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Recovering powder and filling powder cartridges |

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5.6.1

Registering on Dashboard

Dashboard (

formlabs.com/dashboard

) allows individuals and teams to remotely monitor

Formlabs devices, track material usage, and explore past and future Formlabs purchases.
Register your Formlabs SLS printers to Dashboard through the touchscreen and use the
reported metrics to plan or schedule your usage of the Fuse Sift.

5.6.2

Turning off

The Fuse Sift is designed to remain powered on when not in use. Flip the breaker switch
on the back of the unit to the

OFF

position to turn off the machine completely and conserve

power. When moving or storing the machine, unplug the unit from its power source in addition
to flipping the breaker switch.

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Summary of Contents for Fuse Sift

Page 1: ...Manual Fuse Sift ...

Page 2: ......

Page 3: ...tion and Usage Instructions Fuse Sift Powder recovery station for the Fuse 1 SLS 3D printer Original English instructions Read this manual carefully and keep it for future reference January 2021 REV 01 Formlabs ...

Page 4: ...ools to be used 21 3 4 Emergency and exceptional situations 21 4 Preparation and setup 23 4 1 Location and environs 23 4 2 Power and networking 23 4 3 Unboxing the machine 24 4 4 Accessing the serial name 25 4 5 Installing the machine 26 4 6 Setting up a network connection 27 4 7 Updating firmware 28 4 8 Transporting the machine 28 5 Recovering powder and filling powder cartridges 31 5 1 Operation...

Page 5: ...oting 44 7 1 Collecting diagnostic logs 44 7 2 Performing a factory reset 44 7 3 Troubleshooting errors or abnormal activity 44 8 Disassembly and repair 46 8 1 Tasks 46 9 Recycling and disposal 47 9 1 Disposal of powder 47 9 2 Recycling of powder 47 9 3 Disposal of electronic components 47 9 4 Disposal of packaging waste 47 10 Index 48 11 Glossary 50 12 Product compliance 52 ...

Page 6: ......

Page 7: ...or integrator to perform the appropriate and complete risk analysis evaluation and testing of the products with respect to the relevant specific application or use thereof Neither Formlabs nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information that is contained herein Notify us if you have any suggestions for improvements or amendments or have found ...

Page 8: ...Keep all safety information and instructions for future reference and provide them to subsequent users of the product Follow all instructions to avoid fire explosions electric shocks or other hazards that may result in damage to property and or severe or fatal injuries The Fuse Sift shall only be used by persons who have fully read and understand the contents of this manual Ensure that each person...

Page 9: ...ssistance before contacting Formlabs Support For any support or service requests including product information technical assistance or assistance with instructions contact Formlabs Support support formlabs com USA Formlabs Inc 35 Medford St Somerville MA USA 02143 Germany Formlabs GmbH Nalepastrasse 18 12459 Berlin Germany 1 2 2 Warranty This product is protected under warranty Formlabs offers a w...

Page 10: ...egally permitted Formlabs EXPRESSLY DISCLAIMS ANY IMPLIED OR EXPLICIT WARRANTY OF FITNESS for a particular usage the particular nature and circumstances of said usage being unforeseen and unforeseeable to Formlabs Formlabs is not a manufacturer of medical devices Formlabs provides tools and materials that may be used in many applications but makes no claims as to the safety or effectiveness of any...

Page 11: ...on 21 6 lb PA12 nylon Operating environment 18 28 ºC 68 81 ºF Air handling Negatively pressurized hood with replaceable HEPA filter Power requirements With a vacuum that draws less than 6 A 230 VAC 12 A 120 VAC EU 230 VAC 7 5 A dedicated circuit US 120 VAC 15 A dedicated circuit With a vacuum that draws more than 6 A 230 VAC 12 A 120 VAC EU 230 VAC 10 A dedicated circuit US 120 VAC 20 A dedicated ...

Page 12: ...filling the fresh powder hopper Control panel A touchscreen and physical controls for interfacing with the Fuse Sift Build chamber latch Secures the build chamber Build chamber enclosure Area for housing the build chamber with prints ready to be ejected The powder catch at the bottom of the build chamber enclosure is a removable tray for catching loose powder Powder catch Removable tray for catchi...

Page 13: ... control for turning on and off the workspace light and vent 2 3 3 Mixer Mixer turntable The exterior face of the mixer that turns with the cartridge Locking tabs Two spring loaded tabs for securing the cartridge into the mixer Cartridge wing couplers Two brackets that guide the cartridge s wings into place 2 3 4 Power cartridge Cartridge wings Two brackets for locking the cartridge to the mixer C...

Page 14: ... processing a cake Vacuum hose For using the vacuum within the workspace Surface grate Covers the sifter to prevent objects from falling through Large brush Main scrubbing brush for large or well buried parts Double sided brushes Set of two each with a medium and small head Wire brushes Set of five Best for cleaning out cavities slots tubes or hard to reach features Picks Set of two Best for remov...

Page 15: ... its subsystems by either tapping their respective graphics on the left or the cards on the right Tapping a card brings up the specific subsystem s current status and settings In this case the inserted build chamber is cool and ready for part recovery Tapping the icon next to a card activates the subsystem When a subsystem is running its card and icon are highlighted blue A progress bar indicates ...

Page 16: ...h a low level of risk which if not avoided could result in minor or moderate injury NOTICE indicates information considered important but not hazard related CAUTION Mixing powder cartridges poses entanglement and pinch hazards Keep hands loose clothing and cables away from the mixer while running ENVIRONMENTAL HAZARD Unsintered SLS powder is classified as a microplastic a group of plastics that ar...

Page 17: ...ing and or scalding of skin Due to its size and weight do not move or reposition the Fuse Sift alone If the machine needs to be moved at least two individuals should unlock the casters and push the entire unit by the metal frame Avoid using the workspace hood as a push off point Do not lift or reposition the Fuse Sift By grabbing or pulling on the workspace hood workspace lip build chamber enclosu...

Page 18: ...develop or persist seek medical advice attention Use appropriate personal protective equipment when handling loose or unsintered powder Wear non reactive nitrile gloves and safety glasses Wear a respirator N95 or better if the occupational threshold limit value for airborne particle concentration has been exceeded if you are sensitive to dust or pollen or you are concerned about your respiratory h...

Page 19: ... reactive nitrile gloves Recommended when handling loose or unsintered powder as it may draw moisture and oils out of skin If powder is handled at room temperature it is not necessary to wear protective gloves Safety glasses Required when performing maintenance on the Fuse Sift as well as handling loose or unsintered powder at any time Polycarbonate based lenses including prescription glasses are ...

Page 20: ... its power source 2 Open the filter door and locate the emergency chamber door release cable Pull the cable away from the printer until the print enclosure door unlocks 3 Use an ABC fire extinguisher to cover the affected area generously If the fire is too large to control 1 Immediately leave the area and close the door of the room behind you 2 Evacuate the building according to your organization ...

Page 21: ...the Fuse 1 access footprint by more than 30 5 cm 12 0 in 3 Ensure proper ventilation is installed Sintering nylon powder produces laurolactam a white powder that accumulates within the print enclosure filter mediums and exhaust Proper ventilation is required whenever the Fuse 1 or Fuse Sift is operating 4 Purchase additional supplies Compliant vacuum that is grounded and bonded e g Class II Divisi...

Page 22: ... parts basket Powder cartridges and accessory boxes ship separately from the Fuse Sift s packaging Depending on the package you purchase the accessories may ship together on a pallet If you are in a building with palletized deliveries ensure you have access to the loading dock Powder recovery station Vacuum Pallet including product and boxes if applicable Shipping dimensions 99 57 156 cm 39 22 4 6...

Page 23: ... packaging from the outside of the Fuse Sift before connecting the machine to power 9 Remove the Fuse Sift tool shelf from the pallet Hang the tool shelf from the pegs running along the bottom of the vent at the back of the Fuse Sift workspace 10 Remove the surface grate from the accessories box and place it over the sifter 11 Remove the vacuum hose from the accessories box Plug it into the vacuum...

Page 24: ...2 Installing the tool shelf Hook the tool shelf over the pegs on the vent at the back of the work area When installed correctly the tool shelf sits level and is flush against the vent 4 5 3 Installing the powder catch tray Place the powder catch tray in the build chamber enclosure When installed correctly the powder catch tray sits flat and is flush against the back wall of the enclosure 4 5 4 Set...

Page 25: ...he wrench icon on the Home screen The Settings screen appears 2 Tap Connectivity Wi Fi The Wi Fi screen appears 3 Toggle Use Wi Fi to ON The toggle turns blue 4 Tap the desired wireless network 5 If prompted enter your network password and tap the checkmark to confirm 4 6 2 Connecting with Ethernet The rear of the unit is equipped with a RJ 45 Ethernet 10BASE T 100BASE TX 1000BASE T 1000 Mbit LANP...

Page 26: ...opens 8 Follow the on screen instructions to download the latest firmware and then upload the file to the machine To upload firmware the device must be connected to the computer via USB or the machine must be connected to an Ethernet network 9 The machine may automatically recognize that you have sent a firmware update Tap Continue on the touchscreen to finish the installation 10 If you are not pr...

Page 27: ... the breaker switch on the back of the unit to the OFF position to turn off the machine 10 Unplug all cables power Ethernet and USB from the back of the unit 4 8 2 Packaging Thoroughly read and follow the instructions to properly package the machine Skipping any of the following steps may result in shipping damage and void the warranty To package the machine 1 Loop both orange lifting straps under...

Page 28: ...1 Encase the front and the back of the machine with a C fold segment 2 respectively 12 Place the topper 3 on top of the C fold segments 13 Wrap a nylon binding strap commercially available horizontally around the C folds Position the strap approximately 50 cm 20 in up from the bottom of the C fold Tighten and crimp the strap 14 Loop two nylon binding straps vertically around the machine passing th...

Page 29: ...se 1 automatically starts cooling parts after printing completes and indicates the recommended time a print should remain inside the print enclosure This is indicated by an on screen notification as well as the status card in the top right of the Home screen The Fuse 1 s print enclosure is designed to operate at up to 200 ºC 392 F and incorporates high intensity heaters Do not open the print enclo...

Page 30: ...mation To cool the build chamber in the Fuse Sift 1 Check the status of the build chamber on the touchscreen If the build chamber graphic and icon are highlighted red and the touchscreen displays the status Hot allow the build chamber to continue cooling before ejecting the cake 2 When the touchscreen displays the status Ready it is safe to recover and process your printed parts 3 Open the print e...

Page 31: ...rns on the light and vents the workspace 4 On the touchscreen tap Unpack to lift the print bed and eject the cake 5 4 Extracting parts For detailed guidance and visual assistance visit support formlabs com After lifting the powder cake out of the build chamber with the Fuse Sift extract your printed parts from the powder cake To extract parts 1 Move the majority of the cake to the center of the wo...

Page 32: ...r into the Fuse Sift 4 Check that the Refresh Rate is set to your desired ratio then tap Fill on the touchscreen 5 The Fuse Sift fills the cartridge with powder and runs its vacuum to capture loose powder This completes after about one minute 6 Open the cartridge drawer close the cartridge valve and remove the cartridge Ensure that the valve knife is fully pushed into the cartridge before removing...

Page 33: ...your Formlabs SLS printers to Dashboard through the touchscreen and use the reported metrics to plan or schedule your usage of the Fuse Sift 5 6 2 Turning off The Fuse Sift is designed to remain powered on when not in use Flip the breaker switch on the back of the unit to the OFF position to turn off the machine completely and conserve power When moving or storing the machine unplug the unit from ...

Page 34: ...ise skilled and unskilled persons in installing operating and maintaining the Fuse Sift The Fuse Sift shall only be maintained by a qualified and trained person Do not open the Fuse Sift and or investigate internal components unless under the guidance of Formlabs Support or a certified service provider Contact Formlabs Support or a certified service provider for any additional guidance Unauthorize...

Page 35: ...e sifter mesh 6 3 1 6 2 2 Periodic maintenance Inspect Refer to Section Fresh powder level Adding fresh powder to the Fuse Sift 6 4 1 Vent filter Vacuuming the vent filter 6 4 2 Sifter mesh Cleaning the sifter mesh 6 4 3 Powder cartridge Maintaining the powder cartridge 6 4 4 6 2 3 Intermittent maintenance Inspect Refer to Section Doser assembly Cleaning the doser assembly 6 5 1 Fresh powder hoppe...

Page 36: ...tion 6 4 4 Cleaning the sifter mesh 7 Reinsert the grate 6 4 Periodic maintenance The Fuse Sift requires regular maintenance and care The standard cycle for the following procedures is every 10 20 hours of use Task Frequency Refer to Section Filling the fresh powder hopper When there is insufficient powder in the fresh powder hopper to fill a powder cartridge at the selected refresh rate Adding fr...

Page 37: ...n the vacuum by pushing the Vac button on the control panel or by tapping the vacuum hose icon on the touchscreen 3 Starting from the top and moving from left to right vacuum powder out of the filter pleats Note any loose powder that falls down into the workspace 4 Move down and across until the entire vent filter has been covered and loose powder stops falling out 5 Vacuum the powder that fell in...

Page 38: ...n 5 Hold the vacuum crevice tool in place for approximately one minute 6 Move the vacuum crevice tool to the middle right of the valve knife and hold in place for approximately one minute 7 Move the vacuum crevice tool to the far right of the valve knife and hold in place for approximately 30 seconds 8 Move the vacuum crevice tool to the far left of the valve knife and hold in place for approximat...

Page 39: ...ing the rear panel in place with a 2 5 mm Allen wrench or hex driver Set the rear panel aside 4 Locate the doser assembly When facing the back of the Fuse Sift the doser assembly is located toward the left below the two powder hoppers 5 Turn on the vacuum Clean up any powder that has settled on top of next to and behind the doser assembly Be very careful not to damage or dislodge the doser motor c...

Page 40: ...d with fibers or other debris you may need to empty and clean the used powder hopper To clean the used powder hopper 1 If there is clean powder in the hopper that you plan to reuse empty the hopper by dosing powder with a 0 refresh rate into one or more empty powder cartridges 2 If the sifter is on tap Sift on the touchscreen or push the Sift button on the control panel to turn off the sifter 3 Li...

Page 41: ...ilter grate back in place above and around the filter then tighten the six thumb screws until hand tight 6 5 5 Replacing the sifter mesh Clumps of nylon can accumulate in the mesh screen below the collection grate eventually preventing reclaimed powder from passing through to be collected Formlabs recommends replacing the sifter mesh after every 200 hours of use To remove and replace the sifter me...

Page 42: ...causes and proposed solutions Complete the initial troubleshooting steps and carefully document all results Contact Formlabs Support or a certified service provider for additional guidance Provide diagnostic logs if requested 7 3 1 Resolving abnormal functions and errors Error Cause Solution Unresponsive machine The Fuse Sift does not turn on The power cable is disconnected The breaker switch on t...

Page 43: ...ntered used powder in general or recycling waste streams Error message Bad Cartridge Weight Error The Cartridge weight is not reasonable A powder cartridge inserted into the drawer either weighs too much or too little to be accurately filled 1 Check whether the powder cartridge is completely empty before loading it into the cartridge drawer 2 Clean out any powder that has collected in the cartridg...

Page 44: ...act Formlabs Support or a certified service provider to receive repair instructions and authorization including how to disassemble or remove the exterior paneling Task Frequency Replacing the doser gear When advised by Formlabs Support or a certified service provider Servicing the mixer assembly When advised by Formlabs Support or a certified service provider Any maintenance or repair not listed i...

Page 45: ... or cleaned parts Discard cleaned parts and sintered powder with household items as trash Cleaned parts and sintered powder cannot be recycled 9 3 Disposal of electronic components The symbol on the product the accessories or packaging indicates that this device shall not be treated as nor disposed of with household waste When you decide to dispose of this product do so in accordance with local en...

Page 46: ...nylon 13 23 30 33 37 43 48 50 51 O operation 10 17 18 19 21 45 48 P part recovery 17 33 48 powder 6 7 10 12 13 14 15 16 17 18 20 21 22 23 24 25 26 28 29 31 33 34 36 37 38 39 40 41 42 43 45 47 48 50 51 powder credit 18 powder cartridge 6 14 23 28 29 34 36 37 38 40 41 45 48 50 power 19 22 23 25 26 27 28 29 35 36 41 44 48 PreForm 28 48 51 R refresh rate 13 38 42 45 48 S safety 6 9 10 12 18 19 20 21 2...

Page 47: ...ary opening for filling and depositing powder The cartridge valve is opened and closed via the valve knife Hood A transparent covering that prevents powder and debris from leaving the Fuse Sift s workspace Hopper A fixed container that holds powder in a tapered basin for dispensing into a powder cartridge The Fuse Sift has two hoppers one for fresh unused powder and one for unsintered powder recov...

Page 48: ...red powder from previous prints before it is recaptured for reuse Sifter mesh A fine sieve mesh that sifts unsintered powder before it is recaptured in the used powder hopper Surface armor A print process component of the Fuse 1 that surrounds parts with a semi sintered shell of material to alleviate thermal inconsistencies which may adversely affect the accuracy of a part Surface grate A protecti...

Page 49: ...dards European Machinery Directive 2006 42 EC A Type Standards EN ISO 12100 2010 B Type Standards EN 60204 1 2018 C Type Standards None Electromagnetic Compatibility 2014 30 EU IEC 61000 6 2 IEC 61000 6 4 Chemicals and waste Restriction of Hazardous Substances Directive 2011 65 EU EC No 1907 2006 Chemical Substances REACH Regulation ...

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