Patent Description:
<CIT> discloses a cartridge assembly, a cartridge unit, a food forming module, and a cooking apparatus capable of using three-dimensional (3D) printing technology to form and cook food. <CIT> discloses a three-dimensional bioprinter for printing and/or patterning a single type or multiple types of cells into different geometrical arrangements and other three-dimensional structures, such as tissues. The bioprinter comprises multiple heads that can each be loaded with a different cartridge containing a biomaterial or biological material such as cells in a solution or cells in a hydrogel.

In accordance with a first aspect of the present invention, there is provided a 3D printer according to claim <NUM>.

Thus, the 3D printer according to the first aspect of the invention is arranged to print a plurality of consumable items such as pharmaceutical or healthcare supplements in parallel. The print head positions the dispensers such that the printing axes of the dispensers are arranged in an equidistant manner around a circular path to define a regular polygon. The print bed has corresponding print locations. The translation device enables the nozzle of each dispenser to print a layer of a consumable item in a shape at a respective print location. Once a layer has been printed at each print location, the rotation device can be operated to index the print head or the print bed to place the nozzles in registration with another print location in order to build up a second layer of each consumable item on top of the first layer. This process can be repeated a number of times to quickly produce a plurality of multi-component consumable items. The dispensers can dispense quick set material liquid.

The print zone can comprise a plate and the rotation device can be mechanically coupled to the plate to rotate the plate about the second Z axis. Thus, the rotation device can be arranged to rotate the part of the print bed upon which the print head is arranged to print. This can be advantageous in that the print zone plate can be significantly lighter than the liquid dispensers and the portion of the print head which carries them, meaning that smaller, cheaper motors and the like can be utilised, bringing energy and heat efficiencies.

The translation device can be arranged to move the print bed relative to the print head along the Z axis. This enables the distance between the tips of the dispenser nozzles and the print locations on the print bed to be increased as layers of the consumable items are added, enabling the nozzles to be continually close to the top surface of a consumable item as it is built up.

Each dispenser can be a syringe arranged to be mounted in or on the print head, the print head being arranged to support the plurality of syringes. This enables ubiquitous syringes such as food or medicine grade stainless steel syringes to be used for the printing process.

The print head can comprise: a block having a plurality of block apertures extending through the block; and a syringe support arranged to receive and hold the syringes to define the regular polygon, the syringe support being removably coupled to the block.

The block can comprise heating means operable to heat the liquid in the syringes. The heat block can be used to heat the liquid in the dispensers to aid in it being extruded by the actuator device during the dispensing cycles. The block can have a thickness in the Z axis which encompasses at least half of the length of the body of the syringes to provide a large region of thermal coupling. The heating means can comprise resistive electrical wiring or hot water conduits embedded in a metal block.

The syringe support can comprise: a first support plate having a plurality of support apertures, each support aperture being arranged to receive a syringe and being sized such at least some of the body of the syringe can pass through the support aperture but a radially enlarged flange of the syringe body cannot pass through the support aperture; a second support plate having a plurality of support apertures, each support aperture being arranged to receive a syringe and being sized such at least some of the body of the syringe can pass through the support aperture but a radially enlarged flange of the syringe body cannot pass through the support aperture, the support apertures being arranged to define the regular polygon; and coupling formations arranged to enable the first support plate to be coupled to the block with the second support plate being situated between the block and the first support plate. This provides a device via which a plurality of syringes can be quickly and conveniently coupled together in the regular polygon configuration, ready for inserting into the print head.

The coupling formations can comprise regions of ferromagnetic material and the block comprises a plurality of electromagnets situated to align with the coupling regions when the syringe support is situated on the block and operable to magnetically couple the syringe support to the block. The coupling formations can comprise discs which extend from a lower face of the first plate by a distance which places the free axial faces of the discs in registration with the lower surface of the second plate when the plates are pressed together with the syringe flanges between them.

The actuator device can comprise: a drive plate having a drive face with plurality of syringe plunger locations arranged in the regular polygon and a pair of parallel support rails defining a channel between them and having flanged sections spaced from the first plate and extending towards one another, the plurality of syringe plunger locations being defined between the support rails; first and second retention plates, each retention plate including a plurality of retention slots that extend into the retention plate from a first edge and have arcuate end faces which, when the first and second retention plates are inserted into opposite end of the channel, with the syringe plungers located at the syringe plunger locations, overlap the syringe plungers to grasp the syringe plungers; and one or more linear actuators coupled between the drive plate and the block to linearly move the drive plate towards the block to dispense liquid from the syringes. This provides a device via which a plurality of syringes located in a syringe support can be quickly and conveniently coupled to the print head.

The print bed can comprise a plurality of print zones. Thus, the translation device can be utilised to move the print bed along the X axis once a first set of consumable items have been printed at the first print zone and the process can be repeated to print one or more further sets of consumable items at one or more further print zones on the print bed. This can enable a greater number of consumable items to be printed in a fast manner without increasing the size, weight and/or complexity of the print head.

The print head can be arranged to position the nozzles to define a seven sided polygon and each print zone positions the print locations to define a seven sided polygon. The print bed can consists of four print zones disposed in a linear arrangement along the print bed, with the axis of each print zone intersecting a longitudinal axis of the print bed. This can provide an arrangement particularly well suited to printing pharmaceutical or healthcare supplements.

The 3D printer can further comprise a controller configured to cause the 3D printer to perform the following steps: with the first Z axis aligned with the second Z axis, operate the actuator device to dispense liquid from each nozzle onto a respective print location: operate the rotation device to cause relative rotation between the print zone and the print head to place each print location in registration with a different one of the nozzles; and operate the actuator device to dispense liquid from each nozzle onto a respective print location. This process can be repeated a number of times, preferably by the same number as the number of dispensers such that a multi-layer consumable item can be printed having a component provided by each dispenser.

The controller can be further configured to cause the 3D printer to perform the following steps: move the print bed in the Z direction away from the print head following each step of operating the actuator device to dispense liquid from each liquid dispenser onto a respective print location by an amount which corresponds to the thickness in the Z axis of the liquid dispensed on the print locations.

The controller can be further configured to move the print bed in the X and Y directions while operating the actuator device to dispense liquid from each liquid dispenser onto a respective print location to define a closed loop shape.

In accordance with a second aspect of the invention, there is provided a method according to claim <NUM>.

The liquid dispensers may be filled with any of the compositions disclosed in <CIT>, <CIT> or <CIT>. The liquid dispensers may be filled with a fast-setting composition, optionally a fast-setting gel. This can allow faster rates of manufacture.

By way of example only, certain embodiments of the invention will now be described by reference to the accompanying drawings, in which;.

<FIG> show a 3D printer for printing consumable items according to an embodiment of the invention generally at <NUM>. The 3D printer <NUM> is arranged to print a plurality of consumable items such as pharmaceutical or healthcare supplements in parallel.

The 3D printer <NUM> has a print head <NUM> arranged to position nozzles of a plurality of liquid dispensers to define a regular polygon around a first Z axis Z1. In this embodiment the fluid dispensers are syringes arranged to be situated in a downward facing manner on a block <NUM> within the print head <NUM>.

The 3D printer <NUM> has an actuator device <NUM>, which in this embodiment is located within the print head <NUM>, operable to dispense a portion of liquid from each liquid dispenser located within the block <NUM>.

The 3D printer <NUM> has a print bed comprising four print zones PZ, each print zone PZ comprising a plurality of print locations PL arranged to define a regular polygon around a respective second Z axis Z2.

The 3D printer <NUM> has a translation device operable to move the print bed <NUM> relative to the print head <NUM> along X and Y axes. In this embodiment the print bed <NUM> is slidably mounted on a base <NUM> so as to be movable along the X axis.

As can be seen from <FIG>, the first and second Z axes Z1, Z2 are vertical and may be offset and the X and Y axes are horizontal and may be perpendicular to each other.

The 3D printer <NUM> has a rotation device operable to cause relative rotation between the print zone PZ and the print head <NUM> such that, with the first Z axis Z1 aligned with the second Z axis Z2, the actuator device <NUM> is operable to dispense liquid from each liquid dispenser onto a respective print location PL and thereafter the rotation device is operable to cause relative rotation between the print zone PZ and the print head <NUM> to place each print location PL in registration with a different one of the nozzles.

<FIG> are perspective, top and side view diagrams respectively of the movable portion of the print bed <NUM> of the 3D printer of <FIG>.

The print bed <NUM> is supported on a base <NUM>, the base having an X motor (not shown) for moving the print bed <NUM> in the X direction by interaction with an X bearing <NUM>. The print bed has a Z motor <NUM> for moving the print bed <NUM> in a vertical direction, i.e. along the second Z axis Z2 and a Y motor <NUM> for moving the print bed <NUM> along the Y axis.

The print bed <NUM> comprises plates <NUM>, which form print zones PZ. In the disclosed embodiment, there are four plates <NUM> forming four respective print zones PZ, however other numbers of plates <NUM> and print zones PZ may be used. The print zones PZ may be located along a top surface of the print bed <NUM> and separated along the X axis.

The respective print zone PZ defined by each plate <NUM> has a plurality of print locations PL. The plates <NUM> may each be rotationally symmetrical about their respective second Z axis Z2 such that the plates <NUM> can be rotated and the print locations can change position such that a first print location PL may take the position of a second print location PL when the plate <NUM> is rotated by a predetermined number of degrees. The plates <NUM> can be rotated in order to move the print locations PL by rotation motors <NUM>. The rotation motors <NUM> are preferably stepper motors, which can provide a high degree of accuracy of rotation.

While <FIG> show print zones PZ each having seven print locations PL, other numbers of print locations PL on each print zone are possible. The number of print locations PL in each print zone PZ should preferably be the same as the number of syringes supported within the print head <NUM>.

<FIG> shows an extrusion system for operating syringes. The extrusion system comprises an extrusion plate <NUM> for pressing on the plungers of syringes and a stabilising plate <NUM> for securing the plungers of syringes. The extrusion plate <NUM> and the stabilising plate <NUM> are moveable in a vertical direction along rails <NUM>, which define a channel therebetween. Extrusion motors 32a and 32b are arranged to drive the extrusion plate <NUM> and stabilising plate <NUM> vertically in order to exert a downward force on the plungers of the syringes such that material is dispensed from the syringes.

The system may also comprise a heater block <NUM>, which may contain an electrical wire or fluid circulation system and is arranged to heat material within the syringes in order to reduce the viscosity of the material and/or melt the material in order that the material can be more easily dispensed from the syringes and a greater range of materials may be dispensed by using a heater block <NUM>.

<FIG> show an arrangement of syringes <NUM>. Each syringe has a syringe body <NUM>, which may be filled with an esculent material to be dispensed, a nozzle <NUM> for controlling dispensation of the material, and a plunger <NUM>, which can be pressed towards the syringe body <NUM> in order to extrude material from the nozzle <NUM>. Each syringe may also have a lug <NUM> extending from the syringe body <NUM>. The lug <NUM> can be placed between two support plates <NUM>, <NUM>. There may be a first support plate <NUM> above the lug and a second support plate <NUM> below the lug. The first support plate <NUM> may have coupling formations 38a for holding the first support plate <NUM> to a block, such as heating block <NUM> of the print head <NUM> or a non-heated block.

The arrangement of the first and second support plates <NUM>, <NUM> and the syringes <NUM> allows the syringes <NUM> to be held in a stable formation outside the print head <NUM> so that the syringes <NUM> can all be inserted quickly and easily at the same time into the print head <NUM>.

As shown in <FIG>, the first support plate <NUM> may have support apertures 38b sized to be larger than the syringe body <NUM> and smaller than the lugs <NUM> and the second support plate <NUM> may have second support apertures 40b, which may also be sized to be larger than the syringe body <NUM> and smaller than the lugs <NUM>. This allows the syringes <NUM> to be inserted through the support apertures 38b, 40b and held in place by the lugs <NUM> and support plates <NUM>, <NUM>.

<FIG> shows the print head <NUM> with the syringes <NUM> installed. The syringes <NUM> are installed within the heating block <NUM> and are held in place by the first support plate <NUM> and second support plate (not visible in <FIG>). It can be seen that the coupling formations 38a are coupled to corresponding coupling formations <NUM> on the heating block <NUM>. The coupling formations 38a on the first support place <NUM> may be ferromagnetic materials and the corresponding coupling formations <NUM> on the heater block <NUM> may be magnets, preferably electromagnets. The plunger ends of the syringes <NUM> (not visible in <FIG>) are situated under the extrusion plate <NUM>, such that the extrusion plate <NUM> may move vertically downwards in order to extrude material from the syringes <NUM>.

<FIG> shows a view of the stabilising plate <NUM> connected to the extrusion plate <NUM> from underneath. It can be seen that the stabilising plate <NUM> may be formed as two parts, which may be slid into place along slide rails <NUM>. The stabilising plates <NUM> may comprise stabilisation slots 36a which may be slid into place in order to hold the plungers <NUM> of the syringes <NUM>.

<FIG> and <FIG> show how the two parts of the stabilising plate <NUM> may be slid into place.

The machine may be operated such that the extrusion plate <NUM> is operated to push down on the syringes <NUM> so that all plungers are touching the extruding plate <NUM> and the stabilising plates <NUM> may be slid into place to grip onto the plungers <NUM> while the plungers <NUM> are all in contact with the extrusion plate <NUM>. This can prevent the plungers <NUM> from moving away from the extrusion plate <NUM> and ensure stabilisation of the plungers <NUM>.

The 3D printer may be operated so that a print zone PZ is positioned underneath the syringes <NUM>, with the first Z axis Z1 collinear with the second Z axis Z2 and the print zone PZ underneath the plungers <NUM>. An amount of material may be extruded from the nozzles <NUM> of the syringes <NUM> onto the plurality of print locations PL underneath the syringes <NUM>. Following the extrusion of material, the extrusion may be stopped and the print location can be changed by rotating the plate <NUM> about the Z axis Z2. The rotation can occur such that after the rotation each print location PL is underneath a different syringe <NUM>. Subsequently, a second extrusion step can take place, wherein further material is extruded from each syringe <NUM> onto a respective print location PL, with each print location PL having a different material from a different syringe <NUM> deposited onto it between each rotation step. This process can be repeated until every print location PL has all necessary material deposited upon it, such as after a complete rotation of the print zone PZ. Subsequently, the print bed <NUM> can be moved in the X direction such that a new print zone PZ and is positioned underneath the syringes <NUM>.

It is also noted that certain syringes <NUM> of the arrangement may be absent or may be empty, if the number of different materials required to be deposited does not exactly match the number of print locations PL. Alternatively, more than one syringe <NUM> may contain the same material, it is not essential that every syringe <NUM> has a different material.

The syringes <NUM> may be sterile syringes suitable for use in food or pharmaceutical manufacture and may be filled with pharmaceutical or food compositions for manufacturing food or pharmaceutical supplements, including vitamin and mineral supplements. The composition may be solid or may be a gel at room temperature, and may become liquid or a less viscous gel when heated by the heated block <NUM>.

It is also possible to move the print bed <NUM> and therefore the print zone PZ and print location PL in the X and Y directions during the extrusion step in order to control the manner and precise location of deposition of material on each print location.

In between each extrusion step, the print bed <NUM> can be moved in the Z direction, for example in order to prevent deposited material from touching a syringe nozzle <NUM>.

The flowchart in <FIG> illustrates a method <NUM> by which the print head <NUM> may operate.

At step <NUM>, the print head <NUM> is primed, with the syringes <NUM> inserted and a print zone PZ situated underneath the syringes <NUM>. This may include the print zone PZ being moved into position along the X-axis and may include an alignment check to ensure that each print location PL is aligned with a nozzle <NUM> of a particular syringe <NUM>.

At step <NUM>, material is deposited from the syringes <NUM> onto the respective print locations PL by movement of the extrusion plate <NUM>.

At step <NUM>, a check is made as to whether every print location PL within the print zone PZ under the syringes <NUM> has the required materials deposited upon it. If every print location PL has all of the required materials, then the method moves to step <NUM>, otherwise the method moves to step <NUM>.

At step <NUM>, the print zone PZ is rotated so that each print location PL aligns with a different syringe <NUM> so that a different material can be deposited onto each print location PL. A further deposition step <NUM> can then take place.

At step <NUM>, it is determined whether every print zone PZ on the print bed has had materials deposited upon it, or whether there are more print zones PZ that require printing. If all print zones PZ have been printed, then the method finishes at step <NUM>. Otherwise, the method moves to step <NUM>.

At step <NUM>, the print bed is moved in the X direction so that a new print zone PZ is aligned with the syringes <NUM>. This may also include an alignment check to ensure that each print location PL is underneath a syringe <NUM>. Subsequently, a further deposition of material occurs at step <NUM>.

At step <NUM> the method is finished and the printed products can be removed. At this stage a volume of customised esculent products have been produced.

Claim 1:
A 3D printer for printing consumable items, the 3D printer comprising:
a plurality of liquid dispensers (<NUM>) wherein each liquid dispenser comprises a nozzle (<NUM>);
a print head (<NUM>) arranged to position the nozzles (<NUM>) of the plurality of liquid dispensers (<NUM>) to define a regular polygon around a first Z axis (Z1);
an actuator device (<NUM>) operable to dispense a portion of liquid from each liquid dispenser;
a print bed (<NUM>) comprising a print zone (PZ), the print zone comprising a plurality of print locations (PL) arranged to define a regular polygon around a second Z axis (Z2); and
a translation device (<NUM>) operable to move the print bed relative to the print head along X and Y axes;
a rotation device operable to cause relative rotation between the print zone and the print head such that, with the first Z axis aligned with the second Z axis, the actuator is operable to dispense liquid from each liquid dispenser onto a respective print location and thereafter the rotation device is operable to cause relative rotation between the print zone and the print head to place each print location in registration with a different one of the nozzles; and
characterised by a controller configured to cause the 3D printer to perform the following steps:
with the first Z axis aligned with the second Z axis, operate the actuator device to dispense liquid from each nozzle onto a respective print location;
then operate the rotation device to cause relative rotation between the print zone and the print head to place each print location in registration with a different one of the nozzles; and
then operate the actuator device to dispense liquid from each liquid dispenser onto a respective print location.