A three-dimensional (3-D) printer includes build and support material development stations positioned to transfer layers of build and support materials to an intermediate transfer surface. The intermediate transfer surface transfers a layer of the build and support materials to a platen each time the platen contacts the intermediate transfer surface. A sensor detects the thickness of the layer on the platen, and a mechanical planer is positioned to contact and level the layer on the platen as the platen moves past the mechanical planer. Additionally, a feedback loop is electrically connected to the sensor and the mechanical planer. The mechanical planer adjusts the amount of the build material and the support material removed from the layer based on the thickness of the layer on the platen, as determined by the sensor.

A three-dimensional (3-D) printer includes build and support material development stations positioned to transfer layers of build and support materials to an intermediate transfer surface. A platen having a flat surface is positioned to contact the intermediate transfer surface. The intermediate transfer surface transfers a layer of the build and support materials to the flat surface of the platen as the platen contacts one of the layers on the intermediate transfer surface. A dispenser is positioned to deposit a leveling material on the layer on the platen, and a mechanical planer is positioned to contact and level the leveling material on the layer on the platen to make the top of the leveling material parallel to the flat surface of the platen.

In 3-D printing a platen moves toward an intermediate transfer belt (ITB) to have a sheet positioned on the platen contact the ITB to electrostatically transfer a layer of different materials to the sheet, and then the platen moves to a heater to join the layer to the sheet. This processing is repeated to have the sheet repeatedly contact the ITB (with intervening heating at the heater) to successively form layers of the materials on the sheet. The sheet having the layers thereon moves to a rinsing station, where a liquid is applied to dissolve the sheet and leave a freestanding stack of the layers. The freestanding stack is fed to a platform to successively form a 3-D structure of freestanding stacks of the layers. Light and/or heat are applied to the 3-D structure to bond the freestanding stacks to one another on the platform.

In 3-D printing a platen moves toward an intermediate transfer belt (ITB) to have a sheet positioned on the platen contact the ITB to electrostatically transfer a layer of different materials to the sheet, and then the platen moves to a stabilization station to join the layer to the sheet. This processing is repeated to have the sheet repeatedly contact the ITB (with intervening stabilization at the stabilization station) to successively form layers of the materials on the sheet. The freestanding stack is fed to a platform to successively form a 3-D structure of freestanding stacks of the layers. Heat and/or pressure and/or light are applied to the 3-D structure to bond the freestanding stacks to one another through the sheets of collapsible media on the platform.

A method of making a molded article having a curved surface, such as plates or serving trays, and the resulting molded articles. The in-mold label (IML) is a laminated film that includes a backing layer, a printed surface incorporating one or more designs thereon, a protective film layer, and one or more notches each having adjacent edges separated by a gap of predetermined distance and configured to intersect to ensure conformance of the IML to the angled or curved peripheral portion of the article. The article has front and back sides and a central portion bounded by a peripheral portion having a perimeter that is raised on the front side of the article wherein the peripheral portion transitions from the perimeter to the central portion by an angled surface, a curved surface or combinations thereof, with the article including the IML at least peripheral portion of the molded article.