least one 3D printed layer, wherein the at least one 3D printed layer comprises one or more 3D printed parts and powder in between the one or more 3D printed parts;
• raising, by a first linear drive actuator, fully the at least one 3D printed layer located at a top of the plurality of extraction layers to a first predefined height from the open top and partially the at least one powder layer disposed below the fully raised at least one 3D printed layer;
• receiving, by an elevated frame, vertically the fully raised at least one 3D printed layer and the partially raised at least one powder layer, wherein the elevated frame is removably secured to the open top;
• receiving, by the elevated frame, longitudinally a movable unit, wherein the movable unit is engaged to a front end portion of a perforated plate and adapted to move longitudinally along with the perforated plate, within the elevated frame;
• moving, by a rotary actuator of the movable unit, a connecting member of the movable unit transversely within the partially raised at least one powder layer;
• receiving, by the elevated frame, the perforated plate slidably and longitudinally passes through the partially raised at least one powder layer, wherein the perforated plate is configured to depowder at least a part of the partially raised at least one powder layer;
• lifting, by a lifting-lowering mechanism of the apparatus, the elevated frame along with the perforated plate up to a second predefined height upon completion of the slidably insertion of the perforated plate into the elevated frame;
• depowdering, by a depowdering unit of the apparatus, the at least one powder layer, the powder in between one or more 3D printed parts, and powder adhered to the one or more 3D printed parts;
• and
• extracting, by at least one gripper of the apparatus, the one or more 3D printed parts of the fully raised at least one 3D printed layer.