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SLS

  p r o c e s s  

u s e r ’ s   g u i d e

B O S

This section describes the BOS (Breakout Station) and its role in the SLS process. It includes 
operating instructions, as well as maintenance and troubleshooting recommendations.

`

BOS Features

. . . . . . . . . . . . . . . . . . . . . . . . . . 210

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BOS Overview

. . . . . . . . . . . . . . . . . . . . . . . . . 211

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BOS Operator Controls and Indicators

 . 212

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BOS Components

 . . . . . . . . . . . . . . . . . . . . . 215

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BOS Safety

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

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BOS Power-Up Sequence 

 . . . . . . . . . . . . . 220

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BOS Start-up

. . . . . . . . . . . . . . . . . . . . . . . . . . 221

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Breakout Station mode operations

. . . . . 222

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BOS Operating States

. . . . . . . . . . . . . . . . . . 224

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Using the BOS Main Menu

 . . . . . . . . . . . . . 229

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Using the BOS Setup Menu

 . . . . . . . . . . . . 230

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Using the BOS Diagnostics Menu

 . . . . . . 233

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Using the BOS Work Platform

. . . . . . . . . . 239

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Shutting Down the BOS

 . . . . . . . . . . . . . . . 240

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BOS Maintenance

 . . . . . . . . . . . . . . . . . . . . . 241

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BOS Troubleshooting

. . . . . . . . . . . . . . . . . . 242

Summary of Contents for Sinterstation Pro

Page 1: ...sPro SLS and DuraForm are registered trademarks of 3D Systems Inc Other trademarks are the property of their respective owners L In accordance with laboratory equipment safety standards EN61010 1 Sect 5 4 4 If this equipment is used in a manner not specified by the manufacturer protection provided by the equipment may be impaired Observe all warning labels and conform to all safety rules described...

Page 2: ...G U I D E This guide describes how to create finished SLS parts made of DuraForm PA plastic powder laser sintering LS material using 3D Systems sPro SLS system and SLS equipment What s Inside 3 Hazard Warnings 5 Instruction Formats 6 Other Useful Documents 7 ...

Page 3: ...Form Material Safety Data Sheets MSDS s Printed copies of these documents were included in your SLS powder material shipment You can also download MSDS s for SLS materials from3D Systems website See Other Useful Documents on page 7 SLS Process Procedures The instructions in these four sections step you through the SLS process in a general way When necessary they refer you to detailed machine opera...

Page 4: ...s these sections SLS Equipment overview of SLS equipment features and functions This section includes illustrations that help you locate SLS equipment components and controls and convenient menu maps for the IRS and BOS operator panel displays The four sections after the equipment overview contain complete safety operation maintenance and troubleshooting instructions for each SLS process machine T...

Page 5: ...amage and or data loss Electric shock Injury or death from electric shock Hot surface Burn injury or fire on hot non handling surface Allow surface to cool before touching Hot surface touch Burn injury or fire on hot handling surface Allow surface to cool before touching Laser radiation Eye injury or blindness burn injury fire Crush Injury or death from crushing weight Impeller Injury or death fro...

Page 6: ...30 0 for the temperature Setpoint C Keys Keyboard key names are capitalized for example Press the Enter key Labeled Controls and Indicators Labeled switches buttons lights and gauges are in bold uppercase text for example Turn the BOS POWDER TRANSPORT switch to RECYCLE Operator Panel Buttons The icons represent operator panel buttons on the IRS and BOS The buttons perform these functions Scroll me...

Page 7: ...ents for facility electrical power room atmosphere compressed air nitrogen and coolant It also shows equipment dimensions and a recommended arrangement for your SLS equipment This layout was sent to you before installation A pdf copy is included in the dtm docs folder for reference Material Safety Data Sheets MSDS s online copies of the printed MSDS s that ship with DuraForm materials Make sure ev...

Page 8: ...p Online Help from the main window menu bar For help on the currently selected Sinter command or window press function key F1 Material Guides give you the material machine and software configuration information you need to build good parts with the SLS process Each Material Guide describes SLS processing characteristics for one family of 3D Systems DuraForm powder materials such as DuraForm PA The...

Page 9: ...ety 32 Mechanical Motion Hazard Locations 34 Hot Surfaces and Powders 35 DuraForm Material Handling Safety 36 IPC Handling Safety 37 Shutdown 39 Emergency Shutdown 40 Before using any SLS equipment your company should have a safety program in place The safety program should do the following Label and point out hazardous equipment materials and procedures Explain what to do in an emergency situatio...

Page 10: ... the 3D Systems service training package and are certified to perform service tasks Certification may occur at various levels and servicers should only perform tasks they are authorized and certified to complete Machine Handling Do not try to access service or adjust any components inside any SLS equipment enclosure Do not try to open any panel or door while a machine is running Do not access any ...

Page 11: ...any way Do not enter any area displaying posted warning signs during open beam operations Open beam operations refer to the laser and they only occur during service procedures Alarms and Warnings If you hear an alarm or if you see an error alarm or warning message on any SLS equipment display note the state of that machine s Stacklight and refer to its troubleshooting section in this guide Clear t...

Page 12: ...etely Safety Interlocks Safety interlock devices on the SLS equipment help prevent accidental laser exposure electrical shocks crush injuries burns and fires SLS equipment will not operate unless all safety interlocks are satisfied If any SLS equipment safety features fail your actions may be all that will prevent potentially hazardous operating conditions Never try to disable or override any safe...

Page 13: ...by minimizing exposure to heated powder slip hazards by keeping powder from dropping on the floor fire hazards by minimizing airborne dust cloud formation and potential ignition See MSDS for complete hazard details SAFETY INTERLOCKED CONDITION IF THIS INTERLOCK FAILS RCM door open when SLS system is attempting to start a build Build will not start Warning message appears on SLS system display Yell...

Page 14: ...ion from escaping to the outside The process chamber window material also blocks laser radiation so you can safely observe the part bed during a build Other Active Safety Features The Breakout Station BOS coupled with the Dust Collector removes airborne powder during part breakout in accordance with standard industrial ventilation practices An overpressure sensor line monitors the pressure in the ...

Page 15: ... are surfaces and powders in the vicinity that may be hot and could cause severe burns or fire SLS equipment has two types of hot surface hazard labels one with a hand and one without The label with the hand appears on hot surfaces that are normally handled such as process chamber access panels The label without the hand appears on hot surfaces that are not normally handled such as the heat shield...

Page 16: ...hanical Motion Hazard Locations on page 33 NOTCHED BELT PULLEY ENTANGLEMENT HAZARD Motion of notched drive belt on pulley presents an entanglement hazard in the vicinity of this sign Entanglement hazards can result in severe bodily injury or death See Mechanical Motion Hazard Locations on page 33 AIR PRESSURIZED POWDER HAZARD Sudden explosive escape of air pressurized powder presents a hazard in t...

Page 17: ...d Only 3D Systems certified service personnel should operate SLS equipment with access panels or service doors open Heed high voltage warning signs and labels Take common sense safety precautions when operating any electrical equipment After any change to the electrical wiring make sure the equipment is properly grounded Hazardous voltage exists inside the enclosures of all SLS equipment Injury or...

Page 18: ...st raising the oxygen concentration in the chamber This can keep the SLS system from reaching inert or cause an in process build to abort Waste Heat Almost all the electrical power used by the SLS system and RCM is converted to heat that must be removed from the room Air conditioning for the installation room should be sized based on room dimensions the size number and location of wall openings su...

Page 19: ...e quantifies the noise levels for various components of the SLS system EQUIPMENT NOISE LEVEL SLS System 85 dBA operator standpoint BOS and Dust Collector BOS only Dust Collector only Dust Collector self cleaning cycle 85 dBA operator standpoint IRS idle IRS transporting powder IRS blending powder 85 dBA operator standpoint ...

Page 20: ...lth CDRH and by IEC 60825 the International Electrotechnical Commission s Radiation Safety of Laser Products Equipment Classification Requirements and User s Guide The Class I and Class IV laser designations also comply with DIN VDE 0837 02 86 A1 07 90 You can read more about laser safety and classifications in ANSI Z136 1 1993 the American National Standards Institute standard for the safe use of...

Page 21: ...ould only be opened by certified service personnel See Laser Safety on page 20 DEFEATABLY INTERLOCKED PROTECTIVE HOUSING If you defeat the SLS system laser safety interlocks then open this housing panel or door you can be exposed to hazardous direct and scattered Class 4 invisible laser radiation which can cause severe burns and eye injury or start a fire Interlocked SLS system panels and doors ar...

Page 22: ...s a f e t y LASER RADIATION HAZARD LABEL LOCATIONS Behind the process chamber cover Behind raised laser window access door On process chamber left and right exterior wall right side not shown On process chamber rear interior and exterior wall On IPM top access panel ...

Page 23: ...ATIONS CAUTION CLASS 4 INVISIBLE LASER RADIATION WHEN OPEN AND INTERLOCKS DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION At top of SLS system on IPM access panel On back panel of IPM On front face of IPM behind raised laser window access door Internal on IPM base plate visible after removing the IPM access panel ...

Page 24: ... 4 S A F E T Y u s e r s g u i d e l a s e r s a f e t y LASER CERTIFICATION AND MACHINE IDENTIFICATION LABEL LOCATION Machine ID label at left rear of SLS system on AC chassis door Laser certification on machine ID label ...

Page 25: ... a beam Do not operate the SLS system with a broken or missing window Operate the SLS system in accordance with all local regulations If your state or national government does not provide guidelines for operation of Class I laser systems refer to ANSI Z136 1 1993 American National Standards Institute standard for the safe use of lasers Only certified service personnel specifically trained in laser...

Page 26: ...he SLS laser or beam delivery system When this occurs certified service personnel at your site should follow the special laser safety precautions described in the following list Certified service personnel should secure the room containing the SLS system it is called the Nominal Hazard Zone NHZ The room must have locks on the door s that limit entry but do not restrict exit If the SLS system is in...

Page 27: ...The CO2 laser wavelength cannot travel through glass It will create a visible indication on polycarbonate Your company must provide industrial safety glasses of either glass or polycarbonate for adequate eye protection If your company requires any precautions beyond these such as a flashing red light to be in operation during the process your company must provide the equipment Certified service pe...

Page 28: ... 3D Systems material guides for information on specific powders Powder Ignition Information Powdered materials can be flammable and can be ignited by static electricity in a non inert environment Refer to each powder s MSDS for specific information Finding Powder Safety Information Use the Powder Safety Information table on page 29 to locate references and contacts for information on important pow...

Page 29: ...Association Volume 5 of the National Fire Codes Europe Maximale Arbeitsplatz Konzentration January 1990 Powder exposure US Code of Federal Regulations 29 CFR section 1900 1000 available from Superintendent of Documents Government Printing Office Washington D C 20402 Europe DIN EN 26184 Teil 1 06 91 Specific powdered materials Material Safety Data Sheets MSDS from 3D Systems Inc US Canada Europe Mf...

Page 30: ...ound powder Maintain proper clearance from powders when using portable heating devices Store flammable liquids away from powder After removing a part from the process chamber allow it to cool to room temperature in a well ventilated area Use anti static mats in front of SLS equipment Connect the ground wire on the IRS powder umbilical to the IPC before unloading virgin powder INHALATION Avoid brea...

Page 31: ... ready to use Have any equipment specified in the MSDS ready to use MSDS Give operators access to the MSDS s that apply to materials they will be handling and ensure that they read them If necessary translate them File MSDS s in an easily accessible location for immediate reference Strictly follow all the conditions in each MSDS Safe Powder Handling Guidelines continued CATEGORY PRECAUTION ...

Page 32: ... oxygen level drops below a designated point It must be wired to trigger an immediate shutdown of the SLS system and nitrogen generator if in use The table of Oxygen Deprivation Effects and Symptoms on page 33 explains the potential effects and symptoms that can occur at different concentrations of oxygen in the atmosphere When you work in an environment that may become oxygen deficient make sure ...

Page 33: ...lse rate goes up May experience impaired coordination perception and judgment 10 12 Respiration continues to increase in rate and depth Lips become blue May lose consciousness at this point 8 10 Mental failure Fainting and unconsciousness Face becomes ashen lips become blue Nausea and vomiting may occur 6 8 100 fatal after 8 minutes of exposure 50 fatal within 6 minutes Recovery with treatment wit...

Page 34: ...ly open or closed Keep hands away from the door props on the right and left sides of the door Make sure anyone working near the BOS has their hands clear of the door before you open or close it BOS powder transport hopper Do not operate the BOS with the powder transport hopper grate off Disconnect power to the BOS before you remove the grate RCM docking Keep you hands away from the front and sides...

Page 35: ...s described in Safety Labels on page 15 Avoid those surfaces when docking and removing the RCM Use appropriate gloves when removing the part cake from the RCM or let the part cake cool for several hours before you touch it Avoid hot process chamber surfaces behind Hopper Feed Module access doors on left side of SLS system Always wear personal protective equipment insulated gloves when handling the...

Page 36: ...IRS and contact 3D Systems Customer Support Hotline If no leakage or damage is observed store the full IPCs safely according to the storage guidelines below until you need to refill your IRS Storage The shelf life of DuraForm PA model material is one year from date of manufacture Each IPC is tagged with its expiration date Use the oldest IPCs first DuraForm material should be kept indoors in a coo...

Page 37: ...e material expiration date is printed on the IPC shipping tag in the plastic shipping pouch attached to the cover Do not connect an IPC to the IRS if the material is about to expire When the IRS detects an expired IPC it will not draw powder from the IPC and the yellow IRS Stacklight will flash Damage or leakage The IPC is pressurized when in use Before you connect an IPC to the IRS inspect it for...

Page 38: ... especially when it is full The IPC weighs 50 kg 110 lb empty and 150 kg 330 lb full Always follow standard lifting practices one person per 23 kg 50 lb when moving any SLS equipment or material If you are not accustomed to lifting this much weight or if you have back problems do any or all of the following to protect yourself use additional people to lift the items remove mass to reduce weight or...

Page 39: ...the IRS IPC section BOS Shutting Down the BOS on page 232 of the BOS section Depressurization The SLS system IRS and BOS all connect to facility compressed air In addition the IRS pressurizes the IPC container Normal shutdown requires proper depressurization Be sure to follow the depressurization instructions for the individual machines in the shutdown procedures above Only use E stop to shut down...

Page 40: ...d Effects MACHINE E STOP LOCATIONS WHAT E STOP DOES SLS SYSTEM On user interface console See SLS System Features on page 182 Internal behind right and left side process chamber access doors Stops laser Switches off all heaters including RCM heaters if RCM connected Stops all motion inside the SLS system including RCM motion if RCM connected Stops nitrogen flow into the SLS system Stops all powder ...

Page 41: ...on inside the BOS including RCM motion if RCM connected a Stops forced air exhaust out of the BOS if Dust Collector connected Stops all powder transport from the IRS and within the SLS system Switches off BOS operator panel interior work light and Stacklight SLS Process Machine E Stop Locations and Effects continued MACHINE E STOP LOCATIONS WHAT E STOP DOES ...

Page 42: ...of these machines when the RCM is connected Switches off all RCM cylinder heaters and the part piston heater a Stops all RCM part piston motion IPC On IRS operator panel IRS Features on page 135 The IPC is completely controlled by IRS Pressing E stop on any machine except the IRS will not stop powder flow from the IPC to the IRS or depressurize the IPC container Pressing E stop on the IRS will sto...

Page 43: ... go from powder to parts The procedures machines and supplies presented in this section are covered separately in detail later in this guide What is the SLS Process 44 SLS Process Overview 45 SLS Process Steps 47 About SLS Equipment 49 About Installation and Facility Requirements 51 About the Powder Management System 52 Adding SLS Process Capacity 53 ...

Page 44: ...d to other rapid manufacturing methods SLS can produce parts from a relatively wide range of commercially available powder materials including polymers nylon also glass filled or with other fillers and polystyrene metals steel titanium alloy mixtures and composites and foundry sand The physical process can be full melting partial melting or liquid phase sintering And depending on the material up t...

Page 45: ...les and scale profiles to your parts then define custom or default build profiles for each of the three stages of your build i e Warmup stage Build stage and Cooldown stage When you finish defining all these parameters verify the build and save your build packet See Build Setup Help and your Material Guide Clean Preheat the SLS system and RCM The RCM will hold your part cake Load Blend Send batche...

Page 46: ...ousands of consecutive layers of fused cross sections form one or more 3 D SLS parts See Running a Build as well as the Material Guide for the material you are using Also see your Sinter application online Help Breakout parts from the part cake using the BOS But you must wait for the part cake cooldown to finish Your controlled cooldown can take place at the end of the build inside the SLS system ...

Page 47: ...e heated RCM into the RCM bay Be sure to push the RCM all the way in Plug the RCM cable into the RCM then close the RCM door 2 At the SLS system console run the Sinter application wait about 30 seconds until the DSPIF button appears in the Windows taskbar then choose ManOps Piston Control 3 In the Piston Control window a Click the Load button under RCM then wait until the RCM Status shows Engaged ...

Page 48: ...Continue performing Build Set Up function Once the Build Set Up is complete and has been Saved and Verified close Build Set Up 12 In Sinter select the blue Exit button to close all running applications Select the blue Exit button one more time to close the ManOps function 13 Select Build Start Build confirm that the correct material has been loaded and when prompted push the start button on the ma...

Page 49: ...is main SLS process machine It builds solid 3 dimensional parts out of 3D Systems DuraForm laser sintering powder This guide covers two SLS system models the sPro 140 and the taller sPro 230 These two models are the same with one exception the model 230 has frame risers on its main frame and enclosure frame that make it 23 cm 9 in taller than the model 140 This enables the model 230 to build talle...

Page 50: ...u need to remove the sintered parts from the part cake in the RCM and clean them Removing parts from the part cake is called breakout To remove parts from a part cake you roll the cooled RCM into the BOS connect the RCM cable and gradually raise the part piston removing powder and parts as you go Unsintered part cake powder goes into the BOS Powder Transport Hopper where it is sifted and either re...

Page 51: ...the SLS Process Facility Guide and SLS Process Facility Layout for sPro SLS fmodels 140 and 230 The pre installation facility checklist must be completed and returned to 3D Systems Customer Support before you can schedule installation Connecting your network The SLS system computer can be connected to your existing TCP IP Ethernet network However if you connect the SLS system computer to your netw...

Page 52: ...te and time amount transferred and bin weights The APMU shuts down powder transfers if the powder data suggest the powder integrity has been compromised When does the IRS send data to APMU The IRS sends data to the APMU when it reads and updates the IPC RFID tag finishes blending a batch of powder sends powder to the SLS system receives recycled powder from the BOS detects a change in the weight o...

Page 53: ...s Connect multiple SLS systems to a single IRS to perform multiple concurrent builds Use multiple RCM s The easiest and simplest way to increase your SLS parts production capacity is to use two or three RCM s per SLS system instead of one This minimizes the time between builds by enabling you to breakout or preheat one RCM while another is in build or breakout RCM in build RCM cooling down RCM in ...

Page 54: ...use one IRS to service up to three SLS systems all building concurrently and continuously The POWDER OUTLET fitting on the SLS system gauge panel enables you to daisy chain powder transport lines between SLS systems Run concurrent builds on multiple daisy chained SLS systems fed by one IRS powder in powder out powder out powder in powder in Build A Build B Build C ...

Page 55: ...fore you can build parts in the SLS system It steps you through the following procedures Setting Up a Build Packet 56 Cleaning and Checking Equipment 59 Starting the Equipment 60 Unloading the IPC 65 Preheating the RCM 68 Docking the RCM in the SLS System 69 Pre Build Checklist 70 Verifying Sufficient Powder 71 ...

Page 56: ...parts in build volume Set build and part parameters Save the build packet file Copy the build packet bpf file to your SLS system computers dtm build folder Each procedure is summarized below See your Build Setup Help for detailed instructions Run Build Setup 18 Login to Windows on your standalone PC 19 Choose Start Programs SLS System Build Setup 20 Build Setup starts with its Main window displaye...

Page 57: ...cally In time you ll learn optimal placement and orientation strategies for the types of parts you build most often Set parameter values in the build packet Parameters are settings in a build packet that you can change Parameter settings apply to parts or the entire build You set parameters in Build Setup s Part Profile Editor and Build Profile Editor dialog boxes Parameters control most aspects o...

Page 58: ... the SLS system uses to scan parts L You cannot run a build packet until it is verified To save and verify a build packet select File Save Verify After verification the build packet is saved in your dtm build folder with a bpf extension After you perform the rest of the build preparation procedures in this section you ll be ready to run the build as described in Build Parts on page 73 At that poin...

Page 59: ...ter and unload the RCM See Cleaning roller on page 201 3 Clean the laser window before every build The laser window behind is easy to remove for cleaning Simply lift up the IPM front panel loosen the laser window hold down thumbscrews and pull it straight out See Cleaning laser window on page 199 4 Clean the overflow screens before a build if necessary Check the overflow screens in the overflow ch...

Page 60: ...itrogen generator L If the O2 alarm monitor is off AC power light on front is off open the hinged panel to access the power switch then switch power ON For more information see the separate Oxygen Alarm Monitor Operating Instructions that came with your system 2 IRS start up page 64 Start the IRS and load virgin powder into it if necessary For loading instructions see IRS IPC on page 133 3 BOS sta...

Page 61: ...em machine start up sequence These three procedures are described next POWER ON SLS SYSTEM 1 Turn on the SLS system s main power disconnect switch on the AC chassis door at left rear of SLS system 2 Turn on SLS system UI monitor The power button is at top left rear corner of the monitor along with the other display adjustment buttons L The SLS system computer powers up when you turn on the main po...

Page 62: ...till is not SLS SYSTEM MACHINE START UP SEQUENCE If you re starting the SLS system from it s powered off state you must first perform the following machine start up sequence before you start a build Start the chiller Verify the SLS system compressed air Verify the SLS system nitrogen supply Verify the SLS system powder supply Put Sinter in Manual Operations Man Ops mode Load the RCM Move the part ...

Page 63: ...t readings These are sPro 140 lowh air pressure 350 kPa 51 psi highv air pressure 350 kPa 51 psi 6 Verify SLS system nitrogen supply L Skip Step a if you have a nitrogen dewar or bulk tank connected to your SLS system instead of a nitrogen generator a Open the compressed air supply valve at the bottom of the N2 generator b Make sure the NITROGEN INLET ball valve on SLS system gauge panel is open c...

Page 64: ...ress Display says Ready 7 IRS will commence automatic operation it may be blending or transporting powder to the sPro on demand BOS start up L The BOS must have some used powder in its powder transport hopper before it can respond to IRS requests to send used powder If you have not performed a breakout yet and you have some new or used non waste powder in a container you can pour it into BOS powde...

Page 65: ... Unloading the IPC The IRS Blender bin must be full before the IRS can transfer powder to an SLS system When the Blender is low the yellow lamp on the IRS stacklight is on When you are ready to unload the IPC move it next to the IRS connect the IRS umbilical pressure sensor line and grounding clamp through the access opening at the bottom of the crate See Loading Virgin Powder on page 167 for more...

Page 66: ...powder contained in the IPC After the pressure sensor line umbilical and ground wire are connected to the IPC put the IRS in Ready mode and use the IRS operator panel to indicate that an IPC has been attached IPC batch unload sequence Powder is unloaded from the IPC into the Virgin bin in batches of roughly 5 kg The unload sequence below repeats until the Virgin bin is full or the IPC is empty L I...

Page 67: ... are set at the factory and must only be changed by a certified 3D Systems Customer Support Technician or Authorized Service Provider light and display a message on the LCD It will still continue to feed powder to the Sinterstations during this time but no blending cycle will be initiated until a sufficient amount of powder is present in both the Used and Virgin powder bins To load Virgin powder t...

Page 68: ...SLS p r o c e s s 6 8 e m p t y u s e r s g u i d e e m p t y ...

Page 69: ...eheating does not heat the RCM handle 3 Slowly and carefully roll the RCM into the SLS system Push it in as far as it will go 4 Step down on the RCM foot brake to keep it from rolling back 5 Close the RCM bay door Before you start your build you will need to run Sinter and load the RCM in the SLS system i e raise it up until the rim of the part cylinder seals against the underside of the process c...

Page 70: ... Systems Nitrogen Generator The SLS system uses as much as 2800 liters of gaseous nitrogen during the initial purge for a build then up to 7 lpm during the build L If you re not using the Nitrogen Generator and If you know how long the build will take calculate the nitrogen needed if you are not sure estimate and make sure you have plenty of extra nitrogen and or the ability to easily switch nitro...

Page 71: ... sensor light is OFF When the upper material sensor stops sensing powder its light switches OFF and the SLS system requests more powder from the IRS If the IRS has powder in its blender bin it refills the feed hopper and the upper material sensor light switches ON again This automatic refill from the IRS only takes a few minutes so the upper material sensor light should not stay OFF for long If it...

Page 72: ...ation Ratio to 4 and the Feed Roller setting to 0 7 Specify the number of cycles normally 12 at a minimum and begin leveling powder 10 Pay attention to the O2 level in the machine Once it has reached the set point of 5 5 open the Heater control function and activate all of the heaters 11 Once the powder has been leveled and if the next build has not yet been set up minimize the Sinter application ...

Page 73: ...page 55 These procedures include setting up a build packet cleaning and starting the equipment loading powder and preheating docking the RCM Running Sinter 74 Loading the RCM 75 Homing the Part Piston and Roller 76 Messages in the Sinter Application 77 Selecting the Display Language 78 Adding Leveling Powder 79 Running a Build 81 Restarting a Terminated Build 82 Viewing a Build In Progress 83 Chan...

Page 74: ...e the DSPIF application starts appearing as a DSPIF button in the Windows taskbar Sinter uses DSPIF to control SLS system heaters and motion and to communicate with the laser scanning system 3 When you see the DSPIF button in the taskbar you can start a build Sinter should already be running if you started the SLS system as described in SLS system start up starting on page 61 Sinter is already run...

Page 75: ...n SLS system before a build on page 129 To load the RCM L The following two steps summarize the detailed RCM loading instructions found in Loading and Unloading the RCM starting on page 129 1 Put the Sinter application in Manual Operations mode Click the Man Ops button on the main Sinter window toolbar or select Machine Manual Operations 2 Load raise the RCM a Click the Piston Control button on th...

Page 76: ...xcept for Home Limit are dimmed for a piston that needs to be homed 1 To home piston click Home Limit in Piston Control window 2 After piston home click Start Position button 3 To home roller click Home Limit in the Roller Control window To home the roller The roller must be at its left or right limit position Before you can move the roller you must meet the following dependencies The RCM must be ...

Page 77: ...age and then right click to acknowledge it after you do so it turns black whatever its initial color was See Responding to Messages in Sinter Help for more information on acknowledging messages Message Types in Sinter TYPE COLOR SOUND DEFINITION Message Black None Informational only or tells of a minor error These generally occur when you enter different data than the system expects or when a depe...

Page 78: ...an select the language Sinter uses to display window titles menu options commands and button labels To change the language do the following 1 Put Sinter must be in Main or Man Ops mode 2 Select Options Language A Change Language dialog box appears 3 Select the desired language then click OK See Sinter Help for more information on selecting the language ...

Page 79: ...st not be open When you click Add Powder the Add Powder Layer dialog box appears To use the Add Powder Layer dialog box Change the settings for each parameter in the Add Powder Layer dialog box to the settings you want then click the Add Layer button L Click the Stop button if you need to stop the roller while it is adding a layer If you do this you must move the roller back to a limit before cont...

Page 80: ...e bottom of the feed hopper Typical setting is 0 6 rev Layer Thickness 0 0 to 0 508 mm 0 0 to 0 020 in The distance that the part piston lowers each layer Layer Cycle Count 1 and 32 000 The number of consecutive powder layers to be added Roller Rotation Ratio 0 to 10 The ratio of the roller s counter rotation angular velocity to its linear traverse speed The larger the ratio the faster the counter...

Page 81: ...points will not be updated you will see actual values 2 Click the Start Build button If the last build was not completed the system asks you if you want to restart it See Restarting a Terminated Build on page 82 if you need to do this 3 When the file Open dialog appears choose a the build packet file you want to build If you are not using the default material you will have to confirm the material ...

Page 82: ...he temperature at which you were running the build L When you restart a build it resumes building at the layer it was on when the build was terminated Therefore if the part piston was moved after you terminated the build some parts in the build might be ruined Keep the following in mind After restarting the build you may need to increase the laser power for the first few layers to make sure the la...

Page 83: ...ild Viewer Click the Grid button to turn the display of grid marks on or off Click the zoom buttons to expand or contract the scale of the Build Viewer window Options on the Viewer Menu While the system is in Build mode you can set the following options for the Build Viewer These options appear on the Viewer menu in the main window VIEW OPTION DESCRIPTION Set grid size This option displays a dialo...

Page 84: ...TE If you have Variable Layer Thickness enabled these heater setpoints change automatically when layer thickness changes Things to consider before you change setpoints Changes are saved to the build packet even if you terminate the build Changes apply only to the current build stage If you change a setpoint during inerting the system assumes the value is for the Warmup stage A new value clears all...

Page 85: ...alibration during the build perform a manual IR calibration before you start the build as described below L You can opt to have the SLS system simply verify IR sensor readings rather than recalibrate Click the Verification Only checkbox in the IR Cal window to choose this option To disable automatic calibration During a build the system calibrates IR sensors automatically unless you disable the ca...

Page 86: ...sume Build Continue the build Enter Next Stage Move from Warmup stage to Build stage or Build stage to Cooldown Terminate Build Stop the build If you terminate a build when the system is in the Build stage and you do not want to restart the build from the termination point remove any parts from the part bed and review the build packet in Build Setup Make any changes that can improve the build Chan...

Page 87: ...itions of the parameters in the Build Setup Help In most respects these dialog boxes work just as they do in the Build Setup software with the following differences Settings for Z levels below the current are yellow and cannot be changed The current Z level is displayed as a green vertical line in the parameter chart In the Build Profile Editor a new button appears the button Use this button to ma...

Page 88: ...d The application works just as described in the Build Setup Help except that it also displays a plane marking the current Z level Changes you make below the plane such as adding or moving parts will not affect the current build although they will be saved and will affect future runs of this build packet Parts are initially displayed in Box view Running a Prime Cycle Click the Prime Cycle button i...

Page 89: ... e s s 8 9 B U I L D P A R T S u s e r s g u i d e w h e n a b u i l d e n d s When a Build Ends At the end of a build the Sinter application displays a summary of the actual build times such as the example below ...

Page 90: ...the procedures you follow when you break out parts See the BOS section later in this guide for complete BOS operating and maintenance instructions Breakout Overview 91 Unloading RCM Removing the Part Cake 93 Part Cake Cooldown 93 Power on the BOS and Dust Collector 94 BOS Start up 95 Load Raise Part Cake 96 Breakout Parts from Part Cake 97 Dispose of Waste Powder 98 Recycle Used Powder 98 Part Fin...

Page 91: ...onnect the RCM cable Start the BOS put it in Breakout Station mode then select the powder transport mode RECYCLE or DISPOSAL Raise the part piston a few inches to raise the part cake BOS work table surface About part cake cooldown before breakout The part cake in the RCM needs to cool down before breakout so you can handle it safely You must choose where and how to cool down the part cake after a ...

Page 92: ...m You can remove it while it s still warm or let it cool down inside the SLS system If you remove the RCM from the SLS system PART CAKE COOLDOWN LOCATION PART CAKE COOLDOWN METHOD CONTROLLED UNCONTROLLED RCM connected inside the SLS system Use the Cooldown Wizard in Build Setup to create a custom cooldown profile for your build Leave the RCM loaded until the SLS system indicates that the build is ...

Page 93: ...e Unloading RCM Removing the Part Cake Before You Begin Verify that the BOS RCM seal is latched in its upright position Know the size shape and placement of the parts in the cylinder Make sure there is adequate ventilation in the SLS system area Make sure the parts are cool enough to prevent permanent deformation If the core temperature of the part cake is greater than 60 ºC 140 F do not continue ...

Page 94: ...15 seconds the BOS displays In Standby While In Standby the air supply to the BOS is off all motors are off and no powder is transported Dust Collector Power on 1 Open the Dust Collectorenclosure and empty the dust pail if necessary 2 Connect the flexible duct pipe to the air duct flange on the left or right outer wall of the BOS chamber 3 Turn on the power switch on the upper right side of the Du...

Page 95: ...r to the waste drum 2 Press 3 If the BOS sifter is empty the BOS turns on the auger and sifter motors at the bottom of the hopper and attempts to fill the sifter If it can do so in less than 2 minutes it starts a RECYCLE or DISPOSAL powder transfer 4 If the sifter fills in less than 2 minutes then In RECYCLE mode the BOS enters the Waiting for IRS state and waits for the IRS to send it a request f...

Page 96: ...ly until you release the switch or move it to the middle Stop position The jog switch returns to the Stop position when you release it L When the part piston reaches its upper or lower limit its up or down motion stops automatically to prolong the life of the piston motor even if the switch is not in the Stop position After breakout before you remove the RCM from the BOS use the part piston jog sw...

Page 97: ... parts with a spatula and brush Brush unsintered part cake powder into the power transport hopper through the grate When you can easily grasp a part carefully lift it In the case of a tall single part you may need to tilt it to clear the top of the process chamber Gently brush off the parts and place them on the part BOS work table or separate tray The part cake can remain extremely hot for hours ...

Page 98: ...ch on the BOS operator panel to DISPOSAL 3 Press to go into Breakout Station mode and start powder transfer Recycle Used Powder 1 Set the POWDER TRANSPORT switch on the BOS operator panel to RECYCLE 2 Press to go into Breakout Station mode and start powder transfer See Disposing Powder on page 225 of the BOS section for detailed instructions See Recycling Powder on page 225 of the BOS section for ...

Page 99: ...wder from holes and crevices then apply a sealer or other coating You SLS system ships with a basic set of rough and fine part cleaning tools You may find it useful to supplement these with other fine tools picks and brushes such as those used for dental and jewelry work 3D Systems recommends you also purchase a glass bead blaster pneumatic blast cabinet A bead blaster makes fine cleaning much eas...

Page 100: ... being raised or lowered Sifting Network communications with other SLS process machines You must shut down the Dust Collector separately You can do this at any time by simply turning off the Dust Collector s power switch To shut down the BOS properly 1 If the BOS is currently transferring powder to the IRS wait until the BOS operator panel says Powder Xfer Complete 2 Press repeatedly until the BOS...

Page 101: ... and its role in the SLS process It includes operating instructions for the RCM as well as maintenance and troubleshooting recommendations RCM Overview 103 RCM Features 104 RCM Specifications 105 RCM Description 108 RCM Safety 112 Cleaning the RCM 129 Loading and Unloading the RCM 130 Troubleshooting 132 ...

Page 102: ...a build you remove the RCM and part cake and run an uncontrolled part cake cooldown After cooldown you dock the RCM in the BOS for breakout You use the BOS s jog switch to gradually raise the part piston in the RCM as you remove parts from the part cake See BOS Overview on page 210 RCM Rapid part cake Change Module rolls on locking wheels for docking unloading and breakout ...

Page 103: ... the process chamber See RCM part piston and part cylinder on page 109 RCM alignment tooling balls 9X Three top balls and six side balls help ensure safe and proper RCM alignment in SLS system and BOS RCM bays during RCM loading and unloading See RCM part piston and part cylinder on page 109 and Loading and Unloading the RCM on page 129 Part piston inside part cylinder Supports the part cake durin...

Page 104: ...M wheels RCM cable socket For connecting the RCM cable on the SLS system or BOS enables remote power and control of RCM heaters and part piston during preheating build controlled cooldown and breakout RCM handle Safe grip bar for pushing or pulling the RCM To prevent equipment damage and injury always engage the RCM wheel lock when you dock the RCM in the SLS system or BOS Wear insulated gloves wh...

Page 105: ...eight Empty 260 kg 573 lb 360 kg 794 lb Part cake DuraForm GF 117 kg 258 lb 191 kg 421 lb Full empty weight part cake 377 kg 831 lb 551 kg 1215 lb Maximum build volume X Y Z 550 550 460 mm 22 22 18 in 140 liters 550 550 750 mm 22 22 30 in 230 liters Heaters Four total Five total Cylinder heatersb a The RCM is remotely powered by the SLS system or BOS through the RCM cable b blanket heaters that wr...

Page 106: ...SLS p r o c e s s 1 0 6 u s e r s g u i d e ...

Page 107: ...SLS p r o c e s s 1 0 7 u s e r s g u i d e ...

Page 108: ...setpoints when The RCM is loaded in the SLS system with the RCM cable plugged into the RCM and the Sinter application running The RCM heaters include Upper part cylinder heater band Middle part cylinder heater band Lower part cylinder heater band Lower lower part cylinder heater band on the taller RCM model 230 only Part piston heater heats part piston top plate The setpoints for these heaters dep...

Page 109: ...rt piston is at the top of the cylinder or Start position As a build progresses The piston descends in small increments after the laser scans the part bed before each new layer of powder is added The part piston in the RCM part cylinder moves up and With the part cylinder The model RCM 140 140 liter cylinder with part piston all the way down L Be sure to clean the RCM seal after every build See Cl...

Page 110: ...SLS p r o c e s s 1 1 0 u s e r s g u i d e ...

Page 111: ...SLS p r o c e s s 1 1 1 u s e r s g u i d e ...

Page 112: ... are certified to perform service tasks Certification may occur at various levels and servicers should only perform tasks they are authorized and certified to complete Use special caution when handling a heated RCM and when dealing with the heated inert environment inside the SLS system s process chamber Take note of all thermal hazard warning labels on the machines Do not try to open any panel or...

Page 113: ...sages can result from unsafe practices such as opening an enclosure door or panel when equipment is powered up and running Dress electrical cables powder transport tubing and coolant hoses to prevent tripping especially the powder tubing harness that connects the IPC to the IRS Do not try to access service or adjust any components inside any SLS equipment enclosure To prevent injury and equipment ...

Page 114: ...SLS p r o c e s s 1 1 4 u s e r s g u i d e ...

Page 115: ...SLS p r o c e s s 1 1 5 u s e r s g u i d e ...

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Page 121: ...SLS p r o c e s s 1 2 1 u s e r s g u i d e ...

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Page 123: ...SLS p r o c e s s 1 2 3 u s e r s g u i d e ...

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Page 128: ...SLS p r o c e s s 1 2 8 u s e r s g u i d e ...

Page 129: ...n the part bed seal in the SLS system The seal is on the bottom of the process chamber around the square part bed hole Use a non ignition vacuum to clean the seal 3 Remove the RCM lid just before you re ready to start a build L After removing the lid verify that the RCM is still clean before loading it in the SLS system Vacuum up any lid insulation particles you might see After preheating the RCM ...

Page 130: ... RCM wheel lock lever to lock the wheels d Connect the SLS system s RCM cable to the RCM connector e Close the RCM bay door 4 Put the Sinter application in Manual Operations mode click Man Ops on the main Sinter window toolbar or select Machine Manual Operations See the Manual Operations topic in Sinter Help for instructions 5 Load raise the RCM Display the Piston Control dialog box via the Manual...

Page 131: ...n the main Sinter window toolbar or select Machine Manual Operations See the Manual Operations topic in Sinter Help for instructions 3 Unload lower the RCM Display the Piston Control dialog box via the Manual Operations toolbar and click the Unload button See Piston Control under the Manual Operations topic in Sinter Help for instructions Troubleshooting RCM Error Conditions The RCM is held in pla...

Page 132: ...SLS p r o c e s s 1 3 2 u s e r s g u i d e ...

Page 133: ...ns 137 IPC Features 138 IPC Specifications 139 How the IRS IPC Work 140 IPC Description 148 IRS IPC Safety 151 IRS Operator Panel and Stacklight 153 IRS Start up 155 IRS Standby and Ready Modes 156 Using IRS Main Menu 157 Using the IRS Setup Menu 159 Using the IRS Diagnostics Menu 160 Using the IRS Utilities Menu 161 Loading Virgin Powder in the IRS 164 Transporting Powder from IRS to SLS System 1...

Page 134: ... process machines work together to supply powder for up to three SLS systems The IRS draws virgin powder from the IPC blends it with used powder from the BOS then sends the blended powder to the SLS system feed hopper when it receives a hopper refill request IRS Integrated Recycling System IPC Intelligent Powder Cartridge ...

Page 135: ... See Blending on page 166 Power switch Operator panel Displays status and warning messages in Ready mode enables setup diagnostics and manual powder transfers in Standby mode See IRS Error Messages on page 172 Emergency stop button Umbilical not shown Connects IRS to IPC for unloading IPC See IRS Umbilical connections on page 147 and Loading Virgin Powder on page 167 Overpressure safety line not s...

Page 136: ...0 Hz 3 A Facility breaker rating 15 A Weight 350 kg 772 lb Dimensions overall H W D 272 133 117 cm 107 52 46 in Stacklight height 28 cm 11 in Door clearance left and right sides 51 cm 21 in IRS umbilical length 3 m 10 ft Powder bin capacities Blender bin 72 L 2 5 ft3 Virgin bin new powder 240 L 8 5 ft3 Used bin used powder 240 L 8 5 ft3 ...

Page 137: ...PC s are not Umbilical connectors Three nozzles and one socket for the umbilical molded connector Top nozzle pulse air line air pulses fluidize the powder in the container Middle nozzle transport air line transport air conveys powder through the fill hose Bottom nozzle powder outlet hose bottom carries powder to IRS virgin bin RFID tag in molded connector verifies IPC powder matches powder in IRS ...

Page 138: ...uropean Council Directive 99 5 EC and all applicable local laws and regulations Operation of this device is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation The device referenced in this guide contains transmitter FCC ID 2ADGF CLDRCSTM IC 12666A ...

Page 139: ...from the IPC to the Virgin bin After the initial fill the IRS draws powder from the IPC until the Virgin bin is full After Blender bin smaller bin in the right front corner receives blends and stores powder from the Used bin and Virgin bin before the IRS sends it to the SLS system s The IRS monitors the powder level and weight in the three bins and refills them continually as soon as the drop belo...

Page 140: ...blend a full batch When this happens the IRS blends a partial batch Virgin powder storage bin The Virgin bin in the right rear corner of the IRS receives virgin powder from the IPC and stores it for blending The IRS loads virgin powder from the IPC until the Virgin bin is full i e until the bin weight and powder level are both above the factory full setpoint typically L A load cell under the bin a...

Page 141: ...he final desired percent it transfers a load of used powder If below it transfers a load of virgin The weight of powder transferred with each load varies somewhat and it is different between the used and virgin bin due to the slightly different flow properties of each material In addition the desired ratio of virgin to used powder may not be 1 1 Therefore the powder proportioning does not always a...

Page 142: ...powder with a proportionally smaller amount of the other powder Example If the percent virgin is 60 3 kg virgin to 2 kg used and the used bin only has 1 kg left the IRS will blend a partial batch using the entire 1 kg of used but only 1 5 kg of virgin This makes the partial batch blend ratio 1 5 When the IRS blends a partial batch it flashes the yellow stacklight and Please Load Used Powder or Cha...

Page 143: ... determine powder weight in the bins The dust collection fan will ensure that air always flows into the gap around the outside to capture dust TRANSPORTER A conical stopper valve operated by an air cylinder is opened while the transporter is filling and closes to pressurize the transporter and convey the powder The transporter hopper has a high level proximity switch which signals when the transpo...

Page 144: ...eriod elapses without the level sensor turning on the transfer will also begin 4 Pressurize Transporter Valve N5_S2 switches to actuate air cylinder N66 to close the Right Transporter plug valve Note that N5_S2 is a 4 way valve After a short delay valve N5_S10V4 opens and the pressure in the line is characterized using the pressure sensor mounted directly on the I O board and sensed through line N...

Page 145: ... SLS system will continue to call for powder until the SLS system upper feed hopper level sensor is asserted As the powder level falls from use the top level sensor will no longer be asserted and the SLS system will call for powder again Each transfer follows the following sequence 1 Transfer Request SLS system sends the IRS a message requesting a transfer 2 Transfer Acknowledge When ready to tran...

Page 146: ...nd the Used Powder bin is not full the transfer will then follow the following sequence 1 Transfer Request the BOS sends the IRS a message requesting a transfer 2 Transfer Acknowledge When ready for a transfer the IRS sends the BOS an acknowledge message 3 Transfer the BOS transfers one transporter load of powder to the IRS 4 Transfer Completion When the load of powder has transferred the BOS send...

Page 147: ...on the top lid under the IPC cover press in to connect pull to remove IRS UMBILICAL CONNECTIONS Pulse Air top connection under the spring loaded cover inflates the IPC during powder unload and delivers short high volume air pulses to fluidize the powder Powder Connection bottom two connections under the spring loaded cover The large molded connector terminates two umbilical lines the small air lin...

Page 148: ...ll powder has been unloaded the IRS will not unload any further powder and will shut down until the empty IPC is disconnected from the system IPC batch unload sequence Powder is unloaded from the IPC in batches of roughly 5 kg The unload sequence below repeats until the Virgin bin is full or the IPC is empty L If you stop unloading manually before a entire batch 5 kg unloads the IPC continues unti...

Page 149: ...IPC drop below minimum As soon as it does the IRS blows pulsed air in the IPC to clear the powder line This prevents the powder line from clogging when the next unload batch starts IPC overpressure safety shutdown The pressure sensor line at the top of the IPC connects to an overpressure sensor inside the IRS This sensor is completely independent of the IPC batch unload air flow controls If the se...

Page 150: ...Never use a blade to remove the shrink wrap from an IPC You could damage the vinyl container fabric and cause it to leak when the IPC is pressurized during unloading Hazardous voltage exists inside the IRS enclosure Injury or death from electrical shock can result if you remove external panels or attempt to defeat safety interlocks Panels should only be removed and interlocks should only be defeat...

Page 151: ...ises the pressure in the IPC to about 1 25 psi The overpressure switches close all the air valves for air flow from the IRS to the IPC if the pressure in the IPC exceeds 1 8 psi IPC moving and storage safety The IPC is designed to lifted and moved with a pallet jack Do not try to lift or move it manually especially when it is full The IPC weighs 25 kg 54 lb empty and 125 kg 276 lb full Always foll...

Page 152: ...wer on use the operator display and buttons to setup run and troubleshoot the IRS TO DISPLAY ALARM AND WARNING MESSAGES In IRS Ready mode the operatorpaneldisplays status warning and error messages If a warning or error message is on the display when the IRS status changes the status message will overwrite warning or error Integrated Recycling Station Standing By Exit Stand By Setup LCD display Ca...

Page 153: ...t The green yellow and red lights on the IRS stacklight indicate the IRS states described below The blue light is not used COLOR MODE IRS STATUS Red Off Normal Steady IRS is stopped and is not servicing any transfer requests The cause appears on the operator panel display Yellow Off Normal Steady IRS has a warning condition as displayed on the LCD It will continue to provide blended powder to the ...

Page 154: ...ters Ready mode The display you see immediately after you enter Ready mode depends on the states of the bins 4 If all the bins are full including the Blender bin the Ready mode display appears showing the weights of all three bins and the IPC When see the Ready mode display above the IRS is doing its job blending and transporting powder Before you turn on the IRS make sure the IRS umbilical is con...

Page 155: ... The most important powder transfer operation you do in Ready mode is unloading virgin powder from the IPC To do this you must change the IPC status from Do Not Unload to Unloading Menu options in Standby and Ready modes Both modes have a menu options Some of these options appear in both modes and some are mode specific For example Setup and Diagnostics are available in both modes Utilities is onl...

Page 156: ...fic For example The Utilities menu is only available when the IRS is in Standby mode The IPC Status menu option is only available in the Ready mode To select main menu options From Integrated Recycling Station Ready mode press to enter Standby mode The Standby mode display appears along with the list of main menu options Press to choose an option then press To view IRS software version From the Ma...

Page 157: ...i n g I R S m a i n m e n u To access IRS Setup or Diagnostics menus From the Main menu choose Setup or Diagnostics then press The BOS Setup menu or Diagnostics menu appears See Using the BOS Setup Menu on page 229 and Using the BOS Diagnostics Menu on page 232 ...

Page 158: ...s From Ready mode display Press to display the main menu Press to choose Setup from the main menu then press Setup Menu Options Process Parameters Menu IPC Pressure L Pressure and R Pressure Sens Gain Zero Process Percent Virgin Restore Saved Parameters Save Parameters Restore Factory Parameters Integrated Recycling Station Standing By Exit Standby Setup Standby mode display with main menu Integra...

Page 159: ... from the main menu then press Diagnostics Menu Options Blender Blender Load Blender High Level Virgin Powder Bin Virgin Powder Bin Load Virgin Powder Bin High Level Used Powder Bin Used Powder Bin Load Used Powder Bin High Level Left Transporter Left Transporter Load Left Transporter High Level Right Transporter Right Transporter Load Right Transporter High Level IPC Transporter IPC Pressure IPC ...

Page 160: ...enu Options Use the Utilities menu to empty the IRS bins send powder to SLS system manually or transfer powder between bins The menu options are summarized below Instructions for emptying bins and transferring powder are in the next two sections Integrated Recycling Station Ready Blended 25 IPC 20 Virgin 102 Used 70 Ready mode display Integrated Recycling Station Ready Exit to Stand By Setup Ready...

Page 161: ...d connect a spare powder supply line to it 2 Place the open end of the powder line from the POWDER or AUXILIARY OUTLET in a large covered container Empty Used Bin Sends powder from the Used bin to the AUXILIARY OUTLET until the IRS is turned off Manual LS Transfer Sends one transporter load of powder to the SLS system Blender to Virgin Sends powder from the Blender bin to the Virgin bin until the ...

Page 162: ...See IRS Specifications on page 136 for powder bin capacities 3 Access the Utilities menu See To access the Utilities menu on page 160 4 Press to choose Empty Blender bin Virgin bin or Used bin then press Powder begins to flow out the IRS outlet into the container 5 When powder stops flowing turn off the IRS to stop emptying the powder bin To empty another bin repeat from Step 1 Manual LS Transfer ...

Page 163: ...ilds never run out of powder always replace an empty IPC with a full one as soon as possible Step 1 Connect a full or partially full IPC to the IRS 1 Use a pallet jack or forklift to move a full or partially full IPC within 3 m 10 ft of the right side of the IRS 2 If an empty IPC is currently connected reverse Steps 3 and 4 below to disconnect it then move it out of the way 3 Connect the pulse air...

Page 164: ...2 Put the IRS in Ready mode 1 If the IRS power is off switch it on 2 Check the IRS display If it shows Integrated Recycling Station Ready the IRS is in Ready mode 3 If the IRS is not in Ready mode it s in Standby mode Press twice to exit Standby and enter Ready mode Step 3 Change IPC Status from Do Not Unload to Unload 1 Press to change the display from Integrated Recycling Station Ready to IPC st...

Page 165: ...eed hopper is full again i e until the upper level sensor switches on sensor LED switches on Each powder transfer from the IRS to the SLS system follows this sequence 1 Transfer Request SLS system sends the IRS a message requesting a transfer 2 Transfer Acknowledge When ready to transfer the IRS sends the SLS system an acknowledge message The SLS system then sets its powder control valves to recei...

Page 166: ...rred with each load varies somewhat and it is different between the used and virgin bin due to the slightly different flow properties of each material In addition the desired ratio of virgin to used powder may not be 1 1 Therefore the powder proportioning does not always alternate one load of each At the end of the proportioning the last load may be greater than the final weight of powder needed t...

Page 167: ...ulse Air top connection under the spring loaded cover inflates the IPC during powder unload and delivers short high volume air pulses to fluidize the powder Powder Connection bottom two connections under the spring loaded cover The large molded connector terminates two umbilical lines the small air line used to dilute the powder flow and the larger powder flow line The connector also contains a ra...

Page 168: ...hat all powder has been unloaded the IRS will not unload any further powder and will shut down until the empty IPC is disconnected from the system IPC batch unload sequence Powder is unloaded from the IPC in batches of roughly 5 kg The unload sequence below repeats until the Virgin bin is full or the IPC is empty L If you stop unloading manually before a entire batch 5 kg unloads the IPC continues...

Page 169: ...IRS This sensor is completely independent of the IPC batch unload air flow controls If the sensor detects air pressure in the IPC greater than 1 8 psi above the maximum IPC pressure setpoint the IRS shuts down the IPC and air cannot enter the IPC from any source L Minimum and maximum IPC pressure setpoints are set at the factory and must only be changed by a certified 3D Systems Customer Support T...

Page 170: ... IRS Used bin or to the waste powder drum eventually the BOS sifter will fill up and stop running Shutting Down the IRS Shutting down the IRS stops all internal and external powder transport and depressurizes the IPC To shut down the IRS properly 1 Wait for all builds to complete on all SLS systems the IRS supplies 2 If the green IRS stacklight is flashing wait until it stops The flashing green li...

Page 171: ...eed to move the IRS after you fill the bins with powder empty the bins first To empty the bins use the three Empty Bin command options on the IRS utilities menu See To empty powder bins on page 161 Always empty the IRS powder bins before moving the IRS Moving the IRS with powder in the bins can damage the machine ...

Page 172: ...ired Material IPC Powder has expired IPC Capacity Error Amount of Powder unloaded from IPC is greater than contents IPC Tag Mismatch IPC has changed during the unloading process Restore IPC originally used for unload IPC Tag Read Failure Communications problem with RFID reader Machine Config Missing Call Service Non Volatile RAM storing sensor parameters tare weights etc is missing Must re program...

Page 173: ...the load cell is adjusted Restore the previous Blender weight or use the Setup Reset Bin Weight Error menu option Virgin Powder Bin Weight Error The Weight of the Virgin Powder Bin changed unexpectedly No powder will be sent to the Sinterstations until this is resolved This error will also occur if an external object eg a toolbox is placed on the bin the bin tare weight is adjusted the adjustment ...

Page 174: ...t Bin Weight Error menu option See Reactivation after IRS Bin Weight Error on page 176 Insufficient Powder The Transporter did not fill within the requisite time Check Transporter level sensor adjust if necessary according to procedure Air injection pressure Air injection lines for leaks Critical orifice size Orifice for clog IRS in EStop The IRS E Stop switch is set Reset E Stop Switch Please Loa...

Page 175: ...fers 1 Disconnect the IRS umbilical 2 Connect the umbilical to a valid IPC that s not empty Please Load Used Powder or Change Percent Virgin Used Powder is needed to mix another blended powder batch The IRS will continue to feed the Sinterstations it services until the Blender is empty Load used powder into the IRS using the BOS Blender Unexpectedly Full The Blender High Level sensor indicates a f...

Page 176: ...en press repeatedly display and scroll the list of recent IRS error messages 2 Call the 3D Systems Customer Support Hotline number to request a reactivation code You ll be asked to provide the deactivation code on your IRS display 3 Follow the Customer Support Representative s instructions for entering the reactivation code 4 After you enter the code navigate to the Setup menu in either Standby or...

Page 177: ...do not see the Convey Line Clean option on the IPC Transporter menu call 3D Systems Customer Support Hotline for assistance 6 As soon as the convey line clears switch the Convey Line Clean setting back to OFF then press twice to return to Standy or Ready mode L If the convey line clog does not clear after several minutes with Convey Line Clean purge air ON call 3D Systems Customer Support Hotline ...

Page 178: ...hen the IPC is done venting i e when air flow out of the IPC stops unplug the IRS umbilical s powder connection 4 Carefully vacuum powder in the IRS umbilical from the IPC bulkhead connector end 5 Pass the vacuum quickly over the IPC powder outlet to loosen powder in the IPC internal piping IRS umbilical pulse air connector press button to release IRS umbilical powder connector pull out vacuum vac...

Page 179: ...s e r s g u i d e I R S I P C t r o u b l e s h o o t i n g 6 Reconnect the IPC pulse air and powder connections 7 Press to change the IRS status from Do Not Unload to Unloading IPC IRS Status Unloading IPC IRS status Unloading IPC display ...

Page 180: ...tly refers you to the Sinter Help because Sinter is the application you run on the SLS system when you build parts SLS System Overview 182 SLS System Features 183 SLS System Specifications 184 SLS System Description 185 SLS System Safety 191 Starting the SLS System only 192 Shutting Down the SLS System 196 SLS System Service Maintenance 197 SLS System Troubleshooting 203 ...

Page 181: ...rocess chamber the receives powder from the IRS An feed hopper dispenses DuraForm powder material on a sweeper in the process chamber Powder is wiped off the sweeper preheated then a roller spreads the powder over the part bed A laser mounted on top of the SLS system scans the bed of powder After scanning the RCM under control of Sinter program running in the SLS system computer drops the RCM part...

Page 182: ...le IPM Laser window removable Laser and optics Gauge panel right side not shown Nitrogen generator port Oxygen monitor port Flow and pressure gauges Air and coolant valves User Interface UI Emergency Stop button RCM bay Overflow Modules OFM Powder transport tubes Powder transport pumps Hopper feed module HFM Feed hopper Powder dispenser Powder inlets From IRS OFMs Machine Services Module MSM rear ...

Page 183: ...circuit 208 VAC 50 60 Hz 48 A 3 Phase WYE Facility breaker rating 60 A MODEL SPECIFIC sPRO 140 sPro 230 Dimensions enclosure H W D 197 184 185 cm 78 72 73 in 220 184 185 cm 87 72 73 in Stacklight height 36 cm 14 in 36 cm 14 in door clearance for left and right side process chamber access doors 51 cm 20 in on both sides 51 cm 20 in on both sides RCM cable length 132 cm 52 in 132 cm 52 in Max build ...

Page 184: ...ble it to build taller parts in a taller RCM See RCM Description on page 108 for more about RCM models The major sPro model 140 and 230 SLS system subassemblies are described below Process Chamber Module Upper and lower chambers Part Bed Part bed heaters Roller Feed heaters IR sensor and blackbody Laser window damper handle Upper Process Chamber UPC The UPC or upper portion of the completely enclo...

Page 185: ... coupled to the roller one rod in each channel Two sets of pulleys belts and belt tensioners for the roller one set in each channel Flexible thermal curtains on the inner side of each channel provide the isolation for the pulleys and belts They also enable the mechanical coupling of the roller to the guide rods Two pairs of powder heaters one on the right side of the chamber and one on the left Ea...

Page 186: ...Image Processing Module The IPM is mounted on top of the SLS system The components below are found under the IPM s top cover 70 watt CO2 laser Beam focusing and scanning optics including the X and Y scanning mirrors galvos Removable laser window Laser window nitrogen heater Beam shaft with manual damper ...

Page 187: ...dow N2 Flow gauge regulator 6 Coolant Flow gauge 7 Nitrogen Inlet from N2 Generator or tank N2 supply pressure 400 to 600 kPa 60 to 90 psi 8 Compressed Air Inlet 9 Low Air Pressure gauge 10 High Air Pressure gauge 11 Nitrogen Exhaust vent to outside atmosphere 12 Powder Outlet to next SLS system in chain 13 Coolant Return from laser cooling lines back to Chiller 14 Coolant Inlet from Chiller to la...

Page 188: ...wder dispenser Powder inlets From IRS and left right OFMs Machine Services Module MSM At back of machine main interface is gauge panel Electrical and control electronics enclosures Application computer User Interface UI and Application Computer Computer display keyboard and trackball for SLS system application computer Access to Sinter application and utilities as well as Powder Management Network...

Page 189: ...Help for more information on manually controlling the system Access Build Setup directly to modify a build packet on the fly while a build is in progress To start the software see Run Sinter application on page 192 SINTER UTILITIES In addition to the software that controls the SLS system 3D Systems provides utility applications with additional functions such as reducing log files or checking the s...

Page 190: ... who installs your system If you did not order a permanent activation password for Magics RP software when you purchased your SLS system you can order one by contacting Materialise See your Magics RP software documentation for information SLS System Safety When you use any SLS equipment follow all general safety guidelines in Safety on page 9 When you use the SLS system follow the guidelines in th...

Page 191: ...state Power on the SLS system Run the Sinter application Perform SLS system machine start up sequence These three procedures are described next Power on SLS system 1 Turn on the SLS system s main power disconnect switch on the AC chassis door at left rear of SLS system 2 Turn on SLS system UI monitor The power button is at top left rear corner of the monitor along with the other display adjustment...

Page 192: ...ne still is not Start chiller and verify flow gauges If you re starting the SLS system from it s powered off state you must first perform the following start up sequence before you start a build Start the chiller Verify the SLS system compressed air Verify the SLS system nitrogen supply Verify the SLS system powder supply Put Sinter in Manual Operations Man Ops mode Load the RCM Move the part pist...

Page 193: ...cate their correct readings These are 6 Verify SLS system nitrogen supply L Skip Step a if you have a nitrogen dewar or bulk tank connected to your SLS system instead of a nitrogen generator a Open the compressed air supply valve at the bottom of the N2 generator b Make sure the NITROGEN INLET ball valve on SLS system gauge panel is open c Verify that the REGULATED N2 PRESSURE gauge on gauge panel...

Page 194: ...h e S L S s y s t e m o n l y 8 Check pressure and flow gauges Verify the target pressure and flow settings on the SLS system gauge panel GAUGE TARGET PRESS TARGET FLOW Laser Window N2 105 kPa 7 lpm N2 Makeup Flow 105 kPa 0 lpm IR Sensor Flow N A 200 ccm Laser Coolant 420 kPa 9 lpm ...

Page 195: ...n Control window in Man Ops L If Sinter is not running you must run it first then unload the RCM in Man Ops 3 Exit the Sinter application if it is running 4 Shut down Windows 5 Depressurize Close the valves on compressed air lines that serve the SLS equipment below in this order a IRS b BOS c SLS system L Depressurizing stops all powder transport in and between the IRS BOS and SLS system Use an SL...

Page 196: ...However if the laser cover is removed for any reason the unit becomes a dangerous Class IV laser device Direct or reflected laser power from a Class IV laser device can cause severe burns and eye damage It can also be a fire hazard See Laser Safety on page 20 for more information SLS system service and maintenance procedures must only be performed by 3D Systems certified service technicians unless...

Page 197: ...ystem s RCM door and unplug the RCM cable from the RCM 7 Pull out the RCM and place the insulated RCM lid over the cylinder to keep the heat in CLEAN THE LASER WINDOW 1 At the SLS system raise the laser window door top front of machine Close the laser window shutter by pushing the shutter handle up and to the right 2 Loosen the two laser window retaining thumb screws 3 Carefully pull the laser win...

Page 198: ...indows and tighten frame screws sufficient to ensure frame gasket compression CLEAN THE ROLLER BELT CHANNELS IR SENSOR AND BLACKBODY Vacuum the front and back roller belt tracking channels using the rubber hose attachment for the vacuum These are accessible from inside the RCM cavity and by opening the upper access panels on the right side of the machine and removing the heater panel To remove the...

Page 199: ...aser window with both hands and carefully slide unit out of system 5 Place unit on flat surface with handle end up 6 Using lens paper and ethanol carefully clean optic To do so drop ethanol on the lens paper and dragging it across the optic Repeat as necessary until the lens is clean 7 Rotate window assembly over to clean the other side 8 Once unit is clean reinstall into machine 9 Tighten the fin...

Page 200: ...r transporters and tubes L If you run out of powder unexpectedly your overflow chute s and or screen s might be clogged Periodically check and clean the overflow chutes and screens The steps are the same for the right or left side overflow chutes 1 Exit Sinter then wait for the SLS system to cool down 2 Open the left or right side access doors on the SLS system enclosure See SLS System Features on...

Page 201: ... from the machine you now have access to the roller 7 Using a rag and alcohol clean the roller Cleaning the RCM Clean the RCM before preheating it See Cleaning the RCM on page 128 Checking the SLS system gauge panel Before you build always check the gauge panel to ensure that the flow gauges read as follows IR WINDOW N2 FLOW 2 to 3 L min LASER WINDOW N2 FLOW 5 to 8 L min COOLANT FLOW 4 to 5 L min ...

Page 202: ... of SLS system failure modes below COLOR MODE SLS SYSTEM STATUS Red Off Normal Steady An alarm is active Yellow Off Normal Steady A warning is active Flashing Safety override during service by a Field Engineer Green Off SLS system is powered off or not ready Steady Normal SLS system is okay operating normally Blue not used See Using the Stacklight in Sinter Help for Stacklight testing instructions...

Page 203: ...nics problem on CC board Time to add powder layer has been exceeded Part bed is too hot Temperatures not adjusted correctly 1 Adjust part bed heater offsets 2 Adjust part bed heater setpoints Time to add powder layer has been exceeded Part Bed is too hot Feeds too hot 1 Adjust bottom feed heaters so that some minor cracking occurs on the longest layers 2 Reduce duty cycle on top heaters 3 Lower th...

Page 204: ...Contact Customer Support Short Feed Clean exhaust filter Feed roller gap clogged Chunks in feed hopper are clogging feed roller gap Clean out feed hopper and overflows No powder in feed hopper IRS stalled not feeding powder Replace empty IPC Proximity sensors adjusted incorrectly Contact Customer Support 3D CSE Only Adjust proximity sensors Parts are weak Low laser power Laser window is dirty Chec...

Page 205: ...nect full IPC Overflow pinch valve leak Worn durometer rubber Contact Customer Support 3D CSE Only Replace rubber Part bed is melting Uneven part bed heating Thermocouple short circuit tripped breaker Contact Customer Support 3D CSE Only Check breakers and thermocouples Part bed is too hot during warmup Setpoint 100 C Part bed 150 C The piston is set to 150 and the Part bet is set to 100 and the p...

Page 206: ...Support Top part surface is rough Laser scanner problem Chiller not on Turn on Chiller If that does solve problem Contact Customer Support 3D CSE Only Make sure Chiller sensor is installed and working Roller is noisy leaves chatter marks across the part bed Problem with stepper driver software Contact Customer Support Can NOT do offline calibration blackbody never reaches high end of 2 point calib...

Page 207: ... Customer Support 3D CSE Only Clean DSP card contactors Do not have ability to start the inert process but no message A dependency has not been met Software bug Check all interlocks especially the laser lid Parts curling when scan time is long 1 min Long layer times scanning cause right heater duty cycle to go to 0 Use higher part bed setpoint and extend warmup SLS System Failure Modes continued F...

Page 208: ...tions BOS Features 210 BOS Overview 211 BOS Operator Controls and Indicators 212 BOS Components 215 BOS Safety 218 BOS Power Up Sequence 220 BOS Start up 221 Breakout Station mode operations 222 BOS Operating States 224 Using the BOS Main Menu 229 Using the BOS Setup Menu 230 Using the BOS Diagnostics Menu 233 Using the BOS Work Platform 239 Shutting Down the BOS 240 BOS Maintenance 241 BOS Troubl...

Page 209: ...tures BOS Door Air Curtain Powder Transport Hopper Operator panel Emergency Stop button RCM bay RCM raise lower switch Sifter Waste bag Rotating auger in hopper can crush and cut Do not operate with hopper grate removed Follow lockout procedure before removing grate for cleaning ...

Page 210: ...alled breakout To remove parts from a part cake you roll the cooled RCM into the BOS connect the RCM cable and gradually raise the part piston removing powder and parts as you go Unsintered part cake powder goes into the BOS powder transport hopper where it is sifted and either recycled back to the IRS or disposed of L You can find material specific information about breaking out and cleaning part...

Page 211: ...isplays the most recent status Occasionally the status will overshadow a warning or error message You can view the hidden message by pressing to hide the undesired status message It will reappear when the status changes again If there are multiple warning or error messages you can view each in turn by pressing Main About Setup Diagnostics LCD display Cancel Exit button Enter OK button Scroll butto...

Page 212: ...ton jog switch on the left inside wall of the breakout chamber to Raise the part cake during breakout Home lower the part piston after breakout optional recommended COLOR MODE BOS STATUS Red Off Normal Steady Stop error fault BOS trying to re establish lost network connection to IRS Yellow Off Normal Steady BOS has a warning condition as displayed on the LCD It will continue to service IRS request...

Page 213: ...the Stop position when you release it L When the part piston reaches its upper or lower limit its up or down motion stops automatically to prolong the life of the piston motor even if the switch is not in the Stop position After breakout before you remove the RCM from the BOS use the part piston jog switch to home the part piston i e lower it to its lowest position Lowering the part piston has the...

Page 214: ...opper The hopper receives part cake powder that you scrape into the work table grates on the right and left side of the RCM bay The hopper itself is below the larger grate on the right Powder that falls through the grate on the left lands on the left air slide The slide conveys powder to the hopper when air flow to the slide is turned on A motorized auger is at the bottom of the powder transport h...

Page 215: ...able reach reduces arm and back fatigue Before breakout after you dock and lock an RCM in the BOS place the work platform directly in front of the BOS To move the platform lift the right side until the wheels on the left side touch the floor then roll it like a hand truck The platform is designed to support one person weighing 113 kg 250 lb max BOS Pro 230 Work Platform The work platform provides ...

Page 216: ...ne dust from the BOS work chamber via a fixed duct hose The flexible vacuum duct arm enables you to remove glass media from SLS parts after you clean them in the optional Bead Blaster AIR Do not restrict clean air outlet The Donaldson Torit VS 1200 3 phase Dust Collector Dust Collector top view Dust Collector side view BOS top view Fixed vacuum duct hose ...

Page 217: ...n front of the BOS and between the end panels The BOS main door is designed for easy and comfortable access to the breakout area In order to accommodate some users a work platform may be acquired for easier access to the work area This platform is 228 9 mm 9 in high and can accommodate a maximum 114 kg 250 lb person The installation of the platform does not require any tools and is not physically ...

Page 218: ...hey may not be completely cooled before breakout The powder can be very hot prior to cooling Thermal protective gloves should be used if examining the RCM module or prematurely removing the parts or powder The RCM has moving parts They are reasonably protected from human contact Care must be taken not to place the hands or feet inside the lower perimeter of the RCM frame Never place a hand or foot...

Page 219: ...etwork connection L The yellow stacklight lamp is on while the BOS establishes a network connection The green light turns on when it does 3 After about 15 seconds the BOS displays In Standby While In Standby the air supply to the BOS is off all motors are off and no powder is transported Before you turn on the BOS make sure RCM cable is NOT connected to the RCM See BOS Operator Controls and Indica...

Page 220: ...waste drum 2 Press 3 If the BOS sifter is empty the BOS turns on the auger and sifter motors at the bottom of the hopper and attempts to fill the sifter If it can do so in less than 2 minutes it starts a RECYCLE or DISPOSAL powder transfer 4 If the sifter fills in less than 2 minutes then In RECYCLE mode the BOS enters the Waiting for IRS state and waits for the IRS to send it a request for powder...

Page 221: ...ifter motor shuts off and transport sequence begins The transport sequence takes about 2 minutes 1 Sifter air slide air flow turns on 2 The transporter fills until its level sensor switches on 3 Sifter air slide air flow turns off 4 Transporter plug valve closes 5 Transport air turns on does pressure check solids control air is modulated to keep transport pressure below its maximum limit Transport...

Page 222: ...el removed See image at right The left air slide air flow is only turned on in Breakout Station mode and only when hopper is empty level sensor off The left air slide air flow is off In Standby mode and when the hopper is full level sensor is on The auger and sifter motors are coupled They can be controlled separately but the BOS controls them as a pair and they always run together BOS sifter leve...

Page 223: ...en the POWDER TRANSPORT switch is OFF the BOS enters the Powder Xfer Off state If you turn the POWDER TRANSPORT switch to RECYCLE or DISPOSAL the BOS switches to the In Standby state Xfer to Sifter If you press in the In Standby state and the sifter is empty i e the sifter level sensor is off there s no powder to send the BOS enters the Xfer to Sifter state and runs the sifter until the sifter is ...

Page 224: ...fter state change summary THE BOS STATE CHANGES WHEN AND THE SIFTER FROM TO In Standby sifter motor off Xfer to Sifter sifter motor on You press Is empty Xfer to Sifter sifter motor on In Standby sifter motor off You do nothing Stays empty 2 minutes with sifter motor on Xfer to Sifter sifter motor on Waiting for IRS sifter motor off POWDER TRANSPORT switch set to RECYCLE Is full has powder to send...

Page 225: ...te from the Waiting for IRS state when the Sifter is full sifter level sensor on there s powder to send POWDER TRANSPORT switch is set to RECYCLE BOS receives a powder request from the IRS The BOS remains in the Recycling Powder state while there s powder to send After the sifter stays empty for more than 2 minutes the BOS changes to the Stopping state then the In Standby state Disposing Powder Th...

Page 226: ...the BOS enters the Stopping state it stops both these motors After the Stopping state the BOS returns to In Standby BOS in EStop The BOS enters the BOS in EStop state when the E Stop button is pressed or when a BOS safety interlock fails or is disabled The BOS remains in this state until the unsafe condition is removed and either the emergency stop button is reset or the safety interlock is enable...

Page 227: ...he BOS reverts to In Standby state Dispose Error The BOS displays Dispose Error if it detected an error when transferring powder to the waste powder drum After you press to acknowledge the error the BOS reverts to In Standby state Only use E stop to shut down the BOS in an emergency Shutting down the BOS with E stop can result in data loss and material waste Recycling Error Recycling Error display...

Page 228: ...ption then press To view BOS software version From the Main menu choose About then press The BOS software version number and date appears Press to return to the Main menu To access BOS Setup or Diagnostics menus From the Main menu choose Setup or Diagnostics then press The BOS Setup menu or Diagnostics menu appears Main About Setup Diagnostics Main menu display FW Ver R13 03 MAC 0000000002 Build 2...

Page 229: ... option then press To access the Process Params menu Use the Process Params menu to view and change the BOS RCM Com Mode and RCM Type process parameters From the Setup menu choose Process Params then press The Process Params menu appears Press to choose the process parameter you want to set then press BOS engineering parameters on the Eng Params menu should only be changed by 3D Systems certified ...

Page 230: ...ing or press to keep the setting as is and return to the Process Params menu SET RCM TYPE Use the RCM Type process parameter to specify which type of RCM is connected to the BOS an RCM 140 or a taller RCM 230 1 From the Process Params menu choose RCM Type then press The currently selected RCM Type appears 140 or 230 2 Use to change the type to 140 or 230 Be sure to match the type of RCM actually c...

Page 231: ...XTIME PARAMETERS Use the MaxTime operation_name engineering parameters to set the timeouts for various BOS powder transfer operations 1 From the Eng Params menu choose a MaxTime operation_name parameter then press The current value of the MaxTime operation_name parameter appears for example 1000 for MaxTimeStopLVFlow 2 Use to increase or decrease the MaxTime operation_name timeout setting 3 Press ...

Page 232: ...ght lights To select Diagnostic menu options From the BOS Main menu select Diagnostics The Diagnostics menu appears Press to choose an option then press To access the Input Status menu Use the Input Status menu to view and change the status of BOS inputs From the Diagnostics menu choose Input Status then press The Input Status menu appears Press to choose the input you want to view or change then ...

Page 233: ...imit the Move RCM Up Down input status changes to OFF automatically to prolong the life of the piston motor BOS INPUT STATUS OPERATION Move RCM Up ON Raises part piston while RCM Present input is ON the RCM Power Relay output is ON and RCM is connected to BOS OFF Stops part piston from moving up Move RCM Down ON Lowers part piston while RCM Present input is ON the RCM Power Relay output is ON and ...

Page 234: ...Move RCM Up or Move RCM Down input in the ON state the piston will move to its upper or lower limit until you change the status back to OFF before it reaches To access the Force Output menu Use the Force Output menu to view and change the status of BOS outputs From the Diagnostics menu choose Force Output then press The Force Output menu appears L If you see an Access Denied display at this point ...

Page 235: ...lve ON Opens the BOS s air cylinder valve OFF Closes the BOS s air cylinder valve IRS Pch Valve Horz ON Same as moving the operator panel rotary switch to RECYCLE Opens the BOS s horizontal IRS pinch valve on the used powder transport line between BOS and IRS OFF Same as moving the operator panel powder transport switch to OFF Closes the BOS s horizontal IRS pinch valve on the used powder transpor...

Page 236: ...tch the RCM Power Relay or individual Stacklight lamps off or on The outputs on the General Outputs submenu under the Force Output menu perform the BOS operations below Air Cyl Valve display Air Cyl Valve OFF BOS OUTPUT STATUS OPERATION RCM Power Relay ON Switches on closes the RCM power relay supplying power to the part piston motor on the RCM connected to the BOS OFF Switches off opens the RCM p...

Page 237: ...s 4 Press to save the status or press to keep the status as is and return to the General Outputs menu If you saved a Lamp Color output in the ON state the corresponding color Stacklight lamp will remain lit until you change the output status back to OFF If you saved the RCM Power Relay output in the ON state the you will be able to move the part piston subject to the state of the BOS s RCM inputs ...

Page 238: ...ly in front of the BOS To move the platform lift the right side until the wheels on the left side touch the floor then roll it like a hand truck Before breakout after you dock and lock an RCM in the BOS place the work platform directly in front of the BOS To move the platform lift the right side until the wheels on the left side touch the floor then roll it like a hand truck The platform is design...

Page 239: ... is being raised or lowered Sifting Network communications with other SLS process machines You must shut down the Dust Collector separately You can do this at any time by simply turning off the Dust Collector s power switch To shut down the BOS properly 1 If the BOS is currently transferring powder to the IRS wait until the BOS operator panel says Powder Xfer Complete 2 Press repeatedly until the ...

Page 240: ...the hopper table surface Remove the grate and set aside Do not operate the machine while the grate is removed 3 After servicing the machine replace the grate and make sure the grate is flush with the table top Tighten the two captive screws until completely engaged Look into the hopper to be sure no tools or any foreign objects other than powder are left inside Disengage the e stop by rotating the...

Page 241: ...f Bounds Value entered is outside valid range For example the Percent Virgin must be greater or equal to 30 and less than or equal to 100 Enter value that is within range RFID Factory Tag Error RFID Tag information is corrupted Contact 3D System Customer Support RFID Update Tag Error RFID Tag Updated Information not valid Expired Material IPC Powder has expired ...

Page 242: ...cts and solutions that help reduce the time and cost of designing products and facilitate direct and indirect manufacturing Its systems utilize patented technologies that create physical objects from digital input 3D Systems also offers the InVision 3 D printer SLA systems stereolithography as well as related material software and application solutions 3D SYSTEMS CORPORATION 333 Three D Systems Ci...

Page 243: ... in return for ongoing receipt of improvements It is the responsibility of the Licensed User to provide 3D Systems with current information as to its name and address The Licensed User also undertakes to notify 3D Systems promptly in the event that it considers any of the data contained in this document to be incomplete or erroneous in any respect in connection with Licensed User s particular use ...

Page 244: ...s 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 with under actual operating conditions and 3D Systems undertakes no responsibility in these areas IN NO EVENT WILL 3D SYSTEMS BE RESPONSIBLE FOR DAMAGES OF ANY NATURE INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OF OR R...

Page 245: ...the following spreads a powder wave and heats it to feed temperature feeds powder to a new layer heats powder on the part bed to process temperature and then holds the part bed temperature constant while the layer is scanned advisory A type of Sinter application message color code yellow You must acknowledge an advisory It can turn into an alarm if the cause it is not corrected airslide Air assist...

Page 246: ...BOS work table The auger grinds part cake powder to be recycled before it dropping it into the BOS sifter B batch One unit of blended virgin powder and used powder stored in the IRS Blender bin A batch has a specific Percent Virgin and weight e g 5 kg for DuraForm PA The IRS blends one batch at a time beam See laser beam beam delivery system All the optical components of the SLS system including t...

Page 247: ...It stores the powder blend until the SLS system requests a refill BOS Breakout Station The machine used for breakout in the SLS process The BOS can be set to recycle or dispose of used powder after breakout When set to RECYCLE the BOS sifts used powder then sends it to the Used bin on the IRS When set to DISPOSAL the BOS sends used powder to the waste powder container bounding box In the Build Set...

Page 248: ...t a build packet bpf file build packet archive A compressed Exported bpz file containing a build packet and its associated files A build packet archive can also contain the sorted facet file and attached notes for a build packet You must import a build packet archive before you can use the build packet it contains in a build build parameter A property of a build with a default profile you can chan...

Page 249: ...ylinder walls and leaves room for unsintered layers at the top and bottom of the part cake Unsintered layers form a base for parts in a build and thermally insulate the top and bottom of the part cake C CC box Chamber Controller electrical electronics cabinet on the upper left side of the SLS system MSM The CC box controls motion sensors and atmosphere in the PCM certified service personnel Anyone...

Page 250: ...insufficiently preheated part bed Post build curl happens when different regions of a part cool down at different rates Controlled cooldown helps prevent post build curl curling See part curling cylinder See part cylinder D damper The hinged metal plate below the laser window at the top of the process chamber beam shaft When closed it blocks the laser beam from entering the process chamber and hel...

Page 251: ...r building SLS parts in SLS systems Dust Collector Auxiliary machine with a vacuum air duct and removable filter used in the SLS process The Dust Collector connects to the BOS and removes airborne powder from the area above the BOS work table E E stop button EMERGENCY STOP button Any one of several large red buttons mounted on the SLS system Pressing any E stop button shuts down the SLS system imm...

Page 252: ... powder dispenser at the bottom of the feed hopper fill Overlapping parallel vectors that make up the horizontal surface of a slice in a part build Fill Scan Spacing also laser scan spacing On the part bed the distance between adjacent scan lines G galvanometer A small motor that moves one of the two X and Y axis scanning mirrors that deflect the laser beam The motorized scanning mirrors are often...

Page 253: ...hamber inert 5 5 oxygen or less depending on the material to prevent powder oxidation and combustion inerting Lowering the oxygen level and raising the nitrogen level in the process chamber Inerting occurs in the Warmup stage of a build Before the build can advance to the Build stage the process chamber must be inert While inerting the SLS system delivers maximum nitrogen flow purge flow to the pr...

Page 254: ...ensor detects the emissivity of infrared energy at the part bed and maps it to part bed temperature based on the most recent IR sensor calibration IRS Integrated Recycling Station Mixes new virgin powder from the IPC with used powder from a part cake and transports it to the SLS system feed hopper on demand IRS umbilical Flexible 5 meter harness of powder tubing compressed air lines and electrical...

Page 255: ...r it records information in these files continually adding new information as the application runs LPC Lower Process Chamber see process chamber LPM Liters Per Minute the unit of coolant and nitrogen flow in the SLS system LS software Laser Sintering software Applications including Build Setup and Sinter utilities and data files you install on the SLS system computer You use the LS software to set...

Page 256: ...ef color coded text notification that appears in the Sinter application s Message List window Messages keep you informed about SLS system activity New messages always appear at the top of the list The message colors are black information yellow advisory or warning red alarm mode An operating state of the Sinter application software Sinter has three modes Main mode Build mode and Manual Operations ...

Page 257: ...which occurs only during service procedures operator A person trained by 3D Systems to operate the SLS system and all other SLS equipment and to perform all tasks associated with build preparation building parts and breakout Also called a user outline The process of sintering the perimeter of a part before or after sintering the fill of the part on each layer of powder Outlining increases accuracy...

Page 258: ...ial batch is also 60 virgin The IRS only blends a partial batch when there is insufficient virgin or used powder for a full batch It makes the largest partial batch possible using all the limiting amount of powder part cake The block of hot loose used powder and parts in the part cylinder after a build After the part cake cools parts are removed from it in breakout The BOS can be set to recycle or...

Page 259: ...o adhere to the sintered layers and cause the part to exceed its designed dimensions part parameter A part scanning property with a default profile you can change in Build Setup s Part Profile Editor part piston Heated platform that supports the part cake and moves up and down inside the part cylinder during builds and breakout part piston heater The heater under the part piston top plate that hea...

Page 260: ...e roller transports and levels powder from the feed hopper across the powder bed Powder Management System PMS network and database application that enables powder transfers between SLS equipment logs data about every transfer and helps prevent contamination of the SLS system powder supply PowderNet 3D Systems proprietary network that interconnects SLS equipment and carries powder transfer messages...

Page 261: ... a build the atmosphere inside the process chamber is inert and warmed by the heaters The IPM delivers the laser beam through the laser window then down to the part bed profile The set of values assigned to a parameter based on Z height or X Y Z location A build packet contains profiles for part parameters build parameters and scale parameters Profiles can be saved to disk for reuse in multiple bu...

Page 262: ...such as IPC serial number expiration date IRS machine ID current IPC weight etc roller The device in the process chamber that spreads and levels powder across the powder bed and part bed In each Add Powder Layer sequence the powder dispenser dispenses powder on top of the roller cover The roller moves under a scraper which scrapes powder off the cover and deposits it between the powder heaters It ...

Page 263: ...cess by which the laser beam is deflected onto the part plane in order to sinter a part scanning mirrors Mirrors moved by the galvanometers that direct the CO2 laser beam during selective laser sintering SLS scrapers Blades that clean the powder from the roller as it travels across the part bed selective laser sintering See SLS setpoint A value for a particular parameter established by a configura...

Page 264: ...sPro 140 and sPro 230 SLS Selective Laser Sintering A thermodynamic process in which directed laser energy heats particulates in a defined pattern fusing them into a solid mass SLS is one of several 3D Systems rapid manufacturing and prototyping technologies SLS is and integral part of 3D Systems SLS process that creates solid parts from 3 D CAD files It makes parts by rolling a thin layer of powd...

Page 265: ... file SPI Serial Peripheral Interface One of two BOS RCM communications modes set using the BOS RCM Com Mode process parameter stage One of three separate consecutive states of a build Each stage has a separate build profile Standby mode The mode in both the IRS and BOS in which air flow is shut off and powder transfers are disabled All other functions such as setup and diagnostics are available i...

Page 266: ...HT button two USB Universal Serial Bus ports and service access keyswitch UPC Upper Process Chamber part bed heaters and IR sensor w blackbody O2 sensor Used bin On IRS top left rear corner receives used powder from the BOS when the BOS is in RECYCLE mode and stores it for blending with virgin powder The IRS transfers used powder from the Used bin to the Blender bin one batch at a time The Percent...

Page 267: ...build stages The warmup stage defines the first portion of the build profile which applies to unscanned layers added before the Build stage warning A type of Sinter application message color code yellow You must acknowledge a warning An warning can turn into an alarm if the condition that caused it is not corrected For more information see the Messages and the Message List Window topic in Sinter H...

Page 268: ...ity requirements 51 IRS IPC 134 laser safety and classifications 20 Message List window in Sinter application 77 part cake cooldown 91 Powder Management System 52 safety 9 service maintenance laser 196 SLS system 196 SLS equipment 49 SLS system 184 this User s Guide 2 3 About menu option view software version for BOS 228 IRS 156 adding SLS process capacity 53 air valves BOS manually testing 232 Ai...

Page 269: ...tenance 240 noise level 19 operating states 223 operator controls and indicators 211 powder transport 146 POWDER TRANSPORT switch 6 power up sequence 94 RCM Com Mode 230 RCM Type 230 safety 217 Setup menu 229 accessing 228 229 shutdown 100 239 software version display 228 stacklight lamp test 237 stacklight states 212 troubleshooting 241 Valves menu 235 237 work platform 238 breakout fininshing pa...

Page 270: ...r RCM cable 104 106 110 calibration IR sensor about 85 disabling automatic 85 manual 85 checking SLS equipment 59 Chemtrec phone numbers 36 classifications laser safety 20 cleaning overflow chute screens SLS system 59 RCM 128 SLS equipment 59 the IR sensor SLS system 59 the process chamber SLS system 59 the roller SLS system 59 contacting 3D Systems Customer Support 242 Sales and Service 242 curl ...

Page 271: ...S process 3 Facility Layout SLS process 3 feed hopper SLS system 50 134 filters exhaust SLS system 204 HEPA on waste powder drum 240 Nitrogen Generator 201 Force Output menu option BOS Diagnostics menu 234 open close valves 235 stacklight lamps on off 237 G gauge panel AIR INLET for compressed air 63 COOLANT FLOW meter setting 63 193 COOLANT INLET pressure gauge 63 193 diagram 182 187 IR WINDOW N2...

Page 272: ... hot surfaces and powders safety 35 I IEC 60825 laser safety 20 Integrated Recycling Station See IRS Intelligent Powder Cartridge See IPC IPC connecting to IRS 163 description 147 features 137 ground cable 30 37 65 66 148 150 154 168 177 safety 150 receiving inspection 36 status 67 169 transporter status 159 unloading 65 IR sensor calibration 85 disabling automatic calibration 85 manual calibratio...

Page 273: ...laser certification 24 machine I D 24 labels safety locations 22 23 34 types 15 language display selecting 78 laser certification label 24 classifications 20 radiation safety 20 safety 20 Class IV 20 service and maintenance 26 196 LASER WINDOW N2 FLOW on gauge panel 59 201 load RCM 129 in BOS for breakout 96 in SLS system before build 75 129 used powder from BOS into IRS 170 virgin powder in IRS f...

Page 274: ... Man Ops Material Guide DuraForm 8 Material Safety Data Sheet See MSDS DuraForm menus operator panel Message List window Sinter application 11 113 Mode Standby BOS 94 219 228 modifying build in progress 87 MSDS DuraForm 3 7 13 28 N Nitrogen Generator cables and filters 201 maintenance 201 service 201 nitrogen oxygen safety 32 noise level BOS 19 Dust Collector 19 IRS 19 SLS system 19 O open beam op...

Page 275: ...uild Profile editing 57 87 Part Profile editing 57 part cake cooldown 93 load raise in BOS 96 part piston homing 76 Part Profile parmeters editing 57 pausing a build 86 Pist I and I1 I4 output current RCM heater 108 126 Piston Control in Sinter exe 72 platform BOS work 238 platforms SLS 56 powder blending 166 L valve on IRS 143 manifold on IRS 143 144 safety 28 storage guidelines 36 transfer hoppe...

Page 276: ...tem 191 pre build checklist 70 preheating RCM 68 115 129 process parameters BOS RCM Com Mode 230 RCM Type BOS parameter 230 Process Params menu BOS 229 profiles build parameters editing 57 cooldown on RCM 119 part parameters editing 57 R radiation safety laser 20 RCM build heights 49 184 cable disconnect before moving 10 112 on SLS system 108 130 remote RCM heater power 105 socket RCM 104 106 110 ...

Page 277: ...rgets 116 test manually 126 recycle used powder 98 restarting a terminated build 82 roller homing 76 running a build 81 the Sinter application 74 S safety electrical 17 E stop locations and effects 40 general guidelines 10 hot surfaces and powders 35 IPC 150 handling 36 IRS 14 36 150 labels on SLS equipment 15 laser 20 Class IV 20 nitrogen oxygen 32 powder 28 RCM 112 warning symbols 5 service 195 ...

Page 278: ...xiting 48 homing part piston and roller 76 Manual Operations Man Ops 62 72 to load RCM 75 online Help in application 3 8 11 46 70 113 189 202 run 62 74 after dspif initializes 62 74 to load RCM 69 running 47 48 58 61 running Build Setup from 7 starting a build in 72 utilities 189 SLS equipment checking 59 cleaning 59 emergency shutdown 40 environmental issues 18 safety features 12 labels 15 starti...

Page 279: ...ation 11 113 BOS 237 states BOS 212 IRS 153 SLS system 202 testing lamps BOS 232 237 standalone Build Setup 56 Standby mode BOS 219 228 starting a build 72 BOS 220 IRS 154 SLS equipment 60 SLS system 191 STL file 45 56 storage guidelines 36 support contacting 3D Systems 242 T third party software 189 transporter powder IRS 143 status IPC 159 status IRS 159 transporting powder IRS to SLS system 165...

Page 280: ... s s 2 8 0 I N D E X u s e r s g u i d e V A B C D E F G H I J K L M N O P Q R S T U V W X Y Z V view build in progress 83 Virgin bin IRS 66 67 135 137 139 140 capacity 136 status 159 virgin powder loading 163 167 W ...

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