3D Systems Duraform ProX PA Original Instructions Manual Download Page 8

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3D SYSTEMS, INC

PRINT MODES FOR DURAFORM PROX PA

DuraForm ProX PA is available in

Standard Mode

and

Advanced Mode

. Material configuration files for Standard and Advanced

modes are offered by 3D Systems. The process settings in the Standard mode are optimized by 3D Systems to help customers

get the best combination of mechanicals, part appearance (detail, surface finish) and DuraFormProX PA recyclability.

NOTE: 40% fresh powder to 60% recycled powder is the recommended MQC blend setting.

The standard mode has been designed for, and tested in, 3D Systems’ SLS 380 systems with 40% fresh powder to 60% recycled

DuraForm ProX PA on an MQC. Please refer to the

Sifting Material

section for more information on the MQC.

Expected mechanical properties and densities using 40% fresh to 60% recycled are found on 3D Systems Infocenter.
The

Advanced

mode offers more processing latitude for advanced users who may need to vary process settings for their

application.

NOTE: The material process parameter set points may vary slightly from machine to machine, due to

differences in material conditions and thermal sensors. As a result, the process parameters, more specifically

the temperature set points, may need to be adjusted slightly from the defaults. An offline IR sensor

calibration is required before using a material for the first time.

Scale and Offset Print

When you print parts with DuraForm ProX PA, you will perform at least one preliminary print to fine-tune the default

parameters you need to use when you print parts for use.

NOTE: Shrink and Beam offsets: The shrinkage of 100% fresh DuraForm ProX PA is slightly greater than that

of blended DuraForm ProX PA. You should expect to evaluate and adjust the scale values used to compensate

for shrink if the fresh powder ratio in the blend changes. Note that shrinkage may vary slightly based on part

geometry. Expect shrink rate close to 3.3% with 100% fresh powder. 3.1% is normal for 40% Fresh powder

blend

Either the field engineer or the operator will print a preliminary build to verify the appropriate scale and offset parameters. It is

suggested that the following test print job be used.

Build Height is 35 mm, all parts are labeled. Total build
time is approximately 5 hours

PRELIMINARY PRINTS AND PART PRINTS

Before performing the first print, you must perform an offline IR calibration. Refer to you printer’s User Guide for detailed

instructions.

Offline IR Calibration

1. Inspect and clean the Blackbody if needed.
2.

Put the system in Manual Operations mode; close and lock the print chamber doors

Before performing the Offline Calibration, check to make sure DuraFormProXPA standard mode is selected.

4. Click the IR Calibration button.

Calculating Scale/Offset Values

Refer to the Help section in Build Prep software.

Summary of Contents for Duraform ProX PA

Page 1: ...Duraform ProX PA Material Guide Original Instructions ...

Page 2: ... Volume 6 Part orientation and placement in the SLS build volume 6 Part geometry and feature considerations 7 Small Features less than 1 mm will be affected by X Y and Z offset values 7 Print Process Settings 9 Part Bed Heater Set Point 9 Feed Powder Amount 9 Verify Before Every Print 10 Restarting a Terminated Print 10 Sifting Material 10 Recycling Material 10 Blending Fresh and Used Material 11 ...

Page 3: ...INTRODUCTION TO PROBLEM SOLVING 16 Problem Description Format 16 Interaction of Variables 16 BONUS Z 17 CLUMPING 18 CRACKING OF PRINT BED 18 CRYSTALS AND CONDENSATION 19 DISTORTION 19 Preventing Curl in Prints 20 GLAZING DURING PRINT 20 GROWTH 21 MELTING PRINT BED 21 MISSED SCAN 21 ORANGE PEEL 22 SHORT FEEDS 22 STRAY VECTORS 23 WASH OUT 23 WEAK PARTS POROSITY 23 6 GLOSSARY 24 ...

Page 4: ...aboratory work and does not necessarily indicate performance in all conditions Notwithstanding any information provided by 3D Systems or its affiliates the customer remains fully responsible for determining which federal state or local laws or regulations or industry practices are relevant to activities in which it engages as well as assuring that those laws regulations or standards are complied w...

Page 5: ...ems ProX SLS systems Material Safety Datasheets SDS may be found at http infocenter 3dsystems com production printer material laser sintering sls Caution Using any material other than those certified by 3D Systems may cause health hazards and may limit the warranty of the SLS system HOW THE DURAFORM PROX PA PROCESS WORKS The DuraForm ProX PA material process has the following characteristics The m...

Page 6: ...s the IR camera to adjust the output of the 8 individual print bed heaters to maintain a uniform temperature across the part bed Print Stage The print stage maintains the print bed and feed hopper temperatures Laser energy is used to melt the material in each successive cross section of the print As the Print Continues The print bed piston indexes down the parts are covered and begin to slowly coo...

Page 7: ... and or discolor Some part geometries are more susceptible to post print warp than others Condensation in the Process The DuraForm ProX PA contains a small amount of volatile material that vaporizes during processing This material condenses and sticks on cool surfaces in the SLS system print chamber Heated nitrogen gas flow across the laser window helps reduce the condensing material from depositi...

Page 8: ... before using a material for the first time Scale and Offset Print When you print parts with DuraForm ProX PA you will perform at least one preliminary print to fine tune the default parameters you need to use when you print parts for use NOTE Shrink and Beam offsets The shrinkage of 100 fresh DuraForm ProX PA is slightly greater than that of blended DuraForm ProX PA You should expect to evaluate ...

Page 9: ...r more factors such as Desired time for print job to complete Print job time is a function of total build height and time to scan the cross section on each layer For most geometry scan time has very small effect on total build time Use the Sprint Estimate to view layer time and scan time per layer It is best to avoid extremely long or short scan times Tall full stroke builds will take more time to...

Page 10: ...e Offset and Y Outline Offset These parameters are set using the scale offset editor of the respective build preparation software When the first layer of a part or the layer of a part feature is scanned the laser penetrates to the un melted material below the print boundary Z offset is used to compensate for this print through bonus Z To compensate for this downward facing surfaces are offset movi...

Page 11: ...he three sides is perpendicular to the direction of the roller motion and so that the base is not at the top in orientation This offers less resistance to the material as it flows across the print bed thus reducing the possibility of shifting and will result in a flatter base Large blocky part Thick cross sections that have features with X Y slices or Z depth greater than 12 7 mm 0 5 in are more l...

Page 12: ...crease the part heater set point by small increments 0 5 to 1 0 degrees This value is the rotation of the Feed Roller located in the feed hopper It controls the amount of the feed dose The default values should release enough powder from the feed hopper so that when the traverse roller moves across the part bed there is sufficient powder to cover the entire build area and deposit a small amount in...

Page 13: ...the following sifting techniques for DuraForm ProX PA material Do not remove the print cake from the print chamber until the print bed temperature is approximately 85 C Allow the print cake to continue cooling to 50 C before trying to break out parts Remove loose material from the print cake Sift the loose soft material using the MQC System but discard the hard and chunky material from the final b...

Page 14: ... setting for DuraForm ProX PA material is 40 Material may build up on the roller and in other areas in the print chamber as well as on the MQC System Refer to the procedures in your printer s User Guide for the following cleaning information Cleaning the SLS System between Prints Cleaning the Laser Window Cleaning the Blackbody section Cleaning the Overflow Screen Cleaning the Sock Filter Blending...

Page 15: ...rts To clean a DuraForm ProX PA Plastic part 1 Remove the print cake from the print chamber Caution 3D Systems recommends allowing the print cake to cool to room temperature before removing parts from it 2 Brush away all loose material to expose the part 3 Use appropriate hand tools to remove all remaining material in corners and holes Use a drill bit to clear holes NOTE Do not recycle or blend th...

Page 16: ...H 44202 Phone 1 330 562 1440 Toll free 1 800 241 2579 Fax 1 330 562 1510 http www godfreywing com vacuum impregnation sealants types of gw sealants Part Number 95 1000A catalyst UCAR Vehicle 443 Acrylic Emulsion A Union Carbide product Mix 72 emulsion with 28 water to create a 32 solid mixture Dip the parts in this mixture for a surface coat Use an industrial oven at 70 C to dry parts afterwards C...

Page 17: ...part for 5 to 10 minutes to saturate the part surface 4 Turn the part over and apply sealant to the back side of the part 5 Set the oven to 100 C Remove any excess sealant and place the part in the oven for 1 to 1 5 hours or longer for parts with thick cross sections 6 Remove the part and apply a second coat of sealant repeating steps 2 through 5 3 Remove the part from the sealant and shake off th...

Page 18: ...m ProX PA Plastic material it is likely to become airborne during handling For con ditions where exposure to dust is likely 3D Systems recommends a NIOSH approved dust respirator for dust appropriate to the airborne concentration Such conditions might include handling of material at the SLS system or the Material Quality Control MQC System MATERIAL STORAGE AND DISPOSAL This section contains storag...

Page 19: ...tion will become less frequent Problem Description Format You will find the following information about each issue Description Explains the problem and provides a visual representation of it The description includes such things as where and when the problem might occur Theory of Cause Contains a brief explanation of what might have caused the problem Visual Signs Describes any observable informati...

Page 20: ...all then decrease the part bed set point next build by small increment 0 5 to 1 0 degrees Blackbody calibration is incorrect or blackbody is damaged Potential Print Problems Excessive laser energy will affect material outside the cross section of the part and cause growth Insufficient laser energy does not fuse the part completely which results in porous weak parts If the print bed temperature is ...

Page 21: ...print chamber 3 Clean the overflow screen 4 Clean the roller Related Problems Cracking of Print Bed Theory of Cause When the first layer is scanned the laser penetrates to the unmelted material below the print boundary In extreme cases bonus Z will occur with wash out Visual Signs You cannot observe this during printing Consequences The part is out of tolerance in the Z axis Corrective Action Whil...

Page 22: ...ervation of curling Some in build distortion is not visible during the print Consequences Parts especially those with large surface cross sections are not flat If severe the print may shift in the print bed when the roller passes it Corrective Action Appropriate corrective actions depend on whether the curling is severe or minor For minor curling changes during the print may help Once moderate to ...

Page 23: ...t Increase the Print Bed PID Set Point by 0 5 or 1 C Increasing the Print Bed PID Set Point too much might cause a more difficult breakout and reduce the amount of mate rial that can be recycled Allow Time to Cool Allow the print cake to cool longer than one hour inside the SLS system and allow the print cake to cool outside the SLS system completely before removing the parts Increase the ratio of...

Page 24: ...hich areas melt first indicates the hottest spots in your print bed Consequences Melting occurs after glazing The print bed temperature increases Melting is a far more serious condition than glazing Corrective Action Terminate the build There are several actions you can take to prevent melting In the Print Parameters Profile reduce the Part Heater Set Point and or use ramping for the heater set po...

Page 25: ...weak may delaminate at layers where short feeds occurred and may have surface imperfections Corrective Action Increase the Feed Amount parameters in the Print Parameters Profile or use the Prime Cycle button during the build Feed Powder Amount This value is the rotation of the Feed Roller located in the feed hopper This should be adjusted so that the traverse roller moves enough powder across the ...

Page 26: ...wth than surfaces which causes the appearance of rounded corners Visual Signs You can observe wash out when small slots fill in with melted material Otherwise wash out is observed on parts after breakout Consequences The part features become rounded mostly on the downward facing surfaces Wash out may be followed by growth If you correct part wash out early enough you can continue the print with li...

Page 27: ...ild Viewer is located next to the Build Status dialog box CO2 Laser The power source for the selective laser sintering process The beam is invisible and can cause serious burns Cool down Stage The build profile for the layers that come after a build when there is not a follow on build See also Build Stage and Warm Up Stage Default A response or set of conditions used by a computer unless the user ...

Page 28: ...ns Mode A state of the SLS system Sinter software in which options to perform manual operations are available See also Build Mode Main Mode Material The powder used in the laser sintering process Material Configuration File In the SLS application software a file that specifies the defaults and ranges for the build parameters for a particular material Message In the SLS system software any informat...

Page 29: ... feet per minute Selective Laser Sintering SLS Process A thermodynamic process that applies external energy in the form of directed laser energy that causes particulates of a heat fusible powder to fuse into a solid mass Set Point A value for a particular parameter established by a configuration file or by the user and which the SLS system attempts to achieve For example the Piston Heater Set Poin...

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