Provided herein are devices and systems for depositing a material or manufacturing a product, such as a pharmaceutical dosage form, by additive manufacturing. Further provided are methods of using the devices and systems, as well as methods of manufacturing a product, such as a pharmaceutical dosage form, by additive manufacturing. In certain embodiments, the device includes a material supply system configured to melt an pressurized a material, a pressure sensor configured to detect a pressure of the material within the device, and a control switch comprising a sealing needle operable in an open position and closed position. The sealing needle extends through a feed channel containing the material and includes a taper end, wherein the tapered end of the sealing needle engages a tapered inner surface of a nozzle to inhibit flow of the material through the nozzle when the sealing needle is in the closed position.

An example technique includes extruding, by a tow deposition device, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material on a major surface of a substrate. Each respective impregnated tow includes at least one ceramic fiber and a curable resin coating the at least one ceramic fiber. The example technique includes curing the curable resin to form a cured composite component. An example system includes a tow deposition device, an energy source, and a computing device. The computing device is configured to control the tow deposition device to extrude, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material, and is configured to control the energy source to cure the curable resin to form a cured composite component.

An improved method and apparatus for adding a new layer to a stack of previously processed layers. In an example, a method is provided for mounting the previously processed layer on a build platform, mounting the new layer on a substrate, aligning the new layer with the previously processed layer, moving the new layer and the previously processed into contact with one another, and applying energy to the new layer from an energy source through the substrate to simultaneously process the new layer and bond the new layer to the previously processed layer to form a bonded processed multilayer stack on the build platform. A flexible compliant pressure conveyance media is moved into contact with the substrate to apply pressure to the new layer while the energy is being applied.

An improved method and apparatus for adding a new layer to a stack of previously processed layers. In an example, a method is provided for mounting the previously processed layer on a build platform, mounting the new layer on a substrate, aligning the new layer with the previously processed layer, moving the new layer and the previously processed into contact with one another, and applying energy to the new layer from an energy source through the substrate to simultaneously process the new layer and bond the new layer to the previously processed layer to form a bonded processed multilayer stack on the build platform. A flexible compliant pressure conveyance media is moved into contact with the substrate to apply pressure to the new layer while the energy is being applied.

A method of printing a 3D printing a photopolymer composite material includes providing a resin premix material including an acrylate monomer or an acrylate oligomer, an inorganic hydrate, a reinforcing filler, a co-initiator, and an ultraviolet (UV) initiator. A thermal initiator is mixed with the resin premix to form a photopolymer composite resin. The photopolymer composite resin is repeatedly extruded and dual-cured by a 3D printing system to create a photopolymer composite material. The 3D printing system includes a control system, a mixing system, a feeding system in fluid communication with the mixing system, a light curing module controlled by the control system, and a printing head controlled by the control system.

A method of printing a 3D printing a photopolymer composite material includes providing a resin premix material including an acrylate monomer or an acrylate oligomer, an inorganic hydrate, a reinforcing filler, a co-initiator, and an ultraviolet (UV) initiator. A thermal initiator is mixed with the resin premix to form a photopolymer composite resin. The photopolymer composite resin is repeatedly extruded and dual-cured by a 3D printing system to create a photopolymer composite material. The 3D printing system includes a control system, a mixing system, a feeding system in fluid communication with the mixing system, a light curing module controlled by the control system, and a printing head controlled by the control system.

A method of printing a 3D printing a photopolymer composite material includes providing a resin premix material including an acrylate monomer or an acrylate oligomer, an inorganic hydrate, a reinforcing filler, a co-initiator, and an ultraviolet (UV) initiator. A thermal initiator is mixed with the resin premix to form a photopolymer composite resin. The photopolymer composite resin is repeatedly extruded and dual-cured by a 3D printing system to create a photopolymer composite material. The 3D printing system includes a control system, a mixing system, a feeding system in fluid communication with the mixing system, a light curing module controlled by the control system, and a printing head controlled by the control system.

A method of printing a 3D printing a photopolymer composite material includes providing a resin premix material including an acrylate monomer or an acrylate oligomer, an inorganic hydrate, a reinforcing filler, a co-initiator, and an ultraviolet (UV) initiator. A thermal initiator is mixed with the resin premix to form a photopolymer composite resin. The photopolymer composite resin is repeatedly extruded and dual-cured by a 3D printing system to create a photopolymer composite material. The 3D printing system includes a control system, a mixing system, a feeding system in fluid communication with the mixing system, a light curing module controlled by the control system, and a printing head controlled by the control system.

Various methods and systems are provided for mixing and dispensing viscous materials for the creation of additive structures. As one example, during a mixing and dispensing operation of a multi-dimensional printing apparatus, one or more liquids may flow into a mixing chamber via one or more material inlets arranged in a wall of the mixing chamber below a high pressure bearing of a mixing rod positioned within the mixing chamber; and movement of a mixing rod positioned within the mixing chamber is adjusted based on an operating condition of the printing apparatus.

A plasticizing apparatus for plasticizing a material to form a molten material includes a screw having a groove formed face, in which a groove portion in a spiral shape to be supplied with the material is formed, and a first heating portion heating the material, and a barrel having a screw opposed face, which is a face opposed to the groove formed face, and in which a sending-out hole for sending out the molten material is formed at a center, and a second heating portion heating the material.