# US 9,517,592 B2 · Three-dimensional printing system and equipment assembly

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- Number: US 9,517,592 B2
- Document ID: US9517592B2
- Status: Granted
- Kind: B2
- Application number: 15/077,112
- Filed: 2016-03-22
- Published: 2016-07-21
- Granted: 2016-12-13
- Earliest claimed: 2012-09-05
- Assignees: Aprecia Pharmaceuticals LLC
- Applicants: Aprecia Pharmaceuticals Company
- Inventors: Jaedeok Yoo; Thomas J. Bradbury; Thomas J. Bebb; James Iskra; Henry L. Surprenant; Thomas G. West
- Web page: https://patentgrep.com/patent/US9517592B2

## CPC

- B29C 64/35: Cleaning
- B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- 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
- B29C 64/176: Sequentially
- B29C 64/236: for motion in a direction within the plane of a layer
- B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40)
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- B29L 2009/00: Layered products
- Y02P 10/25: Process efficiency
- Y10T 428/24851: Intermediate layer is discontinuous or differential
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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

### Claim 1

A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:
a) initiating operation of a three-dimensional printing build system comprising:
a modular conveyor system adapted to conduct plural build modules along a circuitous path;
the plural build modules engaged with the modular conveyor system, wherein the plural build modules are adapted to receive and temporarily retain powder from a powder layering system, and the plural build modules comprise respective incrementally height adjustable platforms and removable build plates; and
at least one build station comprising: 1) at least one powder layering system adapted to form incremental powder layers on respective removable plates within the plural build modules; and 2) at least one printing system adapted to apply a liquid according to one or more predetermined patterns to the incremental powder layers;
b) with the modular conveyor system, repeatedly transporting the plural build modules from the at least one powder layering system to the at least one printing system to form three-dimensionally printed beds comprising one or more three-dimensionally printed articles in the plural build modules; and
c) transferring the three-dimensionally printed beds and respective removable plates, one or more at a time, away from the plural build modules and respective incrementally height adjustable platforms.

### Claim 2 (depends on 1)

The method of claim 1 further comprising:
a) harvesting the one or more three-dimensionally printed articles from the three-dimensionally printed beds with at least one harvesting system adapted to separate loose powder from the one or more three-dimensionally printed articles.

### Claim 3 (depends on 2)

The method of claim 2 further comprising removing liquid from the incremental powder layers or from the three-dimensionally printed beds with at least one liquid removal system.

### Claim 4 (depends on 3)

The method of claim 3 further comprising dedusting the one or more three-dimensionally printed articles that have been harvested from respective three-dimensionally printed powder beds to remove loose particles of powder from the one or more three-dimensionally printed articles.

### Claim 5 (depends on 3)

The method of claim 3 further comprising:
a) packaging the one or more three-dimensionally printed articles with at least one packaging system;
b) recovering loose powder generated during the process with a powder recovery system;
c) detecting the presence, amount or concentration of liquid present in the one or more three-dimensionally printed articles with a liquid detector; or
d) inspecting the three-dimensionally printed beds or the one or more three-dimensionally printed articles with at least one inspection system.

### Claim 6 (depends on 5)

The method of claim 5, wherein: a) the at least one inspection system is a printed powder inspection system that determines the integrity of printing in incremental powder layers or the one or more three-dimensionally printed articles, or determines whether or not powder was applied in one or more incremental layers; b) the at least one inspection system is a printed article inspection system that determines whether or not the one or more three-dimensionally printed articles have the correct size, shape, weight, appearance, density, content or color; c) the at least one inspection system is a liquid application inspection system that monitors liquid applied to the incremental powder layers; or d) the at least one inspection system comprises one or more cameras.

### Claim 7 (depends on 6)

The method of claim 6, wherein: a) determining the integrity of printing comprises at least one of determining whether or not the liquid has been correctly applied to the one or more incremental powder layers according to the one or more predetermined patterns, or determining whether or not the liquid has been correctly applied to the one or more incremental powder 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.

### Claim 8 (depends on 1)

The method of claim 1 wherein: a) the bed transfer system transfers the three-dimensionally printed beds to one or more liquid removal systems or one or more harvesting systems; or b) the bed transfer system is integrated or synchronized with the modular conveyor system.

### Claim 9 (depends on 3)

The method of claim 3, wherein: a) the at least one liquid removal system processes two or more of the three-dimensionally printed beds at a time; or b) the at least one liquid removal system processes two or more three-dimensionally printed articles at a time.

### Claim 10 (depends on 1)

The method of claim 1 further comprising controlling operation of the equipment assembly with a control system comprising one or more computerized controllers, one or more computers, and one or more user interfaces for one or more computers.

### Claim 11 (depends on 10)

The method of claim 10, wherein one or more of the modular conveyor system, the at least one powder layering system, or the at least one printing system are computer controlled.

### Claim 12 (depends on 10)

The method of claim 10, wherein the at least one printing system is computer controlled and the process further comprises providing to the printing system one or more image files comprising pixels, wherein the one or more image files define the one or more predetermined patterns.

### Claim 13 (depends on 1)

The method of claim 1, wherein: a) the plural build modules further comprise respective bodies comprising upper surfaces with respective cavities within which the respective incrementally height adjustable platforms are disposed, respective height adjusters engaged with the bodies and the incrementally height adjustable platforms, and engagement mechanism; b) the plural build modules are removably engaged with the modular conveyor system; or c) the plural build modules further comprises respective one or more sidewalls surrounding respective incrementally height adjustable platforms and being adapted to retain powder on the incrementally height adjustable platforms.

### Claim 14 (depends on 13)

The method of claim 13 further comprising raising or lowering the incrementally height adjustable platforms by one or more increments after placing respective incremental powder layers thereon.

### Claim 15 (depends on 1)

The method of claim 1, wherein: a) the modular 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 modular conveyor system transports the plural build modules along a path in a counterclockwise direction; or c) the modular conveyor system transports the plural build modules along a path in a clockwise direction.

### Claim 16 (depends on 1)

The method of claim 1, wherein: a) the at least one build station is incrementally height adjustable with respect to the plural build modules, whereby the vertical space between the plural build modules and the at least one build station can be adjusted by one or more increments; or b) the at least one build station is vertically fixed with respect to the plural build modules so that the vertical distance between the at least one build station and the plural build modules remains the same during a print lap or print cycle.

### Claim 17 (depends on 1)

The method of claim 1, wherein the at least one powder layering system comprises at least one powder fill head that does not move either longitudinally or transversely, with respect to the plural build modules, when forming incremental powder layers.

### Claim 18 (depends on 1)

The method of claim 1, wherein the at least one printing system comprises at least one print head that does not move either longitudinally or transversely, with respect to the plural build modules, when applying liquid to the incremental powder layers.

### Claim 19 (depends on 1)

The method of claim 1, wherein the liquid is applied using Cartesian coordinate based printing.

### Claim 20 (depends on 19)

The method of claim 19, wherein the liquid is not applied using polar coordinate based printing.

### Claim 21

A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:
a) initiating operation of a three-dimensional printing build system comprising:
a modular conveyor system adapted to conduct plural build modules along a circuitous path;
the plural build modules engaged with the modular conveyor system, wherein the plural build modules are adapted to receive and temporarily retain powder from a powder layering system and the plural build modules comprise respective sidewalls defining respective cavities, incrementally height adjustable platforms disposed within the cavities, and respective removable build plates disposed within the cavities;
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 on the removable build plates; and 2) at least one printing system adapted to apply a liquid according to one or more predetermined patterns to the incremental powder layers;
a build plate loading system; and
a bed transfer system;
b) with the build plate loading system, loading removable build plates onto the height adjustable platforms;
c) with the modular conveyor system, repeatedly transporting the plural build modules from the at least one powder layering system to the at least one printing system to form on the removable build plates respective three-dimensionally printed beds comprising one or more three-dimensionally printed articles;
d) with the bed transfer system, transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and incrementally height adjustable platforms.

### Claim 22

A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:
a) providing a three-dimensional printing build system comprising:
a modular conveyor system adapted to conduct plural build modules along a circuitous path;
the plural build modules engaged with the modular conveyor system, the plural build modules comprising respective sidewalls defining respective cavities, and respective incrementally height adjustable platforms disposed within the cavities;
removable build plates;
at least one build station comprising: 1) at least one powder layering system; and 2) at least one printing system adapted;
one or more build plate loading systems; and
one or more bed transfer systems;
b) with the one or more build plate loading systems, loading removable build plates onto the height adjustable platforms;
c) with the modular conveyor system, repeatedly transporting the plural build modules from the at least one powder layering system to the at least one printing system to form on the removable build plates respective three-dimensionally printed beds comprising one or more three-dimensionally printed articles;
d) with the one or more bed transfer systems, transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and incrementally height adjustable platforms.

### Claim 23 (depends on 22)

The method of claim 22, wherein the one or more bed transfer systems transfers the three-dimensionally printed beds and respective removable build plates to one or more liquid removal systems, one or more harvesting systems, one or more packaging systems, one or more dedusting systems, or a combination thereof.

### Claim 24 (depends on 22)

The method of claim 22 further comprising:
transferring the three-dimensionally printed beds and respective removable build plates to one or more liquid removal systems; and
reducing the amount of liquid in the three-dimensionally printed beds.

### Claim 25 (depends on 24)

The method of claim 24 further comprising:
transferring the three-dimensionally printed beds and respective removable build plates to one or more harvesting systems; and
harvesting the one or more three dimensionally printed articles from the three-dimensionally printed beds.

### Claim 26

A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:
a) providing a three-dimensional printing build system comprising:
a modular conveyor system adapted to conduct plural build modules along a circuitous path;
the plural build modules engaged with the modular conveyor system, the plural build modules comprising respective sidewalls defining respective cavities, and respective incrementally height adjustable platforms disposed within the cavities;
removable build plates;
at least one build station comprising: 1) at least one powder layering system; and 2) at least one printing system adapted;
one or more build plate loading systems;
one or more bed transfer systems;
one or more liquid removal systems; and
one or more harvesting systems;
b) with the one or more build plate loading systems, loading removable build plates onto the height adjustable platforms;
c) with the modular conveyor system, transporting the plural build modules from the at least one powder layering system to the at least one printing system to form printed incremental layers on the respective removable build plates;
d) lowering the incrementally height adjustable platforms;
e) with the modular conveyor system, transporting the plural build modules from the at least one powder layering system to the at least one printing system to form printed incremental layers on the respective removable build plates;
f) repeating steps d) and e) to form three-dimensionally printed beds comprising one or more three-dimensionally printed articles in the plural build modules;
g) with the one or more bed transfer systems, transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and incrementally height adjustable platforms;
h) transferring the three-dimensionally printed beds and respective removable build plates to the one or more liquid removal systems and reducing the amount of liquid in the three-dimensionally printed beds; and
i) transferring the three-dimensionally printed beds and respective removable build plates to one or more harvesting systems and harvesting the one or more three dimensionally printed articles from the three-dimensionally printed beds.

### Claim 27

A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:
a) providing a three-dimensional printing build system comprising a modular conveyor system that conducts plural build modules, with respective height adjustable platforms, along a circuitous path;
b) loading removable build plates onto the respective height adjustable platforms;
c) forming printed incremental layers on the respective removable build plates by transporting the plural build modules from a powder layering system to a printing system;
d) repeating step c), if needed, to form three-dimensionally printed beds comprising one or more three-dimensionally printed articles in the plural build modules; and
e) transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and height adjustable platforms.

### Claim 28 (depends on 27)

The method of claim 27 further comprising:
f) transferring the three-dimensionally printed beds and respective removable build plates to the one or more liquid removal systems and reducing the amount of liquid in the three-dimensionally printed beds; and
g) transferring the three-dimensionally printed beds and respective removable build plates to one or more harvesting systems and harvesting the one or more three dimensionally printed articles from the three-dimensionally printed beds.