A method and apparatus enabling additive manufacturing of individualized oral therapeutic capsule forms containing multiple medicinal ingredients, also referred to as a personalized polypill process. A process and supporting apparatus to fulfil the formulated therapy prescribed by a physician to address the medical conditions of an individual patient, furthering the practice of personalized medicine. The methods and apparatus apply to the powder forms of active pharmaceuticals, dietary supplements, and specialized chemicals, such as diagnostic inks and dyes. The methods teach the deposition of computer-controlled amounts of high-potency powder forms of active ingredients deposited in sequential layers into a single delivery form. Each active ingredient layer is sequentially deposited to a programmable dosage accurately controlled with closed-loop gravimetric sensing, enabling sub-milligram mass deposition accuracy. Cumulative doses are compacted into segregated layers of programmable density with the optional addition of an inert barrier film between each chemical entity to minimize interactions.

A rotary press includes upper and lower press punches, a die plate defining a plurality of cavities, a filling apparatus that dispenses powder material into the plurality cavities, and a pressing apparatus that presses the powder material in the plurality of cavities into pellets. A scraping apparatus scrapes pellets ejected from the die plate into a first pellet discharge and a sorting apparatus sorts the pellets into a second pellet discharge. The sorting apparatus includes a sorting drive including an electric motor with a magnet driven by a stator and a transmission element, and a sorting element driven by the sorting drive between a sorting position and a rest position. In the sorting position, the sorting element guides pellets into the second pellet discharge. The magnet translates a drive movement, via the transmission element, into a drive movement of the sorting element with a higher drive speed.