3D Systems DMP Flex 350 User Manual Download

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3D Systems, Inc.

p/n: 15-D100, rev. D

3. Remove the printer module from the process chamber:

d. Align the module cart with the holes in the printer

frame.

e. Lock the module cart to process chamber by turning

the wheel clockwise, until the module cart is locked

and the printer module blocks are cleared.

f. Now slide the module on the cart and start turning the

wheel counter-clockwise until the module is fixed on

the cart.

4. Roll the cart to the side.

5.7 Change Material

WARNING: WITH EACH CHANGE IN MATERIAL FAMILY, IT IS ABSOLUTELY CRITICAL TO CHANGE OUT THE

PROCESS FILTER AS WELL. IN DMP DEPOSITION V36.14.0 AND LATER, THIS PROCESS WILL BE MONITORED BY THE

SOFTWARE. FOR MORE INFORMATION ON HOW TO CHANGE THE PROCESS FILTER, PLEASE REFER TO CHAPTER 6:

USER MAINTENANCE.

5.7.1 Swap Printer Modules

Caution: As the DMP printer module is dedicated

to 1 material, a second printer module is needed

for the following procedure.

1. Unplug the 24 V supply cables attached to the printer

module.

Caution: Always make sure the 24V DC On/Off

(printer only) knob is set to Off first.

2. Release the locking pins

Summary of Contents for DMP Flex 350

Page 1: ...DMP Flex 350 Production printer User guide Original instructions ...

Page 2: ...tact Hazards 13 2 3 6 Radiation Hazards 14 2 3 7 Thermal Hazards 14 2 3 8 Material Substance Hazards 14 2 3 9 Sharp Edges on the Printed Part 14 2 3 10 Weak Mechanical Integrity on the Printed Parts 14 2 4 Special Considerations Reactive Metals 15 2 4 1 Electrical Equipment 15 2 4 2 Fire Suppression 15 2 4 3 Good Housekeeping 15 2 5 Lock out Tag out 16 2 5 1 Policy 16 2 5 2 Principles Beliefs and ...

Page 3: ...lding Close to the Platform Borders 39 4 4 9 Configure Automatic Job File Backup 40 4 4 10 Options for the MaterialBatchNumberFormatMask Setting 41 4 4 11 E mail Notifications 43 4 5 DMP Deposition Operator 44 4 5 1 Oxygen Pressure Status 44 4 5 2 Machine Status 44 4 5 3 Menu Bar 45 4 5 4 Tabs 49 4 6 DMP Monitoring optional 57 4 7 DMP Server 57 4 8 Backup DMP Server 57 4 9 Bringing DMP Server to a...

Page 4: ...job 82 6 2 1 Clean Machine Interior and Printer Module 82 6 2 2 Clean Laser Window 85 6 3 Monthly 86 6 3 1 Check Pressure Levels 86 6 3 2 Check Emergency Off Buttons 86 6 3 3 Check Chiller Temperature and Water Level 87 6 3 4 Clean Vent Opening 87 6 3 5 Check Printer Gloves 87 6 3 6 Automatic Laser Power Calibration 88 6 4 Every 3 Months 93 6 4 1 Replace Chiller Fluid 93 6 4 2 Clean Machine Exteri...

Page 5: ...ts are Failing to Process 110 7 5 2 Processing Fails with Errors during hatching 110 7 5 3 Slicing and hatching a large complex part takes longer than 2 days and crashes 111 7 5 4 Processing of block supports fails 112 7 5 5 Speed up the slicing hatching and processing of multiple parts 112 7 5 6 My Computer is slow when DMP Worker is enabled 112 7 6 DMP DEPOSITION 113 7 6 1 Fix Unsafe filter pres...

Page 6: ...r industry practices are relevant to activities in which it engages as well as assuring that those laws regulations or standards are complied with under actual operating conditions and 3D Systems undertakes no responsibility in these areas In no event is 3D Systems responsible for damages of any nature including special or consequential damages resulting from the use of or reliance upon this infor...

Page 7: ...ystem visit our InfoCenter to download the latest version Information that is present in the accompanying documentation will generally not be repeated in this document The following manuals are related to this system PART NR TECHNICAL DOCUMENTATION TARGET AUDIENCE 15 D99 DMP Flex 350 Facility Guide Customer 15 D100 DMP Flex 350 User Guide Customer 80 D0712 DMP Safety Guide Customer 1 5 Safety Prec...

Page 8: ...ng roles are defined Operator An operator performs standard task on the PTM daily operations and preventive maintenance Engineer An engineer has knowledge of the system and performs basic troubleshooting Certified Service Engineer CSE Is certified by 3D Systems to perform all maintenance and troubleshooting ...

Page 9: ...ms Inc 4 p n 15 D100 rev D 1 x at the rear of the printer process chamber 1 x at the front of the printer module 1 x at the front of the printer module cart 2 SAFETY GUIDELINES 2 1 Safety Labels 2 1 1 ID Labels ...

Page 10: ...ms Inc 5 p n 15 D100 rev D 1 x at the rear of the electrical cabinet in the top left corner 2 x at the rear of the printer next to the collimator 2 1 2 Laser Certification Identification 2 1 3 Laser Fiber Label ...

Page 11: ...3D Systems Inc 6 p n 15 D100 rev D 1 x on the printer door 1 x on the scanner 2 1 4 Laser Safety Label ...

Page 12: ...3D Systems Inc 7 p n 15 D100 rev D 3 x on the printer module 2 1 5 Pinch Point Warning 4 x on the printer door 1 x pneumatics cabinet printer ...

Page 13: ...3D Systems Inc 8 p n 15 D100 rev D 1 x on the printer door 1 x on the counterweight 2 x on either side of the counterweight 2 1 6 Tip Over Warning Label ...

Page 14: ...3D Systems Inc 9 p n 15 D100 rev D 3 x at the rear of the process chamber adjacent to the oxygen sensors 1 x on the electrical cabinet 2 1 7 Burn Hazard Warning Label 2 1 8 Electrocution Warning Label ...

Page 15: ...3D Systems Inc 10 p n 15 D100 rev D 1 x in the top right corner of the printer door 2 1 9 Dust Inhalation Label ...

Page 16: ...3D Systems Inc 11 p n 15 D100 rev D 8 x total 1 x electrical cabinet 1 x laser compartiment 1 x each pneumatics cabinet 1 x blower tower 2 1 10 Restricted Access Label ...

Page 17: ...mething other than the RPM cart the RPM may fall and spill metal powder A dust cloud of other metal powder might lead to health risks and or serious injury Do not remove excessive metal powder from the RPM and the printed part after a print task when the RPM is still in the system Do not move the coater by hand use the software and the hold to run button on the system Do not bring a limb inside th...

Page 18: ... Metal powder in the electrical cabinet leads to short circuit or fire or explosion The electrical cabinet is rated to IP 54 regulatory inspections are required 2 3 4 Mechanical Hazards ORIGIN POTENTIAL CONSEQUENCES DESCRIPTION PREVENTIVE OR CORRECTIVE ACTIONS Other Slip trip or fall Trip over loose cables Good housekeeping prevents slips trips and falls The movement of the coater in operator mode...

Page 19: ...CRIPTION PREVENTIVE OR CORRECTIVE ACTIONS Contact with metal powder irritation sensitization occupational Powder contact during cleaning and when the RPM is extracted Wear PPE Argon gas Breathing difficulties suffocation Gas leaks out from the process chamber while the door is open or the operator sticks head in the process chamber The operator must not put their head in the process chamber when t...

Page 20: ...as system for fire suppression argon is recommended halon is prohibited Note Although a class D is required for metal fires also consider having a class ABC portable on hand as well for non metal fires that a class D is not effective against Caution Personnel must be trained on fire prevention and suppression 2 4 3 Good Housekeeping Make sure that dust layers clouds or dangerous concentrations of ...

Page 21: ...o be isolated for repair adjustment or replacement so that inadvertent operation of the equipment or process does not cause injury Servicing equipment in a powered on condition presents unique hazards and must be performed only by personnel trained to perform the needed functions When dealing with potentially hazardous situations approved area procedures must define how to troubleshoot or operate ...

Page 22: ...control knobs to make certain the compressed air and argon gas supplies cannot be turned on accidentally while the system is being serviced 2 5 6 Restore Equipment to Service When the job is complete and equipment is ready for testing or normal service check the equipment area to see that no one is exposed When equipment is all clear remove all locks The energy isolating devices may be operated to...

Page 23: ... PTM is in operation In preparation for a print task or that a print task has ended Is in safe mode C Orange The orange light indicates that the PTM is in operation but a warning is generated The orange stack light indicates a warning perform the following Check the warning and follow standard procedures When a correction is not possible request assistance from the engineer When the situation is c...

Page 24: ...ressed air supply will be closed Oxygen O2 pct sensor Measures in the range in percentage from zero 0 to 25 If the level of Oxygen O2 gas is over 2 the laser will stop or not start Oxygen O2 ppm sensor Measures in the range in Parts Per Million ppm from zero 0 to 1000 ppm If the level of Oxygen O2 gas is over 230 ppm the laser stops or does not start Process door sensor Detects the position of the...

Page 25: ...the safety PLC the 24 V DC electrical power features and the built in computer B Door of the Process Chamber Process chamber door is open The safety motor group stops or does not start Laser stops or do not start The coater and the steering of the build plate within the RPM stop or does not start The coater can be moved with the correct software activation and the hold to run button C Pressure in ...

Page 26: ...nfiguration A Argon Sieving station optional Seiving mesh 60 µm Argon DMP Flex 350 Steel Inconel CoCr 316L 17 4PH Maraging Steel Ni625 Ni718 CoCr F75 DMP Flex 350 printer type B DMP Flex 350 printer Argon DMP Flex 350 configuration B Argon Sieving station optional Sieving mesh 60 µm Argon DMP Flex 350 Aluminum AlSi7Mg0 6 AlSi10Mg DMP Flex 350 printer type B DMP Flex 350 printer Argon DMP Flex 350 ...

Page 27: ...sh China bristles size 3 4 1 151430 Paint brush China bristles size 2 0 1 151434 Allen keys set 1 5 10 1 151436 Dust masks 5 pc box 8835 ML 1 151437 Gloves M powder free nitrile box 1 151438 Gloves L powder free nitrile box 1 151439 Manual sieve 63um diam 305 40mm 1 151440 Collecting pan SST 305mm Height 40mm 1 151444 Thermometer Digital ThermoTester 1 151799 Coater cutting tool 1 151133 12654614 ...

Page 28: ...ge Error but machine is still operational Green Machine is fully operational White Laser is ready Control panel the control panel holds all buttons used to start up the machine 1 2 3 4 5 Emergency off puts the machine in a safe state activating the safety circuit Key switch switches between operator and service mode On starts up the machine after turning on the main power switch and 24 V DC Hold t...

Page 29: ... blower fan vacuum pump network switch printer and the lights in the electrical cabinets Enable switch this switch is reserved for Certified Service Engineers only and allows them to perform specific maintenance operations WARNING THE ENABLE SWITCH MUST REMAIN CONNECTED AT ALL TIMES IF NOT THE MACHINE WILL GO INTO EMERGENCY OFF STATE Main argon valve Main compressed air valve these knobs will open...

Page 30: ...creating a vacuum in the process chamber This allows the process chamber to be filled with argon gas to create inert atmosphere with oxygen levels lower than 100 parts per million ppm Blower the blower continuously circulates the argon through the process chamber to extract all fumes and carry them to the process filter Process filter all fumes and debris extracted from the process chamber are fil...

Page 31: ...ted to the floor but this counterweight is used to counter the weight of the printer door and the RPM Caution As a general rule but especially in the case of a free standing configuration avoid installing the system in a location with a lot of facility traffic This is to reduce the risk of hitting the system with a forklight and tipping over the system 17 ...

Page 32: ...18 19 RPM Removable Printer Module the RPM contains the metal powder and the build platform It can be pulled outwards to have better access to the build platform for a powder switch cleaning or maintenance It can be removed and replaced by another RPM that contains a different metal powder For more detailed information on the RPM see next page Locking pins the locking pins lock the build module in...

Page 33: ... The platform lifts the powder to the correct height to supply the coater with the right amount of metal powder to deposit a new layer on the build platform RPM blower a fan that controls the gas flow over the powder bed on the build plate to remove the fumes created during the printing proces Overflow chute one on each side of the printer module powder deposited in here is pushed to the overflow ...

Page 34: ...es and cools cooling liquid used to keep the laser components at a set temperature It requires a mixture of tap water and a cooling fluid additive The tap water must comply with the water quality standard mentioned in the table in 3 7 Chiller of the DMP Flex 350 Facility Guide p n 15 D99 Cooling fluid additives recommended by SMC are Hexid A4 Controlxid1642 CCl105 Cool flow IGE Dowcal 100 and opti...

Page 35: ...ce File preparation is typically performed from a user PC although the DMP server can also be used to do file preparation if needed 4 1 3DXpert 3DXpert is the all in one software solution for metal additive manufacturing It contains all the necessary tools to assist the user in preparing a part for printing and sending it to the DMP Factory 350 printer For more information on 3DXpert and creating ...

Page 36: ... be started using a specialized task bar at the right of the screen The task bar also gives a visual overview of the state of the components Black background not started Green background with blinking icon starting Green background running Yellow background with blinking icon component lost connection to the machine server but is still running Red background with blinking icon component is still r...

Page 37: ...ailable in the components You can switch user levels by clicking the tile on the bottom right corner of the screen A red tile means no user role is selected On a green button the current user is displayed When clicking the tile a pop up menu will appear which allows the user to select a user level A red warning button will appear whenever the connection to DMP Machine Server is lost ...

Page 38: ...eparately from a user PC to prepare the print job remotely and send it to a printer 4 4 1 Menu Bar The program is build up out of the following components Add group add a group of parts Add parts add one part at a time Optional ProductionWise module allows user to Start your serial manufacturing job in 1 minute If set up properly includes automatic individual ID tagging and serial number generatio...

Page 39: ...ob Analyzer Analyzes the job file for potential mistakes Over 25 potential issues are checked Includes automatic fixing for some issues 3 different levels Error red must be fixed otherwise job can t be started Warning yellow carefully read and see if it aligns with your intentions or not Information white informative message Process job will open the Run job pop up window 4 4 2 Preview Screen Show...

Page 40: ...ge the group name Delete group this will delete the selected group Set scan to False for selected group selecting this option will stop this group from being scanned during the remainder of the build Save group to file save a single group to a new job file Convert clone group into mother group converts a clone to a new mother file so its settings can be adjusted Select all copies of this group thi...

Page 41: ... rev D 4 4 5 Properties By clicking the left bar of the Positioning tools panel the window will switch to the Properties window This window will display different parameters for the job the group and the part see image to the right ...

Page 42: ...ct5 4 Copy this file to your machine and copy it into the folder C 3D Systems Config Machines LM45 Unit x Caution Make sure you place the file in the correct machine folder LMxx where xx is your machine serial number but also in the correct optical unit folder If your machine is equipped with only 1 laser optical unit place the file in the subfolder Unit 1 Caution Should this folder not exist this...

Page 43: ...at hatching parameters were used To find this information 1 Open the job in DMP Control 2 Click on the far left bar to switch to the Properties window 3 In the Group parameters subsection and the Part parameters subsection the Slicesettings can be checked Here the slice settings will be displayed that are used to generate this part ...

Page 44: ...module The scanner zero point is not always in the center of the build platform To verify that your part is not outside of the platform you can test the location by manually pointing the scanner to the test location 1 Switch on the red laser diode pointer to see the location of the spot 2 Select Machine Laser check Show laser diode 3 From DMP Control select Machine Scanner Direct scanner control 4...

Page 45: ...e your job file to a storage location e g on the network After 48 hours the job is automatically deleted from the machine workstation keeping it clean To enable this option perform on each machine 1 Start DMP Control 2 Select Admin Configurations Machine configuration 3 In the field optJobFileAutoBackupPath set the path to the network storage folder Preferably use an IP based address Examples X Ba...

Page 46: ... mask by entering a space MASK SETTING NAME EXAMPLES DESCRIPTION None Batch2012563 123Powder 5 2 5 Titanium Anything can be entered No limitation in length or type of text PB 0000 PX_ PB 1234 PB 0002 PB 0510 Fixed letters PX followed by underscore_ then 0 up to 4 digits PX_9999 PX_ PX_1 PX_1 5 PX_1234 Fixed letters JOB followed by space then 0 up to 3 digits A LL A _ A kR A kr A KR Fixed letter A ...

Page 47: ...able a previous shift up or shift down Escape Escapes a mask character turning it into a literal For example is the escape sequence for a backslash L is the escape sequence for the letter L if you just put L it will be interpreted as mentioned above like a placeholder for any letter A Z All other characters Literals All non mask elements will appear as themselves Literals always occupy a static po...

Page 48: ...tart DMP Control Admin Configurations E mail notifications 3 For the From address in the e mail addresses field you could use DMP3000 mycompany com The character will be replaced automatically by the machine serial number when the machine sends mail 4 Use the Send test e mail button to test your configuration 5 Click Save configuration to permanently save it on the DMP Server making it available f...

Page 49: ...oxygen level The displayed unit will be in while the chamber is at high oxygen content and will switch to ppm parts per million when the oxygen content gets below 1 This will be shown as soon as the printer starts preparing to print Next to the oxygen level the relative pressure in the process chamber in millibar is shown A negative number means there is underpressure a positive number means there...

Page 50: ...t a print job List PLC details Click to open a pop up window with details on the PLC used in the system List safety PLC details Click to open a pop up window with details on the safety PLC used in the system Run filter prepare cycle Click to open the Bring filter to a safe state pop up window Click Start to bring the filter to a safe state after it has been replaced or after a long period of inact...

Page 51: ... material can be loaded Load material Click to open the Load material to printer pop up window Use this window to confirm loading of new material or a new material batch Select the material from the drop down list and enter the batch number Click Confirm material to load Material details Click to open a pop up window Material details which shows a set of data on the material currently loaded in th...

Page 52: ...allow any text For detailed options see the DMP FAQ document optMaterialBatchNumberFormatCursorStartPosition see description at bottom of the window and DMP FAQ document Once Material batch tracking is enabled the material dialog windows will show the material batch number input boxes Batch numbers will be included in all job logs event logs and other optionally enabled tracking systems Caution Re...

Page 53: ...nance log Click to open the maintenance log file of the system Check for updates Click to check for DMP Deposition software updates View version history Click to open a pop up window that shows the history of all software components installed on the system ...

Page 54: ...ors window Sensors will open up the Sensors window Protect will open up the Protect window 4 5 4 Tabs A Manual Operation Click the tab Manual to open the Manual operation Coater Movements 1 Move coater to left end position 2 Move coater left until button is released 3 Move coater to middle left only available when coater is left of the build platform 4 Move coater to middle right only available wh...

Page 55: ...ve Note The accuracy specification of the Z axis of the build platform and the feed platforms on the DMP 350 system are 0 03 of the step size with a minimum of 5 µm 4 Machine position gives the current position of the platform with the top position as 0 µm 5 User position is the platform position that can be set at any location by the user by clicking on it 6 When this button is pressed the applic...

Page 56: ...t the print job Click the Easy door unlock button in the task bar to start the Easy door unlock cycle This will open the dialo window shown below Click the Start unlocking button to create a vacuum in the process chamber pulling the door against the printer frame This makes it easier to loosen the printer door bolts Press Confirm bolts are unscrewed to release the vacuum and open the printer door ...

Page 57: ...ercent of layer thickness Making this number higher will reduce short feed occurrences but will use up more powder Deposition speed how fast the coater will move while depositing new powder on the build bed CAUTION Changing this parameter can change part properties mechanical properties surface roughness etc Deposition from the right only used if you have a limited supply of powder and only want t...

Page 58: ...aintenance task Info link Opens up the applicable work instruction for the maintenance task Perform task Press button when maintenance task has been completed Process filter tracking The maintenance manager also features a Process filter tab This process filter tracking system increases safety improves user experience and traceability to better manage the process filter The tracking system allows ...

Page 59: ...rocess filter Disconnect filter when a process filter is full or when you want to temporarily disconnect the filter before performing a material change on the printer The details of the filter will be saved in the database on the DMP Server The available used filters can always be listed again see the Connect dialog and can also be reconnected The filter details are stored so that no information i...

Page 60: ...used before with compatible materials The test tools buttons allow you to verify if the inductive sensors on the inlet and outlet valves of the process filter are installed correctly For a used filter the button Test valves open is not available due to safety constraints D Message Is a simple notepad like tool that can be used for noting down reminders or communicating remarks to other operators o...

Page 61: ...ll current sensor data H Protect In case a print job is finished but powder still remains in the feeds close the printer door and push the Protect button This will allow the user to leave the powder in the feeds overnight Pushing the Protect button will create a vacuum and fill the process chamber with argon until atmospheric pressure is reached creating an optimal environment to preserve the mate...

Page 62: ... the complete C DMP folder is backed up automatically The easiest way to do this is by using Windows Backup Windows Start Control Panel Backup and restore 4 6 DMP Monitoring optional The DMP Monitoring application is an optional piece of software that allows the user to simultaneously record images and meltpool data of the printing process It consists of two major data acquisition systems i e DMP ...

Page 63: ...d If not the safety circuit will be activated 4 Turn on the main power switch 1 on the electrical cabinet of the printer 5 Turn on the 24V DC power switch 3 on the rear control panel of the printer 6 Check and if closed open the main valves 4 for argon and compressed air on the right side of the electrical cabinet For the recommended argon and compressed air pressure values see 6 3 3 7 Make sure t...

Page 64: ...umber of the machine 8 to start up the DMP task bar 11 At the bottom of the task bar click the Log in icon 9 12 Enter your user name and select the correct user level and click Log in 13 On the task bar click the DMP Deposition 10 and DMP Control 11 icon to start up the software 14 The printer is now ready to be used ...

Page 65: ... powder is needed for a build fill the build shute with 140 mm of extra powder and after inerting move this powder to the feed bins with the coater WARNING ANY TIME POWDER MATERIAL IS HANDLED I E REFILLING SIFTING CHANGING ETC MAKE SURE YOU ARE EITHER STANDING ON AN ANTI STATIC MAT OR YOU ARE WEARING A GROUNDING STRAP THAT IS ATTACHED TO THE MODULE SO THAT YOU ARE GROUNDED TO THE MACHINE ALWAYS PO...

Page 66: ...e arrows in the Manual operation screen to adjust the height of the build plate 5 2 3 Install New Coater Strip 1 Move the coater to the center of the build plate Press and hold the Hold to run button on the control panel of the printer and click the coater movement buttons in the Manual Operation window Caution Keeps hand clear of the process chamber during this operation 2 Remove the recoater hou...

Page 67: ...1 6 Use a sharp utility knife to cut the recoater in one smooth motion WARNING BE CAREFUL WHEN CUTTING THE RECOATER THIS PRESENTS A CUTTING DANGER 7 Leave the recoater housing in the upper part of the coater cutting tool and cut the ends of the silicone strip where they stick out of the recoater housing Cut the corners at a 45 edge Check if the silicone strip is smooth with no irregularities If th...

Page 68: ...coater must be realigned If the layer thickness is consistent continue from step 6 4 To align the coater loosen the hex bolts on top and side 1 3 of the coater bridge and turn the ex center star screw 2 on the side where the powder layer was too thin or too thick to move the coater up and down Tighten the bolts on top and side again and deposit another powder layer Iterate these steps until the po...

Page 69: ...ided by the end user and must be according to the following specs Quality absolute ethanol denaturated with 4 8 isopropanol Grade Purum Assay 99 8 based on denaturant free substance The Sigma Aldrich fluid producer product number 02856 is recommended 3 To clean the window start in the middle and gently move to the outside going in a circular motion see image to the right Caution Make sure no sharp...

Page 70: ...the upper right corner of the door and tighten each bolt to 10 Nm making your way around the door in a counterclockwise direction 5 3 Inert System 5 3 1 Close Printer Door Caution Before closing the printer door make sure the 2 locking pins on each side of the printer module are in the UP position securing the printer module ...

Page 71: ...ough powder is present to complete the job 2 Open DMP Deposition Caution The inertion cycle cannot be initiated as long as the maintenance schedule shows maintenance tasks that still need to be completed 3 Select the Manual tab and click the Prep Cycle button 4 The Automatic inertion cycle window will pop up Press Start and confirm the choice of material to initiate the inertion cycle ...

Page 72: ...ling it with argon This is performed 3 times to achieve oxygen levels of only 100 ppm When the 3 inerting cycles are finished the DMP Flex 350 is ready for printing 11 During the automatic inertion cycle the feeds will move down and the powder in the feeds will become unflat Use manual operation to move the powder surface of the feeds to just above the module top Make sure you do not move the buil...

Page 73: ...first layer to the plate make sure all the parts are on the build plate 5 In DMP Deposition open the Manual tab and use the controls to lower the build plate 20μm and use the coater to deposit a new powder layer over the build plate 4 6 Make sure Single Layer and PowerBurn 5 are no longer on You can now start the job from layer 1 and the printer will start with the direct metal printing process ...

Page 74: ...ome very hot Before handling the powder parts always let the DMP Flex 350 complete the cool down cycle Caution Always wear the appropriate PPE s when performing operations that involve powder contact 4 Click the Unlock icon to release the glove port locks 5 Open the glove ports to access the process chamber 6 The control box allows the operator to move the coater and build and feed platforms witho...

Page 75: ... the build platform and move the build platform up by about 20 mm 20 000µm 10 Use the brush and spatula inside the process chamber to clean the build plate and gradually brush the excess powder off the parts into the overflow bins 11 Continue moving the build platform up 20 mm 20 000 µm at a time lowering the feeds with steps of 100 mm 100 000 µm when needed and brushing away the powder until you ...

Page 76: ...process chamber to atmospheric pressure 17 A pop up window on the PC will confirm you can open the door 13 Click the Start unlocking button 18 Loosen the 4 corner bolts with a 5 mm hex key to remove the build plate Note Make sure to store the hex bolts for later use Caution the build plates are quite heavy Adding newly built parts to that weight makes them even heavier Pay attention not to pinch y...

Page 77: ...let 19 Lift platform up at an angle and let excess powder fall into the feed bin as shown 21 Use a wet separator vacuum cleaner to remove any powder from between the supports of the part 22 Remove the build plate from the process chamber and store for post processing 23 Use a wet separator vacuum cleaner to clean the printer module ...

Page 78: ... Push excess material into the overflow so it can be removed from printer 4 Continue purging material until the feed level is about 10000 µm higher than the position marked in step 6 of the previous paragraph All powder underneath this level has not yet been used and need not necessarily be purged and sieved 5 Repeat steps 1 3 for the opposite side 6 To empty the overflow container open the valve ...

Page 79: ...side 5 7 Change Material WARNING WITH EACH CHANGE IN MATERIAL FAMILY IT IS ABSOLUTELY CRITICAL TO CHANGE OUT THE PROCESS FILTER AS WELL IN DMP DEPOSITION V36 14 0 AND LATER THIS PROCESS WILL BE MONITORED BY THE SOFTWARE FOR MORE INFORMATION ON HOW TO CHANGE THE PROCESS FILTER PLEASE REFER TO CHAPTER 6 USER MAINTENANCE 5 7 1 Swap Printer Modules Caution As the DMP printer module is dedicated to 1 m...

Page 80: ... click Confirm empty The systems is now empty and ready to receive new powder batch material Caution This action needs to be performed before a new batch or new material can be loaded 8 Install the printer module with new material 9 Home the axis of the new printer module 10 In DMP Deposition click Material Load material to open the Load material pop up window 11 Begin your next build 12 Place a c...

Page 81: ...s are completely empty 3 Clean the printer module platform the powder feeds and all areas you can reach using a wet separator vacuum cleaner and paper towels with isopropyl alcohol 4 Move all platforms completely up and down a couple of times to loosen any powder When platforms are down clean power that sticks to the side of the module 5 Shut down the printer 6 Open the overflow container and clea...

Page 82: ...vacuum cleaner 11 Clean the complete inside of the process chamber using paper towels with isopropyl alcohol 12 In DMP Deposition click Material Unload material to open the Unload material from printer pop up window Check all boxes that have been completed and click Confirm empty The systems is now empty and ready to receive new powder batch material Caution This action needs to be performed befor...

Page 83: ...the Load material pop up window 16 Select the new material type from the drop down menu and scan the bar code of the new batch or enter the new batch number manually Check the box confirming the appropriate work instruction has been followed 17 If sufficient powder is loaded insert the printer module in the process chamber and prepare the machine for a new build as dictated earlier in this chapter...

Page 84: ...ill activate a Category 0 emergency stop which will immediately remove all power to the machine actuators i e an uncontrolled stop All printer valves will be closed The argon will remain sealed in the process chamber and pressure levels will stay at a constant level A mechanical pressure release valve will open if the pressure level inside the process chamber continues to rise after an emergency s...

Page 85: ...ncy stop 2 Release the emergency off button that has been pressed 3 Press the ON button to restart the system 4 Wait 1 min for the oxygen sensors to warm up 5 Open DMP Deposition Caution Whenever an emergency off button has been pressed alarm messages may pop up when opening DMP Deposition after recovery Wait 2 minutes for sensors to stabilize before clearing the alarm messages Caution Depending o...

Page 86: ... 3 5 Check Printer Gloves Option 6 3 6 Perform Automatic Laser Power Calibration 6 4 Every 3 months 6 4 1 Replace Chiller Fluid and Check Water Quality 6 4 2 Clean Machine Exterior 6 4 3 Check Blower Oil Level 6 4 4 Check Vacuum Pump Oil Level 6 5 Every 1600 job hours 6 5 1 Replace Process Filter 6 6 Every 6 months 2000 job hours 6 5 2 Clean Overpressure Valve 6 5 3 Clean Vacuum Pump Ventilator WA...

Page 87: ...an below it WARNING ANY POWDER THAT IMPEDES ROTATION OF THE RPM BLOWER SHOULD BE REMOVED COMPRESSED AIR MAY BE USED TO CLEAN THE RPM BLOWER BUT MAKE SURE THE COMPRESSED AIR IS PURIFIED OIL FREE QUALITY CLASS 1 ACCORDING TO ISO8573 1 2010 MAKE SURE TO CAPTURE THE POWDER BLOWN OUT OF THE RPM BLOWER WITH A WET SEPARATOR VACUUM CLEANER Note If no compressed air is available at the system it is possibl...

Page 88: ...wder that could be dropping out with a wet separator vacuum cleaner 3 Clean the rest of the printer module with a wet separator vacuum cleaner Move the modulbe blower out of the way to clean below it 4 Unplug the 24 V supply cables attached to the printer module Caution Always make sure the 24V DC On Off printer only knob is set to Off first 5 Release the locking pins 6 Remove the printer module f...

Page 89: ...hamber using a wet separator vacuum cleaner 8 Additionally clean the complete inside of the process chamber using paper towels with isopropyl alcohol to remove any remaining residue Caution Pay special attention to the door viewing window and the laser window as these are critical components during the printing process For more detailed instructions on how to inspect and clean the laser window see...

Page 90: ... of the laser window and gently move from the inside to the outside of the window Caution Make sure no sharp edges get close to the glass NOTE Make sure you always turn the same direction so you don t get the dirt back to the middle 5 Repeat Steps 3 and 4 a couple of times 6 Check to see if the window is clean To check if window is clean take an LED flashlight and move the light into different ang...

Page 91: ...gency off buttons on the DMP Flex 350 system The DMP Flex 350 system is equipped with four 4 emergency off buttons circled in red in the image below 1 x on the control panel of the printer 1 x on the enable switch located at the rear control panel Press each emergency off button to instantly activate the safety circuit of the entire DMP Flex 350 system WARNING IN THE HIGHLY UNLIKELY EVENT THAT THE...

Page 92: ...ults in the reduction of cooling performance and may stop the operation because the safety device is triggered Shut off the power supply of the product when performing cleaning maintenance or inspection to avoid electric shock injury or burn etc Use a long bristled brush or air gun to clean the condenser to prevent the fins from being deformed or damaged To replace the filter remove the filter pan...

Page 93: ...dure describes how to perform an automatic laser power calibration on the DMP Flex Factory 350 systems Make sure the machine is clean of all powder before starting 1 Preparation Lock the printing module in place using the 2 locking handles Cover the powder feed platforms and clean the laser window using the appropriate materials as indicated in the 15 D98 DMP Factory 350 User Guide 2 Place the las...

Page 94: ...ape 2 x 81 to seal of the gap between printer door and frame 10 Turn the service key ON 11 Open the DMP toolbar and log in as an Engineer 12 Open DMP Control In the task bar click Machine Laser Laser Power Calibration to open the Laser power calibration window 13 When the device is connected for the first time and no drivers are installed an error message will appear 14 Browse to the Ophir website...

Page 95: ...his may happen sometimes due to driver issues 16 When it is connected DMP Control will lock the power meter keypad DMP Control will take care of configuring the Ophir Nova II in order to make accurate measurements Automatic Calibration From here the user can select the Automatic Calibration or perform a manual step by step calibration The automatic calibration will perform a complete calibration p...

Page 96: ...cation will take 5 min After successful verification a confirmation message will appear 2 Click Perform Calibration Measurements The automated measurement will take a couple of minutes 30 sec per data point at least Depending on the type of measurment head the measurement can take up to 30 minutes This long measurement significantly improves the accuracy and repeatability of the calibration Note A...

Page 97: ...00 W laser 5 Click Save to machine configuration The content of the measurement logging window can be saved by clicking the Save icon in the bottom right corner and then specifiying a location for the log text file 6 Close the Laser power calibration window when the message You can now close the window appears in the message board 4 As a double check click Perform verification measurements Verific...

Page 98: ...es recommended by SMC are Hexid A4 ControXid1642 Nalco CCL100 Cool flow IGE Dowcal 100 and optishield The correct mixture of tap water and cooling fluid additives must be according to SMC guidelines 15 Note The cooling fluid additives are to be supplied by the customer ITEM STANDARD VALUE CIRCULATING FLUID FACILITY WATER Standards pH at 25 C 6 0 to 8 0 6 5 to 8 2 Electric conductance at 25 C 1 μS ...

Page 99: ...efore adding new oil 3 If the oil level is empty and no oil leaks can be detected the blower should be sent back for service 1 Check the oil level of the vacuum pump via the viewing window 2 The oil level should be in the middle of the viewing glass 3 If there is not enough oil open the pressure measurement valve above the viewing window and add new oil 4 If there is too much oil open the bleeding...

Page 100: ...standard centering ring that is used for standard mechanical connections throughout the DMP system The second type right image is a centering ring with stand off These are used exclusively on the process filter 6 5 After 1600 Job Hours 6 5 1 Replace Process Filter The inlet and outlet ports of the filter are equipped with a spring loaded valve When the filter is not connected to the system these v...

Page 101: ... certain no print job is running and the system is idle 2 On the rear control panel of the printer turn the main compressed air valve counterclockwise This will close the facility supply of compressed air and bleed any remaining compressed air pressure in the system 3 Disconnect the compressed air tubes from the push fit connections PNV2 PNV3 The process filter valves are only opened by compressed...

Page 102: ...nd remove the KF50 clamp between the outlet valve and the process filter see image to the right Remove the filter outlet valve assembly and the centering ring with stand off The centering ring may stick slightly to the filter housing If needed pry it loose with a plastic tool such as a scraper 9 As you lift the centering ring away from the filter simultaneously check to make certain the spring loa...

Page 103: ... pry it loose with a plastic tool such as a scraper 14 As you lift the centering ring away from the filter simultaneously check to make certain the spring loaded valve has closed WARNING THE FILTER INLET PORT MUST BE CAPPED IMMEDIATELY AFTER THE FILTER INLET VALVE ASSEMBLY IS REMOVED 15 Immediately install a standard centering ring not a centering ring with stand off a cover lid and a KF50 clamp W...

Page 104: ...er may weigh as much as 100 Kg 220 lbs 21 Use the appropriate lifting equipment adjusted to the weight of the filter vessel to lift the old filter from the cart The filter vessel is equipped with a lifting eye There are no fasteners securing the filter to the filter cart 22 Place the filter in the designated hazardous waste location in your facility Make certain the filter is protected from mechan...

Page 105: ...f 2017 to the present may have a total weight of 100 kg 220 lbs Dispose of the used filter in accordance with all local state and federal regulations Have the used filter vessel picked up by a hazardous waste transportation company that handles chemical waste Waste disposal companies generally process the filter vessel in the same way as scrap metal stored in standard metal drums i e by burning th...

Page 106: ...tems Inc 101 p n 15 D100 rev D D Installing the Replacement Filter 1 Place the new filter into the cart Make certain the new filter is installed with the filter inlet and filter outlet ports oriented as shown ...

Page 107: ...ts 5 Remove the KF50 clamp from the filter outlet port 6 Remove the cover lid and store the cover lid for later use 7 Remove the centering ring The centering ring may stick slightly to the filter housing If needed pry it loose with a plastic tool such as a scraper Caution The filter is charged with argon gas It is normal for some of the argon gas to be expelled from the filter when the centering r...

Page 108: ...e in the filter outlet port The stem of the centering ring must be placed directly on the locating pin of the internal valve 10 Press the filter outlet valve assembly directly on top of the centering ring 11 The internal valve is spring loaded Push the valve assembly down against the centering ring until the flanges meet 12 Install the KF50 clamp to secure the filter outlet valve assembly Tighten ...

Page 109: ...r on the outlet valve and tighten the philips screw 17 Next install the inductive valve sensors PNV2 PNV3 a Uncheck ValvesFilter to close valves 2 and 3 b As show in the adjacent figure slide the inductive sensor all the way forward into the slot c Next slide the sensor back gently until the orange light goes on d Use a small flathead screwdriver to secure the sensor in position 18 Connect the com...

Page 110: ... without additional precautions not mentioned in the manual However local legislation regarding the transport of dangerous goods ADR 9 ADR 4 2 ADR 4 3 may apply What is the contents of the used vessel The outer case is steel stainless steel caps and Neoprene or viton gaskets The inner filter element is polyester A stainless support scaffold The internal atmosphere is Argon The waste product is con...

Page 111: ...ials produce more fume particles than others Yes In addition the amount of generated fumes is also dependent on the printer type parameters used and the type of geometries printed How many hours can I expect to get out of a canister before needing to change Follow the guidance of the maintenance management tools The number of operation hours job hours of a filter is a stable measure to assess how ...

Page 112: ...lve with ethanol and a lint free cloth 2 Use 8 bar 116 psi compressed air towards the valve to ensure the valve does not stick 3 Replace clamp tighten thumbscrew 6 6 2 Clean Vacuum Pump Ventilator 1 Switch off power to the DMP Flex 350 system 2 Use the vacuum to remove all dust and other contaminates that have accumulated on the vacuum pump motor ventilator circled red ...

Page 113: ...there could be problems with incorrect scanner driver files in particular when switching between old and new software 7 3 1 Symptoms Error message like Version error or incompatible version for dll firmware or hex DSP file Error about scanner version during program startup The software does not recognize it is a real physical machine DMP Control Menu Info Show machine info tells Is physical machin...

Page 114: ...Restore a Broken DMP Server Computer Make sure you have set up an automatic backup procedure for the C DMP folder on the DMP Server in order to be able to restore at a later time See Backup DMP Server 1 IP address and computer name If the DMP Server was set to fix IP address before reset the fix IP address Set the computer name to DMPSERVER 2 Create the following 2 folders C DMP C DMP SliceCache 3...

Page 115: ...re Failing to Process at the top of the page 2 Try with other DMP Slicer parameter set Expand the processing options in DMP Explorer by clicking the arrow button Then select DMP Slicer set 0 no filtering or 3 lower accuracy Restart the process If the process keeps failing select another DMP Slicer set 3 In case previous steps keep failing you can try to slice the part first with modified slicing p...

Page 116: ...t voids in the part but you will always see the seams When you split the part it can be interesting to make the cuts in the middle and keep an outer contour part The advantage of this strategy is that the outer contour will be a single part without seams But in the middle you are still stuck with the visible section lines Option 1 Provide a small overlap of a 100 micrometers between the sections T...

Page 117: ...Explorer However it is preferrable to start multiple instances can be on the same computer of DMP Explorer and process only a few parts per DMP Explorer You can start multiple instances of DMP Explorer on multiple computers as well 4 The order of processing that the server will apply is random and cannot be prioritized This means that if you really need a particular group to be finished first proc...

Page 118: ...Deposition Available in DMP Deposition software from version v21 0 20 onwards When the DMP Deposition program starts it verifies if the right machine conditions are met to allow for a job start If the machine conditions are met the Run job button can be pressed If this detection failed during program start go to menu Controllers Verify if ready for processing This will repeat the evaluation After ...

Page 119: ...3D Systems Inc 114 p n 15 D100 rev D 8 BASIC REGULATIONS 8 1 EC Declaration of Conformity DoC ...

Page 120: ...C 29730 www 3dsystems com Copyright 3D Systems Inc All rights reserved 3D Systems Inc p n 15 D100 rev D Register Statement 2019 by 3D Systems Inc All rights reserved Specifications subject to change without notice 3D Systems and the 3D Systems logo are registered trademarks of 3D Systems Inc ...

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