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EOS P 396, Training Manual

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9

Troubleshooting and maintenance

9.12

Training manual • Basic training • Status 03.14

EOS P 396

Recoater level not optimal

If the powder level in the recoater is not optimal, the following problems can be 

caused:

➢

Lack of powder on blank layers with large areas

➢

Powder level in the recoater drops/rises from layer to layer

➢

Amount of powder in the collector bins is insufficient/excessive

➢

Large "bow wave" in front of the leading recoater blade

This situation can result in quality problems on the part, in particular in relation to 

part strength.

A Powder in the recoater: 

Optimal level

B Powder in the recoater: 

Level too high

C Powder in the recoater: 

Level too low

1 Recoater blade

Summary of Contents for P 396

Page 1: ...1Training manual 1EOS P 396 1Installation ConditionBasic training ...

Page 2: ......

Page 3: ...1EOS P 396 1Laser sintering system for plastics ...

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Page 5: ...information on the laser sintering process 2 1 Physical process 2 1 Building process 2 2 Factors that affect the laser sintering process 2 3 Building temperature 2 3 Exposure 2 5 Exposure types 2 7 Process related effects 2 8 Shrinkage 2 8 Distortion 2 10 Ambient conditions 2 11 3 Layout function of machine and accessories Machine 3 1 Layout 3 1 Overview 3 1 Front of machine open 3 2 Rear of machi...

Page 6: ... 3 11 Unpacking stand 3 12 Layout 3 12 Function 3 12 Shot peening cabinet 3 13 Layout 3 13 Function 3 13 IPCM EOSINT P 3 3 14 Overview 3 14 Layout 3 14 Function 3 14 Powder conveying system P 3 3 15 Layout 3 15 Function 3 15 Unpacking and sieving station P 3 3 16 Layout 3 16 Function 3 16 Powder conveying vibro kit 3 17 Layout 3 17 Function 3 17 Extension powder conveying 3 18 Layout 3 18 Function...

Page 7: ...ing the powder 4 4 Mixing the powder 4 4 Storage of the powder 4 5 Problems when handling powder 4 6 Electrostatic charging of the powder 4 6 Separation of filled plastic powder 4 7 Material machine compatibility 4 7 5 Part Property Management Introduction 5 1 Parameter sets 5 2 Original EOS parameter sets 5 3 Exposure types for the original EOS parameter sets without PPP 5 3 PPP parameter sets 5 ...

Page 8: ...pairing parts 6 9 Repairing parts with the Fix Wizard 6 9 Orientating parts 6 10 Orientating parts using the Rotate button 6 11 Orientating parts using the Bottom Top Plane button 6 11 Positioning parts 6 13 Positioning parts using the Translate button 6 16 Generating a sinter box 6 17 Reducing triangles 6 19 Saving processed parts using a new name 6 20 Preparing parts using the Build Processor 6 ...

Page 9: ...rt specific shrinkage 7 11 Setting part specific beam offset 7 11 Setting exposure type 7 12 Saving a job 7 12 Calculating the building time 7 12 Preparing building process 7 13 Build 7 13 Monitoring building process using EOSTATE 7 14 Setting up connection 7 14 Monitoring building process using Basic module 7 15 Monitoring building process using Quality Assurance module 7 16 Monitoring building p...

Page 10: ...figuration 8 5 Documenting building process using the PSW 8 6 Documenting building process using EOSTATE 8 7 Exporting job data 8 7 Recording building temperature 8 7 Displaying preparing results reports statistics 8 8 Backing up archiving database 8 10 9 Troubleshooting and maintenance Troubleshooting 9 1 Machine 9 1 Scoring in the surface of the powder 9 2 Curling of exposed surfaces 9 5 Cracks ...

Page 11: ...0 7 Training manual Basic training Status 03 14 Contents EOS P 396 0 Accessories and Options 9 17 IPCM EOSINT P 3 9 17 IPCM P plus 9 17 ...

Page 12: ...0 Contents 0 8 Training manual Basic training Status 03 14 EOS P 396 ...

Page 13: ...1 1About this manual ...

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Page 15: ...a on materials safety instructions on the use of the machine as well as instructions for the operation of the machine are in the Operating instructions for the machine the material data sheets and safety data sheets the parameter sheets as well as in the manuals on the operation of peripheral software Conventions Representations Terms from menus buttons options check boxes functions terms from dat...

Page 16: ...oning of materials for the operation of the machine with the components mixing qualification station MQS docking station and multibox PPM is used to refer to the Part Property Management an EOS concept that standardises and makes reproducible the building processes and results of building for e manufacturing OEP is used to refer to the Original EOS Parameter sets parameter sets approved and licens...

Page 17: ...lding temperature exposure types etc for the processing of a material with a machine Pictograms Safety warning in this manual Notice Draws your attention to information that you should note Warning Indicates the possibility of minor injury the possibility of damage to the machine or its accessories and of possible problems related to the parts quality Warning of hot surface Wear protective gloves ...

Page 18: ...e all the relevant information to hand including Machine type Machine serial number Software version number Process software PSW EOSTATE Telephone 49 0 89 893 36 151 Fax 49 0 89 893 36 196 Address EOS GmbH Electro Optical Systems Robert Stirling Ring 1 D 82152 Krailling München E mail servicehotline eos info Homepage www eos info ...

Page 19: ...2 2Laser sintering process ...

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Page 21: ...CO2 laser During the laser sintering process the plastic powder is briefly heated to a temperature above the melting point by exposure with the laser beam A solid body is produced by this heating and the subsequent cooling In each layer the cross section of the parts is exposed using the laser beam such that the exposed areas are joined to the layer underneath that has already been solidified In t...

Page 22: ...ase is complete the automatic building process starts By exposure using a computer controlled laser beam the plastic powder is solidified to suit the calculated part geometry data Then the building platform is lowered by one layer thickness and a new layer of plastic powder applied The plastic powder is exposed again the building platform lowered and plastic powder applied This process is repeated...

Page 23: ...mperature A prerequisite for a trouble free laser sintering process is the optimum building temperature The recommended building temperature is listed in the parameter sheet for the machine and is dependent on the machine type and the plastic powder used At an excessively low building temperature the outer areas of a layer roll upward This behaviour is called curling The building temperature must ...

Page 24: ...ecreased in steps until the effects no longer occur An indicator for the optimal building temperature is the consistency of the plastic powder in the cooled exchangeable frame and during the unpacking of the parts Using your finger press several points on the surface of the bed of powder The surface of the bed of powder must not be solidified The consistency of the plastic powder should be loose a...

Page 25: ... powder forms around the laser beam For the dimensional accuracy of parts the size of the curing zone must be taken into account during exposure It is dependent on the powder material used and the exposure type selected The dimensional variation is compensated by offsetting the laser beam 1 2 A 1 Kontur Contour 2 Contour line centre of the path of the laser beam for the exposure of the contour A H...

Page 26: ...ure the contour of the part is enlarged by the radius of the curing zone of the laser beam The beam offset compensates for this contour enlargement It displaces the centre of the path of the laser beam inwards A B 1 2 3 1 Actual contour without beam offset 2 Nominal contour with beam offset 3 Centre of the path of the laser beam 4 Beam offset A Exposure of contour without beam offset B Exposure of...

Page 27: ...e type can be allocated to any part 2 1 3 1 2 4 A B C 1 Actual contour without beam offset 2 Nominal contour with beam offset 3 Centre of the path of the laser beam exposure of enclosed area of the layer 4 Centre of the path of the laser beam exposure of contour 5 Beam offset A Exposure of enclosed area of the layer without beam offset B Exposure of enclosed area of the layer with beam offset C Ex...

Page 28: ...e building chamber contribute to improving the part quality Along with these factors that can be influenced process related phenomena such as temperature related shrinkage or distortion must also be taken into account Shrinkage During cooling the part contracts due to physical processes and becomes smaller This shrinkage behaviour varies depending on the material used and can be of varying magnitu...

Page 29: ...ge In the PSW the building height dependent shrinkage Z direction is compensated automatically During this process the linear Z compensation is calculated using the two scaling values Z 0 and Z 600 A Shrinkage behaviour in the exchangeable frame in X Y direction B Shrinkage behaviour in the exchangeable frame in Z direction The shrinkage behaviour can be positively influenced by the optimal settin...

Page 30: ...art too little plastic powder is applied at the outer edges the part lacks material in this area Distortion during the cooling phase Failure to comply with the recommended cooling time removing the exchangeable frame too soon or premature opening of the removal chamber door will result in the overall job cooling down too quickly For physical reasons the part cools down unevenly from bottom to top ...

Page 31: ...nce with the ambient conditions can result in malfunctions in the building process as well as damage to the machine and to the accessories Room temperature too high Overload of the Cooling system Inadequate cooling of the optical assemblies Formation of condensed water on cooled assemblies Room temperature too low Longer warming up of the machine to the building temperature Formation of condensed ...

Page 32: ...2 Laser sintering process 2 12 Training manual Basic training Status 03 14 EOS P 396 ...

Page 33: ...3 3Layout function of machine and accessories ...

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Page 35: ...chine and accessories 3 1 Training manual Basic training Status 03 14 EOS P 396 3 Layout function of machine and accessories Machine Layout Overview 2 1 3 4 1 Front valve 2 Front doors 3 Switching cabinet 4 Control terminal ...

Page 36: ...nual Basic training Status 03 14 EOS P 396 Front of machine open 3 4 5 6 3 7 5 1 2 1 Process chamber 2 Removal chamber 3 Powder supply bin 4 Process chamber door 5 Collector bin 6 Removal chamber door 7 Exchangeable frame 1 Exchangeable frame 2 Building platform ...

Page 37: ...s 3 3 Training manual Basic training Status 03 14 EOS P 396 3 Rear of machine open 3 2 5 6 7 4 1 1 X axis cover 2 Laser 3 Laser terminal box 4 Nitrogen generator 5 Scanner ventilation hose 6 Machine terminal boxes 7 Cooling system terminal box ...

Page 38: ...P 396 Left of machine open 1 Pneumatic service unit 2 Air supply for laser deflection head ventilation 3 NITROGEN FLOW RATE manometer 4 FLUIDISATION manometer 5 Compressed air connection 6 Fine filter 7 Coarse filter 8 NITROGEN FLOW RATE flowmeters 9 SEALING AIR flowmeter 10 FLUIDISATION flowmeters ...

Page 39: ...tus 03 14 EOS P 396 3 Front of switching cabinet 1 5 3 4 2 7 6 8 1 RECHARGEABLE BATTERY LOW indicator 2 SERVICE key operated switch 3 LASER key operated switch 4 LASER READY indication 5 SHUTTER OPEN indicator 6 ACKNOWLEDGE EMERGENCY STOP button 7 EMERGENCY STOP button 8 MAIN SWITCH ...

Page 40: ...ing cabinet open 2 1 3 4 5 7 8 9 6 10 1 Controller 2 Circuit breakers 3 Motor cut outs 4 Stepper motor final stages with integrated PLC Posimo 5 Laser power supply unit 6 Fuses 7 Eurotherm universal regulators Process chamber 8 Eurotherm universal regulators Removal chamber 9 Exposure hours counter 10 Process computer ...

Page 41: ...Layout function of machine and accessories 3 7 Training manual Basic training Status 03 14 EOS P 396 3 Rear of switching cabinet open 1 3 2 1 Mains filter 2 Cooling unit 3 FI PROTECTION SWITCH ...

Page 42: ...steering with 3 deflection mirrors The laser deflection head The pyrometer Hazard due to invisible laser radiation The irradiation of eyes or the skin by direct or scattered radiation will cause severe burns The optics chamber is only permitted to be opened by EOS service personnel A 3 4 5 3 2 1 A Machine with open optics chamber 1 Shutter and deflection mirror cover 2 Laser 3 Powder supply bin to...

Page 43: ...wered by one layer thickness and a new layer of plastic powder applied The computer controlled laser beam then exposes the contours and the areas enclosed by the contours in accordance with the part data defined The final building height is produced by the continuous repetition of layer by layer application of powder and exposure The machine can be filled with plastic powder manually or automatica...

Page 44: ...oled in the Cooling system s condenser by the air drawn in The air is heated and is discharged to the surroundings again via a fan on the rear of the Cooling system Water water Cooling system In the condenser the refrigerant is cooled by cooling water from the internal cooling system in the building The cooling water in the internal cooling system in the building is heated and leaves the Cooling s...

Page 45: ...ut Function The Lifting truck is a manual forklift truck with a winch for removing the exchangeable frame With the aid of the special lifting fork the machine s exchangeable frame can be picked up with the Lifting truck 2 6 1 7 3 4 5 1 Handle 2 Lifting mast 3 Roller 4 Fork roller 5 Lifting slide 6 Lifting fork 7 Hand crank ...

Page 46: ...ejection ram and lowered The building platform sits on the ejection ram In this way the parts are pressed out of the exchangeable frame Loose plastic powder and parts are collected in a tray that sits on the exchangeable frame Two spiral hoses on the tray each feed the plastic powder to a used powder bin A Unpacking stand B Lifting truck 1 Tray 2 Used powder bin 3 Connection for Vacuum cleaner 4 E...

Page 47: ...d Cleaning is undertaken using pure compressed air or with the addition of shot peening medium The shot peening medium is applied at a pressure of 2 4 bar to the part to be cleaned using a shot peening gun The shot peening pressure can be adjusted as required 1 Door catch 2 MAIN SWITCH 3 Viewing window 4 Openings with gloves 5 Shot peening medium hopper 6 Shot peening medium hose 7 Pedal 8 Left ca...

Page 48: ...cost effective manufacture of parts in an industrial environment The IPCM EOSINT P 3 with automated powder conveying and Unpacking station with powder recycling makes possible ergonomic working conditions with little dust Together with the exchangeable frame system optimal machine utilisation and a high level of automation is provided A Spiral conveyor B Machine C Dosing station D Unpacking and si...

Page 49: ...The mixture ratio between new and recycled powder can be adjusted on the switching cabinet for the dosing station The Powder conveying system P 3 can be operated automatically and manually and has a dedicated controller that operates independent of the controller for the machine 1 New powder bin 2 Spiral conveyor 3 Conveyor motor 4 Spiral hose filling 5 Switching cabinet with control panel 6 Recyc...

Page 50: ...ction of dust on unpacking the parts In the unpacking element the sintered parts can be removed from the exchangeable frame for the P 3 Used powder produced during this process is passed to the sieving element where it is sieved via the used powder hopper The recycled powder produced can then be refreshed and used for a new building process 1 Hand lever for building platform carrier 2 Covering hoo...

Page 51: ...e dosing station The ball vibrators in the conical inserts are operated with compressed air Their vibration improves the flow properties of certain plastic powders and as a result ensures an even flow of new and recycled powder through the dosing station for the Powder conveying system to the spiral conveyor 1 Compressed air line for Powder conveying vibro kit 2 Conical insert with ball vibrator 3...

Page 52: ... can be connected to the Powder conveying system The plastic powder transported by the Powder conveying system is transported by the Extensions powder conveying to the powder supply bins or dispensers on the machines connected A Powder conveying system B Machine 1 C Switching cabinet 1st Extension powder conveying for machine 2 D Machine 2 E Switching cabinet 2nd Extension powder conveying for mac...

Page 53: ...Unpacking and sieving station P 3 A Unpacking and sieving station P3 B Powder conveying system P 3 C Recycled powder conveying 1 Switching cabinet with control panel Recycled powder conveying 2 Recycled powder bins 3 Spiral conveyor Powder conveying system 4 Waste bin 5 Inlet pipe Recycled powder conveying hidden 6 Spiral conveyor Recycled powder conveying 7 Switching cabinet with control panel Po...

Page 54: ...ced during the unpacking of the sintered parts can be sieved The plastic powder collected in the recycled powder bin can then be used for a new building process mixed with new powder The oversized grains in the sieve must be removed as necessary using an explosion protected vacuum cleaner of type B1 5 6 4 3 2 1 1 Sieve insert sieve frame 2 Hopper 3 Recycled powder hose 4 Recycled powder bin 5 Siev...

Page 55: ...ed mixture ratio of new to recycled powder The mixing qualification station MQS doses mixes and conditions plastic powder for laser sintering applications The basic principle comprises the precise gravimetric dosing mixing homogenisation and moistening of the plastic powder to be mixed i e of the new powder and the recycled powder A B C D A Mixing qualification station MQS B Multibox C Docking sta...

Page 56: ...esults without the need to discharge the power mixture The prepared refreshed powder is transferred to a multibox mobile container For this purpose a multibox is pushed under the mixing bin and coupled In the base of the mixing bin there is a valve for discharging the powder The level in the multibox is monitored via a powder sensor in the MQS The discharge of the powder into the multibox is contr...

Page 57: ...unction of machine and accessories 3 23 Training manual Basic training Status 03 14 EOS P 396 3 the powder discharge as soon as the active seal is released the multibox can be pulled out of the docking station ...

Page 58: ...3 Layout function of machine and accessories 3 24 Training manual Basic training Status 03 14 EOS P 396 ...

Page 59: ...4 4Basic information on materials ...

Page 60: ......

Page 61: ...wder sieved recycled powder Refreshed powder Mixture of sieved used powder recycled powder and new powder Waste Residue from the sieve or plastic powder that has already been removed on unpacking the parts Damage to the powder during the building process During the building process the plastic powder is damaged by two effects Baking of the powder grains During the building process the plastic powd...

Page 62: ...critical in relation to ageing The damage to the plastic powder in the exchangeable frame varies depending on the position in the exchangeable frame Powder in the middle of the building area is damaged more than powder at the edge of the building area The temperature in the middle of the building area is higher than at the edges as a consequence the powder is damaged more in the middle Powder in t...

Page 63: ...ainst this background the plastic powder should be coarsely separated on unpacking such that only the amount required for mixing with the new powder is left If e g the desired refresh factor is 50 and the volume of the parts built is approx 15 approx 35 of the powder from the exchangeable frame can be removed based on the rules given above On building with materials that are not refreshed it is no...

Page 64: ...he energy applied by the laser due to the greater exposure volume As a consequence the temperature in the exchangeable frame increases and the plastic powder is damaged more Mixing the powder Mixing the plastic powder may cause electrostatic charging The plastic powder can therefore not be used for the building process immediately instead it must be stored in powder bins after mixing So that an ai...

Page 65: ...rotected against soiling 4 The storage duration is necessary for the electrostatic charging of the powder produced by mixing to dissipate Temperature C Atmospheric humidity Storage duration New powder used powder sieved used powder recycled powder refreshed powder In closed bins 5 35 20 70 2 years 1 New powder Prior to opening the sacks 15 20 50 80 Min 24 h 2 20 25 40 60 25 30 30 45 New powder use...

Page 66: ...hange Atmospheric humidity too low Excessively slow dissipation of the electrostatic charging of the powder Problems when handling powder Electrostatic charging of the powder Effect Lumpy plastic powder like snowflakes Plastic powder is not transported in front of the recoater Plastic powder cannot be homogeneously mixed Flow behaviour of the powder not optimal Cause Charging when sieving or mixin...

Page 67: ...aviour is not constant with the same batch Cause Excessively long mixing times Powder allowed to fall an excessive height on filling or transfer Problem rectification Keep to recommended mixing times Maximum height the powder falls on filling or transfer should not be more than 1 meter Material machine compatibility The materials approved by EOS for the machine are listed in the material informati...

Page 68: ...4 Basic information on materials 4 8 Training manual Basic training Status 03 14 EOS P 396 ...

Page 69: ...5 5Part Property Management ...

Page 70: ......

Page 71: ... Property Profiles PPP for different applications Parts are given these PPPs by using related PPP parameter sets and the related EOS materials allocated In addition to the parameter sets from EOS it is possible to develop custom parameter sets with the aid of the Exposure editor For this purpose parameter sets that can be edited are available with the additional Initial values for parameters modul...

Page 72: ...arch and development in the area of laser sintering Possible parameter sets within the Part Property Management OEP Original EOS parameter sets All parameter sets published officially by EOS for various materials including the PPP parameter sets PPP parameter sets Qualified part and process properties for defined materials Customer parameter sets Custom parameter sets developed using the Exposure ...

Page 73: ...re Part skin and part core are exposed using different exposure types As a result the building time and the part weight can be reduced with good surface quality Not recommended for the production of complex parts _Speed Universal exposure type optimised in relation to the building speed Very suitable for the production of complex parts _Surface Exposure type optimised in relation to the surface qu...

Page 74: ...posure type for the exposure of the core of a part _Skin Exposure type for the exposure of the skin of a part The outer contour of the part is not exposed The exposure type _Contour is only available in the Exposure editor module It can only be used as part of the SkinCore exposure type which comprises several exposure types The exposure type _Core is only available in the Exposure editor module I...

Page 75: ... a part was manufactured the same part properties are ensured This quality is described by the Part Property Profile PPP TopSpeed The PPP parameter set Top Speed is built with a layer thickness of 0 18 mm It is suitable for the manufacture of parts with medium to high quality requirements with high pressure on costs Particularly large and thick walled parts can profit here from the high building r...

Page 76: ...peed is built with a layer thickness of 0 15 mm Due to its good all round qualities it is suitable for large to medium parts The surface quality and the mechanical properties are somewhat higher than for TopSpeed At the same time the productivity is higher than with the parameter set Balance Example part PPP Speed ...

Page 77: ...rom EOS It is suitable for the widest range of geometries part sizes and requirements Example part PPP Balance Performance The PPP parameter set Performance is built with a layer thickness of 0 10 mm Its outstanding feature is its isotropic strength and stiffness in all three spatial directions The fine resolution in this layer thickness ensures very high detail resolution and surface quality at t...

Page 78: ...remely fine and fragile geometries and the highest surface quality The building height with this parameter set is limited to 300 mm Example part PPP TopQuality Overview of PPP properties The appropriate PPP parameter set can be selected depending on the required part properties and manufacturing requirements TopSpeed Speed Balance Performance TopQuality Productivity Mechanical properties Surface A...

Page 79: ... exposure function Edge thin wall thicknesses 2 x value of the beam offset are also exposed with this exposure type In certain circumstances radii and edges are however built with coarser steps This situation is dependent on the shape and the building position of the parts Exposure type EOS_noEdge Unlike the exposure type EOS with the exposure type EOS_noEdge thin wall thicknesses that are less th...

Page 80: ...e for the production of complex parts Exposure type EOS_UD_noEdge Unlike the exposure type EOS_UD with the exposure type EOS_UD_noEdge thin wall thicknesses that are less than twice the beam offset are not exposed In certain circumstances radii and edges are however built with finer steps Exposure type EOS_SkinCore Part skin and part core are exposed using different exposure types As a result the ...

Page 81: ...or do not contain any initial values that can be used for building These values must be prepared independently or obtained using the Initial values for parameters module Possible applications Process optimisation for special applications Development of optimised exposure parameters for parts with very complex geometries Research and development in the area of laser sintering Exposure parameters wi...

Page 82: ...ith parameters that can be edited These parameters are pre defined such that it is possible to build parts on which there are no special requirements By deriving a new custom exposure type and changing the parameters special requirements for applications and parts can be met You will find an overview of the exposure types in the Initial values for parameters module in the Operation manual section ...

Page 83: ...6 6Data preparation ...

Page 84: ......

Page 85: ... with the aid of the software application EOS RP Tools combined edited and saved in a job using the process software offline on a workstation or at the machine Finally the job is loaded on the machine edited if necessary and started Procedure for data preparation Starting the job CAD construction CAD data IGES VDA Positioning in Magics RP STL data stl Slicing using EOS RP Tools Magics RP Build Pro...

Page 86: ...Slicing parts Setting up machine in Magics RP First the machine type with which the parts are to be built must be selected as the platform in Magics RP or if it does not yet exist in the software application loaded from the machine library In this way the machine specific data e g the building height width and depth exchangeable frame are represented in Magics RP so that the parts can be accuratel...

Page 87: ...ary window appears 3 In the Add machine from the Magics Library window select the required unit of measure e g mm settings 4 By double clicking the EOS folder open the EOS machine library in which all EOS machines are listed When you open Magics RP for the first time or want to work with a new machine you must first setup the scene machine platform If you have already added the scene go to section...

Page 88: ...ining Status 03 14 EOS P 396 5 Select the required machine type using the button copy to the My Machines group box and close the window 6 In the Machine library window add the selected machine using the Add to Default View button and close the window ...

Page 89: ...orrect data for the transformation of the 3D data into layer data are available in Magics the machine type must be setup as a printer 1 In Windows Control Panel select Build Processor Manager The 3D Printers window is displayed 2 In the 3D Printers window click the Add a 3D Printer button 3 Select machine type to be installed and continue using Add ...

Page 90: ...w and continue using Add The software installs the related machine type and displays a message on successful installation 5 In the Installing 3D Printers window click the Close button to close the window The Configure EOS Printer window opens 6 In the Upload Folder group box enter the folder where the part data are to be exported and accept using OK 7 Close 3D Printers window ...

Page 91: ...click the Show hide platform button 3 Scale building chamber On the Scenes menu select the Machine properties option The Machine Properties window appears For the Build Processor option the related machine type with the prefix B PRoc machine type must be selected so that the correct layer data can be exported at the end The parts are scaled in the PSW To ensure the further processing of the parts ...

Page 92: ...using Apply and close the window using OK Importing parts 1 On the File menu choose the Import parts option 2 Select one or more parts from the folder structure and open Selecting parts To further process one or more parts the parts must be selected It makes it easier to manage the parts if you display the Part Pages worksheet on the right of the screen window Here specific information on each par...

Page 93: ...utton The result of the error analysis appears in the Message group box 5 If no error messages are displayed click Close button The Fix Wizard window is closed 6 If error messages are displayed repair parts Click Go to Advised Step button Click the Automatic Fixing button to start the automatic repair After the repair a message with the result appears in the Advice group box 7 Checking repair Sele...

Page 94: ...entating parts Problems with the quality of the parts can be avoided by optimum orientation of the parts The following recommendations should be followed To ensure high process stability sudden changes in surface area should be avoided i e parts should start with small surface areas and grow slowly in the X Y direction Large flat surfaces should be at the top To ensure the parts are accurate avoid...

Page 95: ...is selected a copy of the selected part can be generated that automatically rotates by the required angle 3 Accept entries using Apply and close the window using OK Orientating parts using the Bottom Top Plane button Using the Bottom Top Plane button a surface can be aligned parallel to the building platform X Y plane 1 On the Marking tab click the Mark Plane button 2 On the Scenes tab click the B...

Page 96: ...ion on alignment If in the Positioning group box Keep Original Z Position is selected the lowest Z position of the part is retained If in the Positioning group box Translate To Default Position is selected the part is automatically moved to the pre set default position 8 Accept entries using Apply and close the window using OK The part is aligned For EOS machines the pre set default position is X ...

Page 97: ...at parts could be deformed The distance between the parts should be at least 5 mm The parts should be positioned in the Z direction at a start position of at least 6 mm The building temperature is measured in the building temperature measuring area using a spot pyrometer Parts must not be positioned there The parts should be positioned and sorted in the same place in the building area from job to ...

Page 98: ...ottom third of the job as here shrinkage and distortion will increasingly occur due to the proximity to the cooler removal chamber Parts critical for distortion should not be positioned in a block close together instead they should if possible be mixed with parts that are not critical for distortion In this way interaction between the parts can be avoided ...

Page 99: ...e between the dummy parts and the real part should be approx 0 6 mm to 1 mm The number and distance to the dummy parts depend on the volume and geometry of the real part The dummy parts must be separate from each other to avoid transferring distortion Parts critical for distortion with long surfaces should as far as possible be positioned diagonally in the building chamber 1 Part 2 Dummy part ...

Page 100: ...oning parts using the Translate button The part is placed in its final building position using the Translate button 1 On the Tools tab click the Translate button The Translate Part s window appears 2 Enter movement On the Relative tab the part can be moved by entering the required value in the dX dY or dZ fields On the Absolute tab the part can be moved by an absolute value 1 Area of optimised bui...

Page 101: ... of the sinter box In the Margin to Part a field enter the minimum distance between the bounding box for the part simplified rectangular body that encloses the maximum dimensions of the part and the sinter box EOS recommends the pre set default values In the Thickness b field enter the wall thickness for the sinter box not including the top EOS recommends the pre set default values In the Cover Th...

Page 102: ...p of the Sinterbox Wizard The Sinterbox Step 3 of 3 Labeling window appears In the Parameters group box enter the depth and the spacing for the lettering In the Direction group box select the position of the label In the Text group box enter the label text or automatically label with the name of the part using the Part Names button Using the Font button set the required font type size and face 4 G...

Page 103: ... head Parts with more than 30000 triangles The number of triangles can be seen on the Part Pages menu Part information tab in the Mesh info group box 1 Select component 2 On the Triangle Reduction tab click the Triangle Reduction button 3 On the Global tab enter the following default values recommended by EOS Smallest detail 0 02 mm Max Angle 5 Number of Iterations This value defines how often the...

Page 104: ...b Fix Wizard in the Triangles area Further repairs can be made here Repairing parts with the Fix Wizard Saving processed parts using a new name After repairing orienting and positioning the parts must be saved with a new name 1 On the File menu choose the Save part as option 2 Save selected parts each using a new name If several parts are selected the individual parts are saved one after the other...

Page 105: ...ckness 3 In the Exposure Profiles group box select the standard exposure type for the parts in this job and accept using OK Setting part specific exposure type 1 Click Configure Parts button 2 Select exposure type for parts and accept using OK Exporting parts 1 Click Build button 2 Enter the name of the job in the Job name group box On exporting the part data the Build Processor adds to the file n...

Page 106: ... 6 22 Training manual Basic training Status 03 14 EOS P 396 3 In the 3D Print window check the entries and accept the export of the part data using Submit Job The part data are exported to the destination folder defined ...

Page 107: ...ous layers slices with a definable layer thickness At the same time errors in the data are detected and corrected fixed The result is a number of data records that are added to an SLI file and that can be processed directly by the machine 1 Start Windows Explorer For more advanced data processing using EOS RP Tools please see the Operation EOS RP Tools manual During slicing attention is to be paid...

Page 108: ...ing part errors can be corrected Correcting part data using SLIFIX Correcting part data using SLIFIX Data errors are detected by slicing and automatically corrected In addition specific minor corrections can be made to individual layers lines or gaps Data errors smaller than 1 mm can be corrected using SLIFIX 1 In Windows Explorer use the right mouse button to click the SLI file for the part 2 Cli...

Page 109: ...are application EOS RP Tools appears Procedure in case of erroneous layers of more than 1 mm Run SLIFIX again with the already corrected file Risk of process problems If unchecked and uncorrected SLI files are processed using the PSW process malfunctions such as exposure errors or process cancellation can occur A Graphic depiction of the layer data with SLIVIEW B Error list 1 Depiction of error 2 ...

Page 110: ...en removed it is imperative the related layers are replaced Consider repair effort If necessary replace part with an error free part and prepare again section 6 Preparing parts with Magics RP section 6 Preparing parts using EOS RP Tools Risk of data loss The extension _c sli appended during the SLIFIX correction run is not a defined code for the Automatic parameters function in the PSW On loading ...

Page 111: ...7 7Operation of machine accessories ...

Page 112: ......

Page 113: ...d After the end of the building process the exchangeable frame with the parts lying in the bed of powder must cool down in the machine Then the exchangeable frame is removed from the machine and the parts unpacked with the aid of the components of the IPCM EOSINT P On unpacking the parts excess used powder is sieved and as recycled powder mixed with new powder The resulting refreshed powder can be...

Page 114: ...izard will guide you through the necessary installation steps Selection of the installation wizard language The programs required for the installation are marked with a green arrow Programs already installed or that are not required for the installation are marked with a grey minus sign Components can be selected or their selection cleared by clicking using the right mouse button If you click a pr...

Page 115: ...ftware Dongle CNS dongle is required A computer acts as a licence server and manages the licences for the individual clients in the network The CmStick only needs to be inserted in the licence server The licence server must be in operation continuously Licences can have varying validity periods Prior to the expiry of the licence EOS will send an enquiry as to whether the licence is to be extended ...

Page 116: ...rated by e mail to licensing eos info The e mail should contain the following information for the licence request E mail template licence request for a Customer Machine Software CMS dongle E mail template licence request for a Customer Network Software CNS dongle EOS generates a licence or licence update and sends it back by e mail RaU file If you request a licence for an empty dongle e g CNS dong...

Page 117: ...gs for a licence server all clients will lose their licence and network settings In this case re assign to the clients the licence and network settings via the CodeMeter Control Center in the WebAdmin group box You will find an overview of the licences their validity periods and properties in the CodeMeter Control Center in the WebAdmin group box The existing licences are listed on the Content Lic...

Page 118: ... involves the following steps Making material specific settings Loading creating EOS default job or user defined default job If necessary changing material dependent shrinkage in X Y Z direction If necessary changing material dependent beam offset Loading existing job Or Preparing new job and loading parts Making part specific settings If necessary changing position of the parts If necessary addin...

Page 119: ...the PSW is started and apply for every new job Loading EOS default job The default parameters for the processing of the materials are saved in the EOS default jobs It is important that the default job that matches the material has been loaded Operation EOS P 396 manual section 6 EOS Loading default job Preparing user defined default job In addition to the EOS default jobs it is also possible to cr...

Page 120: ...ing and the scaling actually measured on the part This new value for the scaling is then entered in the PSW section 8 Determining adjusting material dependent shrinkage 1 Original size 2 Scaled up For the recommended scaling values for the individual plastic powders see the parameter sheet A change in the scaling values after loading the parts results in the movement of the parts in the X and Y di...

Page 121: ...ing job can be modified by adding removing positioning or scaling parts after loading into the PSW A job that was created using the default parameters for a different material or a different PSW version can be loaded using the default parameters in the default job currently loaded During this process all parameters saved in the job are ignored and the currently applicable parameters allocated The ...

Page 122: ...ased on various criteria to avoid steps between the parts during exposure and in this way to shorten the exposure time Normally the Next by midpoint sorting function is to be used unless otherwise stipulated in the application instructions Making part specific settings Making part specific settings The parts loaded can be allocated different exposure types Depending on the part and the requirement...

Page 123: ...fset entered Operation EOS P 396 manual section 6 Setting part specific beam offset Using a part dependent scaling the part can be scaled in the X and Y direction however not in the Z direction Part dependent scaling values are added to the material dependent scaling values The sum of the scaling values is indicated in the Job parameters window in the Scaling column of the list of parts The value ...

Page 124: ... transferring the job to another computer will then be avoided On opening the packed job file is automatically unpacked Operation EOS P 396 manual section 6 Saving a job Calculating the building time The PSW can calculate the building time to be expected with an accuracy of approx 5 Operation EOS P 396 manual section 6 Calculating building time The recommended or possible exposure types for the in...

Page 125: ...ual section 6 Preparing building Build The building of the parts commences with the start of the building process If problems occur the process can be interrupted at any time and on completion of the necessary work continued or cancelled completely During an interruption in the building process the current job can be modified by loading additional parts changing exposure types or recoating paramet...

Page 126: ...t system DBMS that is also installed on every machine computer EOSTATE establishes a network connection with the DBMS on the machine computer and in this way permits direct access to all data that the PSW logs in the database EOSTATE comprises the modules Basic standard scope of delivery Quality Assurance optional Controlling optional Machine Park Management optional Setting up connection After th...

Page 127: ...raightforwardly transfer all relevant machine data to the EOS hotline in the case that technical support is required Functions of the Basic module Monitoring machine Maintaining database Exporting job data Recording building temperature Machine monitoring and building temperature recording in the EOSTATE Basic module You will find further information on function and operation in the Software EOSTA...

Page 128: ...valuation of the building task All the available information of relevance for quality can be specifically exported to statistics Data over a selected period can be shown filtered and depicted graphically A trend analysis is made easier by querying tasks undertaken such as maintenance powder changes or software updates Functions of the Quality Assurance module Showing events Preparing exporting Job...

Page 129: ...ns cost related data for defined and freely selectable periods These data can be studied based on key criteria in the statistics mode Functions of the Controlling module Showing events Preparing exporting Controlling Report Preparing statistics Events reports and statistics in the EOSTATE Controlling module You will find further information on function and operation in the Software EOSTATE manual ...

Page 130: ...e systems and to view data on the utilisation of the systems Using the software it is therefore possible to plan ahead the utilisation of the machines Functions of the Machine Park Management module Showing events Preparing exporting Machine Report Preparing statistics Reports and statistics in the EOSTATE Machine Park Management module You will find further information on function and operation i...

Page 131: ...ing parts With the aid of the Unpacking and sieving station the parts can be conveniently unpacked and the used powder sieved and prepared For this purpose the exchangeable frame is placed in the Unpacking and sieving station the parts and plastic powder are then separated The surplus used powder is sieved and can be transported manually or automatically via the optional Recycled powder conveying ...

Page 132: ...he spiral conveyor to the powder supply bin in the machine You will find the mixture ratio recommended by EOS for the plastic powder in the application instructions for the related material Necessary activities Filling new powder bin and recycled powder bin in the dosing station Checking levels Setting mixture ratio on the switching cabinet for the Powder conveying system P 3 Switch on Powder conv...

Page 133: ...eed to discharge the power mixture You will find the mixture ratio recommended by EOS for the plastic powder in the application instructions for the related material Necessary activities for the preparation of the plastic powder Set mixture parameters on the MQS controller Transport new powder and recycled powder to the mixing bin Set type and quantity for the powder mixture Set mixture ratio Acti...

Page 134: ...he refreshed powder Move multibox with refreshed powder to the docking station on the machine and couple Switch on docking station You will find further information on operation in the Components IPCM P plus manual section 4 Mixing qualification station Risk of process problems When the building process is supplied with refreshed powder prepared using the MQS for the first time it is necessary to ...

Page 135: ...using glass balls For shot peening the parts EOS recommends Shot peening medium for parts made of plastic powder type PA 2200 Glass beads with a size of 70 110 µm Shot peening pressure 2 bar fine part geometries up to 4 bar solid part geometries For all other materials follow the application instructions for the related material For the thorough post treatment of parts EOS recommends the installat...

Page 136: ...warm water max 60 80 C EOS recommends washing off the parts with warm water In this way parts are freed of excess adhering powder It is also possible to clean the parts in a dishwasher max 60 80 C You will find further information on cleaning the parts in the Accessories and Options EOS P 396 manual section 8 Shot peening cabinet ...

Page 137: ...8 8Process monitoring ...

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Page 139: ...s in the machine s settings it is sensible to document the building process Checking determining setting building temperature It is necessary to check or re determine the building temperature On the usage of pure new powder at the start of a new powder circuit In case of process problems that can be traced back to an incorrectly adjusted building temperature In case of change between different mat...

Page 140: ...s 3 Document actual situation Open evaluation file enter general job data and save file with a new file name In the PSW open the Material tab in the HWI parameters window In the Material dependent scaling group box read the actual values for X and Y with which the measurement job has been built and enter in the evaluation file 4 Determine new values for the material dependent shrinkage Measure mea...

Page 141: ...e Material dependent scaling group box and accept using OK A change in the scaling values after loading the parts results in the movement of the parts in the X and Y direction In this case check the job for the positioning of parts outside the building area Changes in the material dependent scaling values are saved in the material parameter set and therefore act on all jobs that are based on this ...

Page 142: ...uation file enter general job data and save file with a new file name In the PSW open the Material tab in the HWI parameters window Read beam offset with which the measurement job was built and enter in the evaluation file 4 Determine new value for the beam offset Measure measurement part at the points defined if possible using a co ordinate measuring machine Enter values measured in the evaluatio...

Page 143: ...ng building process using the PSW Events and parameters for the individual jobs and components are documented in the EOSTATE software and can be used for further analyses and evaluations Documenting building process using EOSTATE Backing up machine configuration The file packcft exe packs all machine specific files in one file with a time stamp In case of a system crash or data loss this file can ...

Page 144: ...se The data should be archived so they are immediately available in case of an error The database contains the following data Building process data Sequence of layers in the building process over time Part exposure times Exposure parameters for the parts Recoating parameters for the parts Building area temperature and heating power during the recoating Parts in the job Event log Errors and interru...

Page 145: ... OK 6 In the Export job data group box select the Complete job export check box 7 Export job data Click Export button The Browse For Folder window appears Select destination folder and accept using OK The selected job s is are exported Recording building temperature Using the EOSTATE Basic module the building temperatures of the individual machines jobs and PPP can be recorded 1 In EOSTATE establi...

Page 146: ... building temperature 9 Accept entries using Apply Temperature values are recorded in the EOSTATE database and appear in the Job Quality Report or in the Machine Report Displaying preparing results reports statistics Using the optional EOSTATE Quality Assurance Controlling and Machine Park Management modules events reports and statistics can be displayed and exported The procedure is the same for ...

Page 147: ...box Preparing exporting report 1 Select period that contains the jobs to be analysed See Software EOSTATE manual section 4 Defining period 2 Select Report view 3 Open job list Click Open job list button 4 In the Job list field select the job s to be exported and accept using OK 5 Display job to be analysed using the arrow buttons 6 In the Reports group box in the Type list box select the required ...

Page 148: ...lication In case of problems with the software the database with the saved job data can be sent to the EOS hotline for analysis 1 Quit process software on the machine 2 In EOSTATE select the DB Service view 3 Make backup copy of the database In the DB maintenance local DBMS group box click the Backup button The Browse For Folder window appears Select folder and accept using OK A backup copy of the...

Page 149: ...9 9Troubleshooting and maintenance ...

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Page 151: ...he recoater blades or due to coarse particles in the plastic powder require the cancellation of the building task and subsequent re starting of the job If the building process is only interrupted in this case the process chamber will cool down excessively and as a result jeopardise the rest of the building process Machine The most common mechanical malfunctions on the machine or malfunctions in th...

Page 152: ...ing process See Operation EOS P 396 manual section 6 Cancelling building process 2 Move building platform 50 mm below the building plane In the Building platform Step movement group box enter 50 in the field and click the Step movement up down button Depending on the severity of the error you can terminate the building process or continue the job after an adjustment However after the adjustment of...

Page 153: ...t in a building process crash 6 Check recoater blades for scratches and coating wear clean if necessary Check underside of the recoater blades using the inspection mirror if necessary remove any baked on powder using a plastic spatula 7 Close process chamber door and front valve Operation EOS P 396 manual section 6 Closing front valve 8 Move building platform up 50 mm In the Building platform Step...

Page 154: ...6 Deleting parts In the PSW move down SLI data for the parts still to be built Operation EOS P 396 manual section 6 Moving parts 13 Start building process In the Minimum warm up time field select a value and accept with OK 14 Monitor recoater alignment in the PSW in the Recoater adjustment group box in the PSW main window during the building process See Troubleshooting Maintenance and Spare parts ...

Page 155: ... in the process chamber On the Options menu choose the HWI option The HWI parameters window appears In the Nominal temperature group box increase the process chamber temperature by 1 to 2 C and accept entry using OK 3 Continue building process On the Process menu choose the Continue option The building process is continued with the next layer to be recoated or exposed Curling on the parts can resu...

Page 156: ...ding process 2 Lower building platform On the Process menu choose the Adjust option The Adjust window appears Move recoater to the left filling position Click Filling position left button Lower building platform by 3 mm In the Building platform Step movement group box enter 3 in the field and click the Step movement up down button Depending on the severity of the error you can terminate the buildi...

Page 157: ...ndow appears In the Nominal temperature group box reduce the process chamber temperature by 1 to 2 C and accept entry using OK 5 Load temperature job and determine building temperature section 8 Checking determining setting building temperature 6 Load a job Operation EOS P 396 manual section 6 Loading a job 7 Adjust job In the PSW delete from the job the SLI data already built Operation EOS P 396 ...

Page 158: ...roup box in the PSW main window during the building process See Troubleshooting Maintenance and Spare parts P 396 manual section 4 Checking adjusting recoater alignment 10 If it is not possible to rectify the problem Check pyrometer aperture for soiling clean if necessary Operation EOS P 396 manual section 6 Cleaning pyrometer aperture Contact service hotline ...

Page 159: ...mum building temperature set Cleaning the recoater blades 1 Cancel building process See Operation EOS P 396 manual section 6 Cancelling building process 2 Move building platform 50 mm below the building plane In the Building platform Step movement group box enter 50 in the field and click the Step movement up down button Depending on the severity of the error you can terminate the building process...

Page 160: ...ght at blades at a shallow angle Soiling such as baked on powder or a film of powder will then become visible Clean recoater using a fluff free cloth soaked in alcohol 96 ethanol not denatured Powder adhering to the recoater will result in dips in part of the powder cake that may result in a building process crash 8 Fill holes in the bed of plastic powder Manually dose an adequate amount of plasti...

Page 161: ...ccept with OK 14 Monitor recoater alignment in the PSW in the Recoater adjustment group box in the PSW main window during the building process See Troubleshooting Maintenance and Spare parts P 396 manual section 4 Checking adjusting recoater alignment At points that are refilled a layer of power at least 3 mm thick must be applied before it is possible to start to build parts at these points The p...

Page 162: ...ers with large areas Powder level in the recoater drops rises from layer to layer Amount of powder in the collector bins is insufficient excessive Large bow wave in front of the leading recoater blade This situation can result in quality problems on the part in particular in relation to part strength A Powder in the recoater Optimal level B Powder in the recoater Level too high C Powder in the rec...

Page 163: ...ow appears Choose the Recoating II tab Enter parameter in the Powder dosing group box 3 Continue building process On the Process menu choose the Continue option The building process is continued with the next layer to be recoated or exposed Ideally the pile of powder in the recoater on leaving the building area i e when the recoater movement is almost complete should be approx 3 to 10 mm from the ...

Page 164: ... circuit In the worst case brush hairs could cause a building process crash Check sieve in the Sieving machine in accordance with servicing plan and change immediately in case of damage Components IPCM manual section 10 Sieving machine P 3 Accessories and Options IPCM EOSINT P 3 IPCM P plus This problem is not obvious and therefore makes troubleshooting more difficult You will find help on malfunc...

Page 165: ...rating instructions manuals Machine Cleaning the laser window The cleaning of the laser window is a very important maintenance step and can result in high costs if the procedure is not followed When new the laser window is completely transparent when viewed from the process chamber and is free of scratches and other defects 1 1 Laser window A lot of soiling only becomes visible if you point a torc...

Page 166: ...e wiping direction due to cleaning laser window when still excessively warm Cleaning fluid smears burnt onto the laser window due to failure to follow the cleaning procedure Risk of damage Cleaning at an excessively high temperature may cause cleaning fluid to burn into the surface of the laser window Leave the laser window to cool down before you start the cleaning work The maximum surface temper...

Page 167: ...o completely remove the rest of the fluids Then wipe again with dry cleaning paper to remove the residual moisture You will find detailed cleaning instructions in the Troubleshooting Maintenance and Spare parts P 396 manual section 4 Inspection and servicing tasks Accessories and Options IPCM EOSINT P 3 IPCM P plus You will find maintenance and servicing schedules on the related accessories in the...

Page 168: ...9 Troubleshooting and maintenance 9 18 Training manual Basic training Status 03 14 EOS P 396 ...

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Page 170: ...ünchen Telephone 49 0 89 893 36 0 Telefax 49 0 89 893 36 285 Internet www eos info e mail info eos info Translation of the original training documentation Training manual EOS P 396 Article number 9241 3501 Edition 03 14 2014 EOS GmbH Electro Optical Systems All rights reserved ...

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