S SLS ™ process user’s guide Thank-you for purchasing 3D Systems® SLS® equipment and DuraForm® materials. Before you start building parts in your SLS™ process facility, please read this guide carefully to enjoy optimum process performance and longer equipment service life.

Original Instructions

CONTENTS

Contents ` About This Guide ...... 2 ` IRS & IPC...... 133 ` Safety ...... 9 ` SLS System ...... 180 ` SLS Process ...... 43 ` BOS ...... 208 ` Prepare to Build ...... 55 ` Contacting 3D Systems ...... 242 ` Build Parts...... 73 ` Glossary ...... 245 ` Break Out Parts ...... 90 ` Index...... 268 ` RCM ...... 101

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 in this manual.

Document 23348-M12-00 Revision B August 2017 Copyright © 2006 by 3D Systems Corporation. All rights reserved. 3D Systems, the 3D logo, Sinterstation, sPro, SLS, and DuraForm are registered trademarks of 3D Systems, Inc. Other trademarks are the property of their respective owners. SLS process user’s guide

ABOUT THIS GUIDE 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 ` Instruction Formats ...... 6 ` Hazard Warnings...... 5 ` Other Useful Documents ...... 7 SLS process 3 ABOUT THIS GUIDE user’s guide what’s inside?

What’s Inside? This SLS Process User’s Guide includes the SLS Process Procedures sections summarized below. General safety The instructions in these four sections step you guidelines are presented first. The rest of the through the SLS process in a general way. When Guide is organized in two parts. The first part necessary, they refer you to detailed machine covers SLS process procedures and the second operating and maintenance instructions in the covers SLS equipment. equipment section of this guide. At the end of this guide, you will also find a SLS Process - overview of the SLS process from Glossary of SLS process terms and an Index. Click powder to parts. on any red TLA (three-letter acronym) or SLS process term in this section to display a Build Preparation - how to prepare 3-D parts for definition. building using the SLS system’s Build Setup software; how to clean, power-up, and start-up Safety Guidelines and Instructions SLS equipment, and perform pre-build checks. The Safety section tells you what you need to L A “build” is a 3-D printout of a build packet know to avoid injury or equipment damage. Read containing STL files of one or more 3-D parts. this section before you switch on power to any You create build packets in the Build Setup SLS equipment or handle DuraForm material. application. See your Build Setup online Help for detailed build packet setup instructions. L To verify that your facility was properly Build Parts – how to run builds on the SLS prepared for SLS system installation, see the sPro SLS Process Facility Guide and SLS Process system, and how to monitor, control, and modify Facility Layout. For detailed material safety a build in progress. information, see the DuraForm Material Safety L You use the Sinter application to run a build. Data Sheets (MSDS’s). Printed copies of these See your Sinter application online Help for documents were included in your SLS powder detailed build instructions. material shipment. You can also download MSDS’s for SLS materials from3D Systems’ website. (See Other Useful Documents on page 7.) SLS process 4 ABOUT THIS GUIDE user’s guide what’s inside?

Breakout Parts – how to remove and cool down SLS® system - preparing for, and running builds the part cake after a build, then use the BOS to using the Sinter application and utilities, and remove parts from the part cake. This section also maintaining the SLS system between builds. describes how to recycle or dispose of used part BOS - breaking parts out of the part cake and cake powder. managing waste and recycled part cake powder. SLS Equipment This second half of the User’s Guide provides detailed instructions for the functions you need to perform on SLS equipment during SLS process procedures. The process instructions in the first part of the guide frequently reference equipment instructions 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. They focus on the following: IRS and IPC - loading powder from the IPC to the IRS and transferring powder between the IRS, SLS system, and BOS. SLS process 5 ABOUT THIS GUIDE user’s guide hazard warnings

Hazard Warnings You will find nine different types of warnings in L See the Safety section for descriptions of safety this guide. Always heed these warnings. Ignoring labels on your SLS equipment. them can expose you and your SLS equipment to the hazards listed below.

WARNING TYPE HAZARD

Safety Alert Machine damage, part damage, and/or data loss.

Electric shock Injury or death from electric shock.

Burn injury or fire on hot non-handling surface. Allow surface to Hot surface cool before touching. Burn injury or fire on hot handling surface. Allow surface to cool Hot surface - touch before touching.

Laser radiation Eye injury or blindness; burn injury; fire.

Crush Injury or death from crushing weight.

Impeller Injury or death from rotating blade or impeller.

Notched belt Injury or death from entanglement in notched pulley drive belt. entanglement Air-pressurized Eye injury or blindness; dust-cloud ignition from escaping powder pressurized powder. SLS process 6 ABOUT THIS GUIDE user’s guide instruction formats

Instruction Formats Instructions in this guide use special text formats Operator Panel Buttons to highlight menu commands, keys on the The icons represent operator panel keyboard, operator panel buttons, and text on buttons on the IRS and BOS. The buttons the operator panel display. perform these functions: Text on Computer Display Scroll menu options up/down; increase/ decrease/change parameter values. Text in LS software menus and windows you need to find or act on is in bold; for example: Select option/accept change; similar to Enter key on keyboard or YES or OK “Open the Machine menu and select Manual dialog button. Operations > Inerting.” Cancel/reject change/exit up one menu “Click the Build button on the main toolbar. level; similar to Esc key on keyboard or NO, Cancel, or Exit dialog button. Text you enter in LS software programs is underlined in typewriter font; for example Operator Panel Display Text In the Heater Control window, enter 130.0 Text displayed on the IRS or BOS operator for the temperature Setpoint (°C).” panel appears in green text; for example:

Keys From the Process Params menu, choose RCM Type, then press . 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.” SLS process 7 ABOUT THIS GUIDE user’s guide other useful documents

Other Useful Documents The documents listed below will help you get the ` Material Safety Data Sheets (MSDS’s) – most out of your SLS process and equipment. You online copies of the printed MSDS’s that ship can find them in the ..dtm\docs folder of your LS with DuraForm materials. Make sure software installation hard drive (...except for Build everyone in your facility who handles Setup Help and Sinter Help. You access these DuraForm materials reads these MSDS’s and through the Build Setup and Sinter applications). follows the safety guidelines in them. To order extra printed copies of these MSDS’s, ` SLS Process Facility Guide – details SLS contact 3D Systems Customer Support. process requirements for facility electrical power, room construction and atmosphere, ` Build Setup Help – provides detailed compressed air, nitrogen, coolant, powder, instructions on how to use the Build Setup and network. It also provides SLS equipment application to create and modify build specifications, shipping and information, and packets you can run on the SLS system. To moving instructions. (This guide was sent to view Build Setup Help, run the Build Setup you before installation. A pdf copy is included program, then select Help > Help on Build in the ..dtm\docs folder for reference.) Setup ... from the main window menu bar. For help on the currently selected Build Setup ` SLS Process Facility Layout – illustrates SLS command or window, press function key F1. process requirements for facility electrical power, room atmosphere, compressed air, L You can also run Build Setup from the nitrogen, and coolant. It also shows Sinter Application by clicking the Setup toolbar button. 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.) SLS process 8 ABOUT THIS GUIDE user’s guide other useful documents

` Sinter Help – provides detailed instructions on how to use the Sinter application to run and manage builds on the SLS system. To view Sinter Help, run Sinter, then select Help > 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. They also include safety and regulatory guidelines for DuraForm material handling. SLS process user’s guide

SAFETY This section gives the information you need to use 3D Systems’ SLS equipment and DuraForm LS materials safely. It includes the following topics:

` General Safety Guidelines ...... 10 ` Nitrogen/Oxygen Safety ...... 32 ` SLS Equipment Safety Features ...... 12 ` Mechanical Motion Hazard Locations . . . 34 ` Safety Labels...... 15 ` Hot Surfaces and Powders ...... 35 ` Electrical Safety ...... 17 ` DuraForm Material Handling Safety . . . . . 36 ` Environmental Issues...... 18 ` IPC Handling Safety ...... 37 ` Laser Safety ...... 20 ` Shutdown...... 39 ` Powder Safety ...... 28 ` 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, ✓ Provide information about the hazards of materials, and procedures. equipment and materials in the form of ✓ Explain what to do in an emergency Material Safety Data Sheets. These are situation. provided with all materials supplied by 3D Systems. SLS process 10 SAFETY user’s guide general safety guidelines

General Safety Guidelines All SLS equipment is designed with safety in Machine Handling mind. However, improper use, malfunctions, and ` Do not try to access, service, or adjust any excessive exposure could cause injury. components inside any SLS equipment Follow these general safety guidelines when enclosure. operating any SLS equipment: ` Do not try to open any panel or door while a machine is running. Training and Instructions ` Do not access any area of the machine near ` Do not operate any SLS equipment before the process chamber high-temperature- receiving proper training. material builds. ` Read and follow all operating instructions. ` Use special caution when handling a heated ` Follow all safety rules in this section and heed RCM and when dealing with the heated, inert all hazard warnings in this guide. environment inside the SLS system’s process ` Do not try to do any equipment maintenance chamber. Take note of all thermal hazard procedures you were not trained to do. warning labels on the machines. • Operators are trained to operate the ` Always disconnect the RCM cable before system and perform all the necessary tasks moving the RCM out of the SLS system or to print a part. BOS. • Certified service personnel are those ` To prevent crush injuries to the body, use who have completed the 3D Systems extra caution when rolling the RCM into and service training package and are certified out of the SLS system and BOS, and when to perform service tasks. Certification may closing the BOS overhead door. Take note of occur at various levels, and servicers all crush hazard warning labels on the should only perform tasks they are machines. authorized and certified to complete. SLS process 11 SAFETY user’s guide general safety guidelines

` Dress electrical cables, powder transport Alarms and Warnings tubing, and coolant hoses to prevent ` If you hear an alarm, or if you see an error, tripping; especially the umbilical tubing that alarm, or warning message on any SLS connects the IPC to the IRS. equipment display, note the state of that machine’s Stacklight and refer to its Material Handling troubleshooting section in this guide. Clear ` Do not use any material without first the alarm, error, or warning message before reviewing its Material Safety Data Sheet resuming operation. (The SLS System (MSDS). Troubleshooting section might refer you to the Messages and the Message List Window ` To prevent injury and equipment damage, be topic and/in your Sinter application online sure to follow all handling guidelines in Help.) Powder Safety on page 25 and Nitrogen/ Oxygen Safety on page 30. ` Displayed error, alarm, or warning messages can result from unsafe practices, such as Laser opening an enclosure door or panel when equipment is powered up and running. ` Do not try to access, service, or adjust the laser system in 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. SLS process 12 SAFETY user’s guide SLS equipment safety features

SLS Equipment Safety Features The main design goal for all SLS equipment is to Safety Interlocks provide a safe operating environment. The frame Safety interlock devices on the SLS equipment and enclosure designs passively limit hazardous help prevent accidental laser exposure, electrical access while the electronics and software actively shocks, crush injuries, burns, and fires. and automatically sense and react to unsafe SLS equipment will not operate unless all safety conditions when they arise. For example, if the interlocks are satisfied. SLS system detects unsafe operating conditions, it will immediately stop operating and, in some Never try to disable or override any cases, shut down completely. safety interlock device on any SLS equipment. Operating If any SLS equipment safety features equipment without all safety fail, your actions may be all that will interlocks enabled can cause prevent potentially hazardous equipment damage, injury, or death. operating conditions. If you suspect a safety interlock device is not working properly, do not operate your SLS equipment. Rather, disconnect power from the equipment and contact 3D Systems Customer Support for assistance. SLS process 13 SAFETY user’s guide SLS equipment safety features

SLS SYSTEM RESPONSE IF AN INTERLOCK FAILS Safety interlock devices mounted on the SLS system sense the hazardous operating conditions below. The SLS system takes the actions listed when an interlock fails.

SAFETY INTERLOCKED CONDITION IF THIS INTERLOCK FAILS... RCM door open when SLS system is attempting to start a build • Build will not start RCM not fully raised or engaged with the process • Warning message appears on SLS system display chamber floor after RCM loading • Yellow Stacklight illuminates One or more internal process chamber panels are opena E-stop button pressed on user interface console • SLS system shuts down External oxygen monitor connected to SLS system • Nitrogen generator (if in use) shuts down detects too little oxygen in room • Warning message appears on SLS system display • Yellow Stacklight illuminates a. Internal panels are for service access only.

Limited Access And Barrier Shielding ✓ burn hazards by minimizing exposure to SLS equipment frame and enclosure designs limit heated powder access to the following: ✓ slip hazards by keeping powder from dropping on the floor Service areas, such as cabinets and enclosures for electrical power and automation controls. This ✓ fire hazards by minimizing airborne dust prevents accidental exposure to electrical shock cloud formation and potential ignition. See hazards. MSDS for complete hazard details. Powder areas, such as powder feed hoppers, storage bins, and transport tubes. This prevents: SLS process 14 SAFETY user’s guide SLS equipment safety features

Laser beam optics and scanning areas, Other Active Safety Features including the fully-enclosed Image Processing ✓ The Breakout Module (IPM)—where the laser beam Station (BOS), See BOS on page 208. originates—and the interior of the process coupled with the chamber, into which the beam projects. The IPM Dust Collector, removes airborne powder and process chamber are designed to minimize during part breakout in accordance with hazards such as burns, eye injury, and fire in the standard industrial ventilation practices. following ways: ✓ An overpressure sensor line monitors the ✓ The IPM optics and laser beam duct (at the pressure in the Intelligent Powder Cartridge top of the process chamber, below the (IPC) when it is connected to the Integrated removable laser window) prevents the laser Recycling Station (IRS). This prevents IPC beam from being aimed outside the process container ruptures and accidental material chamber. leakage. ✓ The fully enclosed process chamber blocks ✓ A room oxygen monitor automatically laser radiation from escaping to the outside. initiates SLS system shutdown when it ✓ The process chamber window material also detects too little oxygen in the room. blocks laser radiation so you can safely ✓ Software in the SLS system, IRS and BOS observe the part bed during a build. automatically initiates immediate equipment shutdown if certain unsafe conditions are detected during operation. SLS process 15 SAFETY user’s guide safety labels

Safety Labels Safety labels are posted on all SLS process machines. The following table describes each of these labels.

SAFETY LABEL WHAT IT MEANS

ELECTRIC SHOCK HAZARD High voltage electricity is accessible in the vicinity of this sign or behind the access panel. High voltage can cause severe burns or death. Access panels are for service only and should be opened only by certified service personnel or trained maintenance personnel.

HOT SURFACES HAZARD There 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 around the RCM part cylinder.

LASER RADIATION HAZARD Invisible laser radiation is accessible in the vicinity of this sign or behind the access panel. Direct and scattered radiation can cause severe burns and blindness. Access panels are for service only and should be opened only by certified service personnel. See Laser Safety on page 20. SLS process 16 SAFETY user’s guide safety labels

SAFETY LABEL WHAT IT MEANS

CRUSH HAZARD Mechanical motion of machine components presents a crush hazard in the vicinity of this sign. Crush hazards can result in severe bodily injury or death. See Mechanical Motion Hazard Locations on page 33.

ROTATING BLADE CUTTING HAZARD Rotating motion of machine blade or impeller presents a cutting hazard in the vicinity of this sign. Cutting hazards can result in severe bodily injury or death. See Mechanical 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 the vicinity of this sign. Failing to shut off the main powder valve before servicing can result in sudden explosive escape of air-pressurized powder. This can result in bodily injury or fire if the powder cloud ignites. See DuraForm Package Handling Safety on page 35. SLS process 17 SAFETY user’s guide electrical safety

Electrical Safety To prevent electrical shock, SLS equipment will When operating any SLS equipment, keep the not operate unless all external panels are following electrical safety points in mind: installed and all electrical safety interlock circuits ✓ Only 3D Systems certified service personnel are closed. should operate SLS equipment with access Hazardous voltage exists inside the panels or service doors open. enclosures of all SLS equipment. ✓ Heed high voltage warning signs and labels. Injury or death from electrical shock ✓ can result if you remove external Take common-sense safety precautions when panels or try to defeat safety operating any electrical equipment. interlocks. Panels should only be ✓ After any change to the electrical wiring, removed, and interlocks should only make sure the equipment is properly be defeated, by trained and certified grounded. 3D Systems Customer Support personnel.

Verify your facility’s electrical service ratings before connecting power to any SLS equipment.z Power must only be connected by certified electrician.

All SLS equipment was designed to minimize operator exposure to electrical hazards during normal operations. All exposed electrical circuits are inside limited-access cabinets. This is to separate the operator from service and maintenance areas. SLS process 18 SAFETY user’s guide environmental issues

Environmental Issues The SLS system emits no toxic substances when Waste Heat using materials approved by 3D Systems. Almost all the electrical power used by the SLS system and RCM is converted to heat that must Emissions be removed from the room. Air conditioning for Powder heating – Analytical testing on the installation room should be sized based on 3D Systems powders indicates no detectable room dimensions; the size, number, and location emissions outside acceptable limits from the of wall openings (such as windows and doors), SLS system. (See the MSDS’s.) the number of people typically working in the room, and the electrical power supplied to the Nitrogen – The SLS system uses nitrogen, which SLS system(s) and RCM(s). must be passively vented to the outside. Use the sPro SLS system, RCM-140, and L Do not install a fan in the nitrogen vent. The RCM-230 electrical power requirements below nitrogen-inert atmosphere in the SLS system process chamber is at higher pressure than the to size your facility A/C: outside atmosphere. The chamber will vent without a fan. Installing a fan in the nitrogen MACHINE POWER (HEAT) vent will draw nitrogen-rich air out of the sPro 17 kW (~58000 Btu/h) process chamber too fast, raising the oxygen concentration in the chamber. This can keep RCM-140 4.8 kW (~16400 Btu/h) the SLS system from reaching inert, or cause an RCM-230 5.3 kW (~18000 Btu/h) in-process build to abort. BOS/IRS negligible (compared to SLS system and RCM) for the purpose of A/C sizing

Powder Disposal Refer to the DuraForm material MSDS for disposal information. Follow any applicable local regulations. SLS process 19 SAFETY user’s guide environmental issues

Noise Levels The following table quantifies the noise levels for various components of the SLS system.

EQUIPMENT NOISE LEVEL <85 dBA @ operator SLS System standpoint BOS and Dust Collector BOS only <85 dBA @ operator Dust Collector only standpoint Dust Collector self- cleaning cycle IRS idle IRS transporting <85 dBA @ operator powder standpoint IRS blending powder SLS process 20 SAFETY user’s guide laser safety

Laser Safety The SLS system You can read more about laser safety and contains a 70-watt See Laser Safety classifications in ANSI Z136.1-1993 (the American continuous-wave CO2 Classifications below. National Standards Institute standard for the safe laser. The laser itself is use of lasers). designated Class IV. Very brief exposure to a direct—or specularly or diffusely reflected—laser Reporting Laser Radiation Exposure beam can cause significant burns or eye damage. If anyone at your site is exposed to laser radiation It can also be a fire hazard. from the SLS system, report the following During normal operations of the SLS system, the information to 3D Systems, Inc.: laser beam path is wholly contained within the ` Nature of the accident and circumstances machine. This makes the entire machine a Class I surrounding it Laser System. That means the SLS system does not produce damaging emissions under normal ` Where the accident occurred operations. ` Model and serial number of the machine ` Number of people involved Laser Safety Classifications ` Any other pertinent information Class I and Class IV are designations established by the U. S. Department of Health and Human Please send this information to 3D Systems Services, Public Health Service, Food and Drug within a day of the accident. The information can Administration, Center for Devices and be sent by regular mail to 3D Systems marked Radiological Health (CDRH), and by IEC 60825 “Attention: Laser Safety Officer” or by e-mail to (the International Electrotechnical Commission's [email protected]. 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. SLS process 21 SAFETY user’s guide laser safety

Laser Safety Labels on the SLS system The SLS system has the two types of laser safety labels below. Laser safety label locations on the SLS system on shown in the figures that follow the table.:

LASER SAFETY LABEL WHAT IT MEANS LASER RADIATION HAZARD Invisible laser radiation is accessible in the vicinity of this sign or behind the access panel. Direct and scattered radiation can cause severe burns and eye injury, or start a fire. Access panels are for service only and should only be opened by certified service personnel. See Laser Safety on page 20. DEFEATABLY INTERLOCKED PROTECTIVE HOUSING CAUTION If you defeat the SLS system laser safety interlocks, then open this CLASS 4 INVISIBLE LASER RADIATION WHEN OPEN AND housing (panel or door), you can be exposed to hazardous direct INTERLOCKS DEFEATED and scattered Class 4 invisible laser radiation which can cause AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION severe burns and eye injury, or start a fire. Interlocked SLS system panels and doors are for service only and should only be opened only by certified service personnel. See Laser Safety on page 20.

LASER CERTIFICATION/IDENTIFICATION Identifies laser system Class and shows CDRH Statement of Compliance. SLS process 22 SAFETY user’s guide laser safety

LASER RADIATION HAZARD LABEL LOCATIONS

Behind raised laser window access door

Behind the process chamber cover

On process chamber left and right exterior wall (right side not On IPM top shown) access panel

On process chamber rear interior and exterior wall SLS process 23 SAFETY user’s guide laser safety

DEFEATABLY INTERLOCKED PROTECTIVE HOUSING LASER LABEL LOCATIONS

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 back panel of IPM on IPM access panel

On front face of IPM; (Internal) on IPM base plate; visible after behind raised laser window access door removing the IPM access panel SLS process 24 SAFETY user’s guide laser safety

LASER CERTIFICATION (AND MACHINE IDENTIFICATION) LABEL LOCATION

Laser certification on machine ID label

Machine ID label at left rear of SLS system, on AC chassis door SLS process 25 SAFETY user’s guide laser safety

General Laser Safety Rules

Use of controls or adjustments, or ` Do not operate the SLS system with a broken performance of procedures other or missing window. than those specified herein, may ` Operate the SLS system in accordance with result in hazardous radiation all local regulations. If your state or national exposure. government does not provide guidelines for Failure to follow laser safety rules can operation of Class I laser systems, refer to also result in exposure to hazardous ANSI Z136.1-1993 (American National radiation. Radiation can cause burns Standards Institute standard for the safe use on the skin and cornea, which can of lasers). temporarily or permanently damage ` Only certified service personnel specifically your vision. trained in laser safety should perform laser service procedures. You should always comply with the following rules when working with laser equipment. ` Do not enter any area displaying posted warning signs during open beam operations. ` Operators must attend a training class for Open beam operations occur only during SLS system procedures. service procedures and with a warning sign ` Operate the SLS system only with the RCM posted. properly loaded and all process chamber covers in place. The SLS system laser is enclosed in a protective housing to prevent exposure to radiation. The protective housing has tool-access locks to prevent access to the laser during normal SLS system operation. However, if someone tampers with or defeats the interlocks and opens the protective housing, the potential for exposure exists. ` Do not look directly into a laser beam or even at diffuse reflections of a beam. SLS process 26 SAFETY user’s guide laser safety

Laser Service and Maintenance Laser Service Guidelines WARNING! SLS system laser service On occasion, certified service personnel must and maintenance procedures must perform alignment or focus adjustments on the only be performed by 3D Systems- SLS laser or beam delivery system. When this certified service technicians. occurs, certified service personnel at your site Attempts by non-3D Systems- should follow the special laser safety precautions certified personnel to perform laser described in the following list: service or maintenance procedures ` Certified service personnel should secure the could result in serious injury. All SLS room containing the SLS system; it is called the system users must observe the Nominal Hazard Zone (NHZ). The room must guidelines and warnings in the “Laser have locks on the door(s) that limit entry but Safety” section of this guide. do not restrict exit. If the SLS system is in an The SLS system conforms to applicable area that cannot be secured by door locks, requirements of 21 CFR Subchapter J at date of your company must provide laser safety manufacture. It is designated a Class 1 Laser curtains or alternative safety precautions. Device by the Center for Devices and Radiological ` Certified service personnel should post Health (CDRH). In normal operation, the laser Exposed Non-Visible Laser in Operation signs at beam is completely confined and the viewing each entrance to the room containing the windows in the process chamber block infrared SLS system. radiation. 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 process 27 SAFETY user’s guide laser safety

` Certified service personnel should notify and instruct everyone in the area to wear safety glasses (ANSI Z136.1-1993 section 4.6.2 and ANSI Z87.1; DIN 58215/01.86 and DIN 58219/ 02.86). 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 personnel should comply with all of your safety requirements. SLS process 28 SAFETY user’s guide powder safety

Powder Safety All powders certified by 3D Systems are safe Powder Ignition Information during normal operation. However, you should Powdered materials can be flammable and can be aware of the following issues: be ignited by static electricity in a non-inert ` Any powder, powder-like substance, or environment. Refer to each powder's MSDS for airborne cloud of powder has a remote specific information. chance of rapid combustion. Use only a safety agency-approved ` Breathing some powders may cause certain vacuum rated for explosive people to experience respiratory irritation. environments to clean up powder. ` Powder safety hazards are minimized by Contact 3D Systems Customer good industrial housekeeping and Support for vacuum supplier ventilation practices. recommendations. ` Spilled powder can cause the floor to become very slippery. Finding Powder Safety Information ` Powder should be sifted in a well-ventilated Use the Powder Safety Information table on room. page 29 to locate references and contacts for information on important powder safety topics. Refer to the MSDS’s and to 3D Systems material Also check the MSDS of the material used for the guides for information on specific powders. specific precautions to be observed. Using materials that have not been certified for use in the SLS equipment may cause health or safety hazards and may damage to the equipment and void the warranty. SLS process 29 SAFETY user’s guide powder safety

Powder Safety Information

TOPIC REFERENCE / CONTACT Standard industrial US: American Conference of Governmental Hygienists, Committee on Industrial ventilation practices Ventilation Europe: Maximale Arbeitsplatz Konzentration, January 1990 Housecleaning and US: NFPA 654: Standard for the Prevention of Dust Explosions in the Plastics Industry; prevention of National Fire Protection Association, Volume 5 of the National Fire Codes accumulation of Europe: Maximale Arbeitsplatz Konzentration, January 1990 explosive dust concentrations 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 Material Safety Data Sheets (MSDS) from 3D Systems, Inc.: materials US/Canada: Europe Mfgr. Contact: 3D Systems Corporation 3D Systems GmbH 333 Three D Systems Circle Guerickeweg 9 Rock Hill, SC 29730 USA D-64291 Darmstadt, Germany Information Phone: 803-326-4080 or Phone: +49 (0) 6151 357-357 Toll-free: 800-889-2964 Fax: +49 (0) 6151 357-111 Emergency 800-424-9300 - Chemtrec 703-527-3887 - Chemtrec (U.S.) SLS process 30 SAFETY user’s guide powder safety

Powder Handling Precautions During normal operation of the SLS system using 3D Systems’ materials, you are not required to wear a dust mask or special personal protection equipment unless specifically designated. Check the MSDS of the material used for the specific precautions you should observe. Use the following table of precautions as a general guide: Safe Powder Handling Guidelines

CATEGORY PRECAUTION • Never smoke or ignite any materials around powder. • Maintain proper clearance from powders when using portable heating devices. • Store flammable liquids away from powder. FIRE/HEAT • 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. • Avoid breathing powdered materials; when exposure to dust or fumes is likely, wear a INHALATION NIOSH approved respirator appropriate to the airborne concentration. • Always provide adequate ventilation. • Train operators in SLS system procedures. • Wear safety glasses. SHOP SAFETY • Use extreme care with all heated powders. • Make sure that the room is well ventilated. SLS process 31 SAFETY user’s guide powder safety

Safe Powder Handling Guidelines (continued)

CATEGORY PRECAUTION • Keep containers closed when not in use. AVOIDING • Have a fully-grounded internal non-ignition vacuum cleaner ready to use. SPILLS • Have any equipment specified in the MSDS ready to use. • 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. MSDS • File MSDS’s in an easily accessible location for immediate reference. • Strictly follow all the conditions in each MSDS. SLS process 32 SAFETY user’s guide nitrogen/oxygen safety

Nitrogen/Oxygen Safety The SLS system uses nitrogen to create an inert The table of Oxygen Deprivation Effects and atmosphere in the process chamber. The Symptoms on page 33 explains the potential nitrogen inhibits any potential rapid combustion effects and symptoms that can occur at different of particulate matter during the selective laser concentrations of oxygen in the atmosphere. sintering process. When you work in an environment that may The oxygen content of air is approximately 21 become oxygen-deficient, make sure you comply percent. Displacement of the normal atmosphere with the following items: with an inert gas, such as nitrogen, can reduce ` You have received oxygen/nitrogen safety the oxygen content in a room. In the remote training. chance that nitrogen leaks into the room during the sintering process, the situation can be ` The room is well-ventilated; at least 4 air hazardous. exchanges per hour. Your site must have an oxygen alarm monitor ` Self-contained breathing apparatus is installed in the room containing the available and easily accessible. SLS system. This monitor will alert you if the ` The room oxygen alarm monitor is oxygen level drops below a designated point. It functioning and audible must be wired to trigger an immediate shutdown ` Leave the SLS system room/area immediately of the SLS system and nitrogen generator (if in when you hear the oxygen alarm. use). Exposure to an atmosphere containing 12 percent or less oxygen causes unconsciousness without any warning symptoms. This happens so quickly that you cannot help or protect yourself. SLS process 33 SAFETY user’s guide nitrogen/oxygen safety

Oxygen Deprivation Effects and Symptomsa

OXYGEN CONTENT (% BY VOLUME) EFFECTS AND SYMPTOMS AT ATMOSPHERIC PRESSURE Decreased ability to work strenuously. May impair your coordination or may 15 – 19 % induce early symptoms in persons with coronary, pulmonary, or circulatory problems. Increases respiration during exertion. Pulse rate goes up. May experience 12 – 14 % impaired coordination, perception, and judgment. Respiration continues to increase in rate and depth. Lips become blue. May lose 10 – 12 % consciousness at this point. Mental failure. Fainting and unconsciousness. Face becomes ashen, lips become 8 – 10 % blue. Nausea and vomiting may occur. 100% fatal after 8 minutes of exposure. 6 – 8 % 50% fatal within 6 minutes. Recovery with treatment within 4 to 5 minutes. 4 – 6 % Coma within 40 seconds; convulsions, respiration ceases, death occurs. a. From Safety Bulletin SB-2 - 1983—”1983 by the Compressed Gas Association, Inc. 1235 Jefferson Davis Highway, Arlington, VA 22202 SLS process 34 SAFETY user’s guide mechanical motion hazard locations

Mechanical Motion Hazard Locations You should be aware of the following pinch, crush, and rotating blade hazard locations on the SLS equipment:

BOS door The BOS door is hinged at the top Keep hands with props on the left and right sides to help away from you safely raise and lower it. To avoid injury, BOS door always follow these precautions when side props opening and closing the BOS door: and hinges ✓ Warn anyone near the BOS before you open or close the door. ✓ Keep hands Open and close the door with both away from hands on the handle. the front ✓ Fully open or close the door. Do not and sides of leave it partially open or closed. the RCM ✓ when Keep hands away from the door props docking on the right and left sides of the door. ✓ Make sure anyone working near the BOS Use both hands on handle when Keep protective has their hands clear of the door before opening BOS door. grate on top of Keep hands off BOS table top (and hands out of) you open or close it. when closing door. the BOS powder BOS powder transport hopper Do not transport hopper 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 BOS RCM seal Always clip the hinged BOS RCM front and sides RCM when you dock it in the SLS seal in its up position before docking the RCM. system or BOS. SLS process 35 SAFETY user’s guide hot surfaces and powders

Hot Surfaces and Powders The SLS system process chamber and the RCM both contain heaters. During and after a build, the surfaces of both are hot—and they both contain hot materials. Take the following precautions to avoid burns: Avoid hot Always wear personal surfaces behind protective equipment feed hopper (insulated gloves) when access doors handling the RCM. ✓ Know which surfaces in the process chamber are likely to be hot after a build. These are indicated by warning labels (described in Safety Labels on page 15). Avoid those Allow system to cool with door open after a build surfaces when docking and removing the RCM. Avoid hot RCM part ✓ Use appropriate gloves when cylinder surfaces removing the part cake from the Wear gloves when RCM, or let the part cake cool for you pull the RCM out several hours before you touch it. of the SLS system ✓ Avoid hot process chamber surfaces after a build. The behind Hopper Feed Module access handle might be hot. doors on left side of SLS system. SLS process 36 SAFETY user’s guide DuraForm material handling safety

DuraForm Material Handling Safety

Emergency (MSDS) Storage ChemtrecUSA (800) 424-9300; The shelf life of DuraForm PA model material is Europe +1-703-527-3887 one year from date of manufacture. Each IPC is tagged with its expiration date. Use the oldest Packaging Inspection IPCs first. DuraForm material should be kept DuraForm material is packaged in the Intelligent indoors in a cool, dry area with adequate Powder Cartridge (IPC). Upon receipt of a ventilation, and at temperatures between 16°C material shipment, inspect the IPC for signs of (60°F) and 27°C (80°F). DO NOT EXCEED A physical damage and evidence of leakage by MAXIMUM STORAGE TEMPERATURE OF 35°C inspecting the exterior. If leakage or damage is (95°F). Keep away from direct sunlight, heat, observed, do not connect the IPC to the flames and other direct light or UV energy Integrated Recycling Station (IRS), and contact sources. 3D Systems Customer Support Hotline. If no Never try to open an IPC. Material leakage or damage is observed, store the full IPCs must only be removed from the IPC safely according to the storage guidelines below through the IRS umbilical. until you need to refill your IRS. SLS process 37 SAFETY user’s guide IPC handling safety

IPC Handling Safety DuraForm material ships in a recyclable, palletized container called an IPC. Air flows into the IPC, and powder flows out of it, through the IRS powder fill hose. The IPC is designed to remain in its crate during operation. Before connecting the IRS powder fill hose to the IPC always check that the crate is intact (see image on next page). Here are some details on the design of the IPC:

Overpressure sensor line connection at top of IPC (available through crate opening at bottom)

IPC sidewall an cover

IRS umbilical connection point.

Material expiration The material expiration date Damage or leakage The IPC is pressurized when is printed on the IPC shipping tag in the plastic in use. Before you connect an IPC to the IRS— shipping pouch attached to the cover. Do not inspect it for damage or powder leakage. Do not connect an IPC to the IRS if the material is about connect a leaking or damaged IPC. to expire. When the IRS detects an expired IPC, it Never uncrate or try to open an IPC. will not draw powder from the IPC and the yellow Powder must only be removed from the IRS Stacklight will flash. IPC using the IRS umbilical. SLS process 38 SAFETY user’s guide IPC handling safety

Lifting and Moving the IPC The IPC is designed to always remain in its built- in crate. The crated IPC can be lifted and moved with a pallet jack. Do not try to lift or move it manually, 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 use a mechanically assistance such as a pneumatic lift cart.

Crated IPC SLS process 39 SAFETY user’s guide shutdown

Shutdown Unless there is an Depressurization emergency, always See Emergency Shutdown on page 40 The SLS system, IRS, and BOS all connect to shut down SLS process facility compressed air. In addition, the IRS machines in a safe, for SLS process machine emergency shutdown pressurizes the IPC container. orderly way. instructions. Normal shutdown requires proper Only use E-stop to shut down a depressurization. Be sure to follow the machine in an emergency. Shutting depressurization instructions for the individual down a machine with E-stop can machines in the shutdown procedures above. result in data loss and material waste.

Proper shut down procedures for each SLS process machine are found in the following sections of this guide: SLS Sys tem – Shutting Down the SLS System on page 192 of the SLS System section. IRS – Shutting Down the IRS on page 168 of the IRS & IPC section. BOS – Shutting Down the BOS on page 232 of the BOS section. SLS process 40 SAFETY user’s guide emergency shutdown

Emergency Shutdown Every SLS process machine has at least one large red emergency stop button (“E-Stop”). If you press an emergency stop button on a machine, that machine—and any other machine or device it’s controlling—shuts down immediately and completely. To ensure safety, train everyone at your site who works on or near SLS equipment how to stop these machines in an emergency.

SLS Process Machine E-Stop Locations and Effects

MACHINE E-STOP LOCATIONS WHAT E-STOP DOES... •Stops laser • Switches off all heaters, (including RCM heaters if RCM connected) • Stops all motion inside the SLS system • On user interface console. (including RCM motion if RCM (See SLS System Features on page 182.) SLS SYSTEM connected) • Internal: behind right and left side • Stops nitrogen flow into the SLS system process chamber access doors • Stops all powder transport from the IRS and within the SLS system • Switches off application computer, process chamber lights, and Stacklight • Stops powder transport from the IPC, to/ from the BOS and SLS system, and within On IRS operator panel. IRS the IRS (IRS Features on page 135.) • Switches off IRS operator panel and Stacklight SLS process 41 SAFETY user’s guide emergency shutdown

SLS Process Machine E-Stop Locations and Effects (continued)

MACHINE E-STOP LOCATIONS WHAT E-STOP DOES... • Stops all motion inside the BOS (including RCM motion if RCM connected.a) • Stops forced air exhaust out of the BOS (if On BOS operator panel. BOS Dust Collector connected) (See BOS Features on page 209.) • Stops all powder transport from the IRS and within the SLS system • Switches off BOS operator panel, interior work light, and Stacklight SLS process 42 SAFETY user’s guide emergency shutdown

SLS Process Machine E-Stop Locations and Effects (continued)

MACHINE E-STOP LOCATIONS WHAT E-STOP DOES... When connected to SLS system: • On SLS system user interface console when connected to SLS system. See SLS The RCM is completely controlled by the System Features on page 182. machine its cable is connected to the SLS • Internal: behind right process chamber system or BOS. Pressing E-stop on one of access doors these machines when the RCM is RCM connected: • Switches off all RCM cylinder heaters and the part piston heater.a When connected to BOS: • Stops all RCM part piston motion. • On BOS operator panel. BOS Features on page 209. The IPC is completely controlled by IRS. • Pressing E-stop on any machine except the IRS will not stop powder flow from On IRS operator panel. IRS Features on the IPC to the IRS or depressurize the IPC IPC page 135. container. • Pressing E-stop on the IRS will stop powder flow from the IPC to the IRS and depressurize the IPC powder container. a. When the RCM is connected to the BOS RCM cable, the RCM heaters cannot be enabled. SLS process user’s guide

SLS PROCESS This section introduces you to 3D Systems’ unique SLS process and the SLS equipment you use to 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 ` About Installation and Facility Requirements ...... 51 ` SLS Process Overview ...... 45 ` About the Powder Management System 52 ` SLS Process Steps ...... 47 ` Adding SLS Process Capacity ...... 53 ` About SLS Equipment ...... 49 SLS process 44 SLS PROCESS user’s guide what is the “SLS process”?

What is the “SLS Process”? “SLS” stands for “Selective Laser Sintering”; an Compared to other rapid manufacturing additive rapid manufacturing technique that methods, SLS can produce parts from a relatively uses a high power CO2 laser to fuse DuraForm wide range of commercially available powder plastic powder into a mass representing a materials, including polymers (nylon, also glass- 3-dimensional object, or “part.” filled or with other fillers, and polystyrene), metals (steel, titanium, alloy mixtures and The laser selectively fuses powder by scanning composites) and foundry sand. The physical cross-sections generated from a “sliced” 3-D process can be full melting, partial melting, or digital description of the part (e.g. an STL file liquid-phase sintering. And, depending on the created from a CAD file) on the on a smooth bed material, up to 100% density can be achieved of powder. Typically, the taller a part is, the more with material properties comparable to those cross section layers it has. The number of layers from conventional manufacturing methods. In can run into the thousands. many cases large numbers of parts can be packed After the laser scans each cross-section, the within the powder bed, allowing very high powder bed lowers by one layer thickness, a new productivity. layer of material is applied on top, and the process repeats until the part is done. SLS is performed by machines called SLS systems; the most widely known model of which is the sPro® SLS system. SLS technology is in wide use around the world due to its ability to easily make very complex geometries directly from digital CAD data. While it began as a way to build prototype parts early in the design cycle, it is increasingly being used in limited run manufacturing to produce end-use parts. SLS process 45 SLS PROCESS user’s guide SLS process overview

SLS Process Overview ➊ ➊ Design... ➋ 3-D CAD models of the parts you want to build. save them as STL files. When you’re done, open 3D System’s Build Setup application. See Build Setup application online Help. ➋ Set up... ➌ a build packet in Build Setup using the part STL files you designed. Assign custom or default part profiles 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 ➍ save your build packet. See Build Setup Help and your Material Guide. ➌ Clean & Preheat... the SLS® system and RCM. The RCM will hold your part cake. ➎ ➏ ➍ Load, Blend, & Send... batches of virgin powder from the IPC and used powder from the BOS via the IRS. During builds and between builds, the IRS continually receives, blends, and sends powder to the feed hoppers in up to three SLS systems. SLS process 46 SLS PROCESS user’s guide SLS process overview

➎ Build... parts in the SLS system. First you dock the cake. As you remove used part cake powder clean (optionally preheated) RCM in the SLS during breakout, you can use the BOS to system, run the Sinter application from the automatically sift and either recycle or SLS system console, load the RCM, then dispose of it. All that remains after breakout is choose the build packet you want to build in to fine-clean and optionally finish coat your Sinter. parts. After you start your build, the SLS system ➐ Voilà!... warms up and inerts the process chamber. Here are your parts! Then a roller spreads a thin layer of powder across the heated powder bed in the process chamber. A laser beam scans one or several part cross sections on the layer, fusing powder along the scanning path. The many (possibly thousands) 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. ➏ 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, or, you can remove the RCM while it’s still warm. After the part cake is cool enough to handle, you dock the RCM in the BOS, raise the part cake, then breakout the parts from the part SLS process 47 SLS PROCESS user’s guide SLS process steps

SLS Process Steps The general steps are as follows: way in.) Plug the RCM cable into the RCM, then close the RCM door. 1 Connect an IPC to the IRS. 2 At the SLS system console, run the Sinter See Connecting an IPC to an IRS on page 66 application, wait about 30 seconds until the 2 Power on the IRS, SLS system, and BOS. DSPIF button appears in the Windows See Starting the Equipment on page 60. taskbar, then choose ManOps > Piston Control. Separate machine start-up instructions are also found in: 3 In the Piston Control window:

Starting the SLS System (only) on page 191 a Click the Load button under RCM, then wait until the RCM Status shows Engaged. IRS Start-up on page 154 b Click the Home Limit button under Part BOS Power-Up Sequence on page 219 Piston to move the piston in the RCM to its lowest (“home”) position. (This takes several minutes.) 3 Turn on your facility compressed air open air valves at the IRS, SLS system, and BOS. L At this point, if Build Set-Up has already been performed, the Inert and Pre-Heat steps can be 4 If you’re using liquid nitrogen tanks (instead disregarded, as these functions occur of the 3D Systems Nitrogen Generator), open automatically upon starting the build. If the the nitrogen supply valve at the tank. build set-up has not been performed, inerting and pre-heating manually can reduce the amount of wait time before the roller begins moving. 4 Select the Inert button and select Enable. Power on and start up the SLS system and IRS. 5 Minimize the Sinter application, open Build 1 Open the RCM door on the front SLS system, Set-Up and begin performing that function. then roll the (optionally pre-heated) RCM into the RCM bay. (Be sure to push the RCM all the SLS process 48 SLS PROCESS user’s guide SLS process steps

6 Once the Part Piston has been homed, 14 When the build has completed, open the maximize the Sinter application and select front access panel, unplug and remove the Start position in the Piston Control screen. RCM. 7 Continue Build Set-Up 15 If a controlled cool-down is not required, the 8 Once the piston has been homed, open the RCM can be moved directly to the BOS for Roller command and select the home radio part removal. button. 16 Once in the BOS, the parts are removed from 9 As soon as the roller is homed, select the the cake and the remaining powder is Level Powder command and begin leveling processed through the BOS to the IRS. powder. 17 Clean the machine, insert the next RCM, and 10 Once the machine has reached an inert level repeat the process. (<5.5% O2), select the Heat radio button to open the heater function and enable all of the heater selections. 11 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 machine. SLS process 49 SLS PROCESS user’s guide about SLS equipment

About SLS Equipment This section introduces you to each piece of equipment used in the SLS process. L Refer to the equipment operations sections in the second half of this guide for detailed component descriptions, locations, and functions.

SLS system This 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 taller parts in a taller RCM. L The “140” and “230” sPro model numbers indicate the maximum part cake build volume for the machines; i.e, 140 liters or 230 liters. SLS process 50 SLS PROCESS user’s guide about SLS equipment

IRS & IPC BOS During a build, the When a build is complete, you need to remove IRS sends powder to the sintered parts from the part cake in the RCM the SLS system on and clean them. Removing parts from the part request. The IRS cake is called “breakout.” 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.

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 parts in your Material Guide. SLS process 51 SLS PROCESS user’s guide about installation and facility requirements

About Installation and Facility Requirements 3D Systems certified service personnel install the Connecting your network SLS equipment. Prior to installation, your The SLS system computer can be connected to company receives specific facility requirements your existing TCP/IP (Ethernet) network. and a pre-installation facility checklist from However, if you connect the SLS system 3D Systems. computer to your network, do not use the For complete information, refer to the following IP addresses: ` SLS Process Facility Guide and 192.88.202.1 ` SLS Process Facility Layout for sPro SLS 192.88.202.2 fmodels 140 and 230. These addresses are used by the beam delivery The pre-installation facility checklist must be system. If this presents a problem, contact the completed and returned to 3D Systems Customer 3D Systems Customer Support Hotline for Support before you can schedule installation. technical assistance. SLS process 52 SLS PROCESS user’s guide about the powder management system

About the Powder Management System 3D System’s Powder Management System When does the IRS send data to APMU? enables powder transfers between SLS process The IRS sends data to the APMU when it: machines, logs data about every transfer, and helps prevent contamination of the SLS system • reads and updates the IPC RFID tag powder supply. • finishes blending a batch of powder • sends powder to the SLS system What does PMS consist of? • receives recycled powder from the BOS PMS has two main software components: • detects a change in the weight of one of its bins, though no powder transfer is ` PowderNet – A closed network connecting occurring all the SLS machines with the IRS as its hub (the server) and the SLS system(s) and BOS as clients. The BOS, IRS, and SLS system(s) send When does APMU stop powder transfers? send powder transfer messages over to each Normally, APMU operates invisibly in the other over this network, along with data background. However, it will stop all powder about the transfers. transfers to preserve powder integrity if the IRS ` APMU – A database application, which sends it an error message saying it: resides on one of the client SLS system ` Cannot validate the RFID tag for the currently computers. APMU logs data the IRS sends connected IPC about every powder transfer, such as ` Detected a change in the weight of one of its machine ID, date and time, amount bins, though no powder transfer is occurring transferred, and bin weights. The APMU shuts down powder transfers if the powder data After either one of these events, the APMU suggest the powder integrity has been disables powder transfers, logs the error event in compromised. its database, then waits for the error to be fixed. See Reactivating Powder Transfers on page 175 in the IRS & IPC Troubleshooting section. SLS process 53 SLS PROCESS user’s guide adding SLS process capacity

Adding SLS Process Capacity You can grow your capacity to produce SLS parts Use multiple RCM’s by doing the following: The easiest and simplest way to increase your SLS ` Use multiple RCMs to reduce time between parts production capacity is to use two or three builds RCM’s per SLS system instead of one. This minimizes the time between builds by enabling ` Connect multiple SLS systems to a single IRS you to breakout or preheat one RCM while to perform multiple concurrent builds another is in build or breakout.

Reducing time between builds with multiple RCMs

RCM in build RCM cooling down RCM in breakout SLS process 54 SLS PROCESS user’s guide adding SLS process capacity

Use multiple SLS systems To increase capacity further, 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. Build (C) Run concurrent builds on multiple daisy-chained SLS systems fed by one IRS Build (B) powder in

powder out

powder in

Build (A) powder out

powder in SLS process user’s guide

PREPARE TO BUILD This section describes what you need to do before you can build parts in the SLS system. It steps you through the following procedures:

` Setting Up a Build Packet...... 56 ` Preheating the RCM ...... 68 ` Cleaning and Checking Equipment . . . . . 59 ` Docking the RCM in the SLS System. . . . . 69 ` Starting the Equipment ...... 60 ` Pre-Build Checklist ...... 70 ` Unloading the IPC...... 65 ` Verifying Sufficient Powder ...... 71 SLS process 56 PREPARE TO BUILD user’s guide setting up a build packet

Setting Up a Build Packet The instructions in this section summarize the ` Reposition parts in build volume more detailed build setup instructions in your ` Set “build” and “part” parameters Build Setup application Help. ` Save the build packet file. You can set up a build ` Copy the build packet (.bpf) file to your SLS packet on the SLS There are advantages to system computers ..\dtm\build folder system computer or a setting up your build standalone PC. These packet on a standalone Each procedure is summarized below. See your PC if you have several instructions are for Build Setup Help for detailed instructions. different SLS systems. setup on a standalone For example, you can PC. After you learn create and preview Run Build Setup how to start up the builds for more than 18 Login to Windows on your standalone PC. SLS system (which one SLS system model comes later in SLS (platform) on a single 19 Choose Start > Programs > SLS System > system start-up on computer. See Platforms Build Setup. page 61), you can > Standalone Build 20 Build Setup starts with its Main window setup build packets on Setup in your Build displayed showing an empty virtual build Setup Help for more. the SLS system volume, known as the Workspace. computer if you wish. To set up a build packet, you need to do the following: Add STL files to build packet ` Run the Build Setup application SLS systems can build parts from computer-aided L Build Setup is installed when you install the design (CAD) data saved in the STL file format. LS Software on your PC. Install the LS You add parts to your build by selecting the Add software now if you have not done so. To tab on the left side of the window. Then use the install, insert the LS Software CD in your file browser to locate an appropriate STL file, and standalone PC and follow the prompts. drag and drop the file onto the representation of ` Add STL files (“parts”) to your build the build area. SLS process 57 PREPARE TO BUILD user’s guide setting up a build packet

Add tab in Build Setup Main view

Reposition parts in the Workspace (build You set parameters in Build Setup’s Part Profile volume) Editor and Build Profile Editor dialog boxes. Build Setup gives you many ways to move parts Parameters control most aspects of how a part is around in the Workspace. For example, you can: built. ` Drag parts ` Positioning parts numerically ` Snap parts a 3-D grid ` Rotate and align parts to each other or a plane You can even have Build Setup place your parts automatically. 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 Build Profile Editor in Build Setup “Parameters” are settings in a build packet that And, as with part placement, you’ll eventually you can change. Parameter settings apply to discover the best parameter settings for the types parts or the entire build. of parts you build most often. SLS process 58 PREPARE TO BUILD user’s guide setting up a build packet

Save and Verify Build Packet When all parts are arranged and parameters are set, the last step is to save and verify the build packet. This step ensures that the build will work. It also creates a sorted facet file (.sff) 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 point, you copy this .bpf file to the ..dtm\build folder on your SLS system computer, then run the build packet in the Sinter application. SLS process 59 PREPARE TO BUILD user’s guide cleaning and checking equipment

Cleaning and Checking Equipment Follow these procedures to clean the 4 Clean the overflow screens before a build if SLS equipment before you build parts. For necessary. Check the overflow screens in the detailed cleaning instructions, refer to the overflow chutes on the right and left sides of sections indicated. the process chamber before a build. Clean them with a vacuum. Clean the SLS system See To clean overflow chutes and screens on 1 Clean the IR sensor before every build. You page 200. can access the IR sensor for cleaning using 5 Clean the process chamber window as one of the three possible IR sensor methods. necessary using a clean, dry dust rag. See Cleaning the IR sensor and blackbody on 6 Clean the RCM before every build, before page 199. preheating, and after you remove the RCM 2 Clean the roller if you see material adhered to rim. Vacuum the rim and cylinder. it. (You should not have to clean the roller 7 Check the N2 and chiller coolant flow on the after every build unless the roller was run SLS system gauge panel before you build. “cold,” which can cause material to adhere to Verify that three flow gauges read as follows: it.) • IR WINDOW N2 FLOW (2 to 3) L/min Use a rag and alcohol to clean the roller after you move it to the center and unload the • LASER WINDOW N2 FLOW (5 to 8) L/min RCM. • COOLANT FLOW (4 to 5) L/min

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. SLS process 60 PREPARE TO BUILD user’s guide starting the equipment

Star ting the Equipment You need to power-on and start all your 2 IRS start-up (page 64) SLS equipment before you can build parts. The Start the IRS and load virgin powder into it if SLS equipment start-up sequence, and start-up necessary. For loading instructions, see IRS & sequences for each machine are summarized in IPC on page 133. this section. 3 BOS start-up (page 64) SLS equipment startup sequence Start the BOS if you plan to recycle powder from the BOS back to the SLS system.

1 SLS system start-up (page 61)

Make sure the room O2 alarm monitor is on, then start the SLS system, chiller, and nitrogen generator. Before you start the SLS system or N2 generator, verify that the room O2 alarm monitor is ON and that the O2 alarm cable is properly connected to the SLS system gauge panel.

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. SLS process 61 PREPARE TO BUILD user’s guide starting the equipment

L To save time, connect the RCM now and begin POWER-ON SLS SYSTEM preheating it, then continue starting the other 1 Turn on the SLS equipment. See Preheating the RCM on system’s main See SLS System Features page 68. power disconnect on page 182 to locate switch on the AC the switches in this startup procedure. Also SLS system start-up chassis door (at left see Starting the SLS Before you power on the SLS system rear of SLS system). System (only) on or open the N2 generator air supply 2 Turn on SLS system page 191. The SLS valve, verify that the room O alarm 2 UI monitor. The system connects to 208 monitor is ON and that the O alarm 2 power button is at VAC, 50-60 Hz, 3-phase cable is properly connected to the top left rear corner WYE facility power. SLS system gauge panel. of the monitor, L If the O2 alarm monitor is off (AC power light on along with the other display adjustment front is off), open the hinged panel to access buttons. the power switch, then switch power ON. For L The SLS system computer powers up when more information, see the separate Oxygen you turn on the main power disconnect. Alarm Monitor Operating Instructions that You don’t need to turn it on separately. came with your system. Perform the procedures below to start up the SLS system from its powered-off state: ` Power on the SLS system ` Run the Sinter application ` Perform SLS system machine start-up sequence These three procedures are described next. SLS process 62 PREPARE TO BUILD user’s guide starting the equipment

RUN SINTER APPLICATION SLS SYSTEM MACHINE START-UP SEQUENCE 1 Login to Windows. If you’re starting the SLS system from it’s powered-off state, you must first perform the 2 Start the Sinter application: from the following machine start-up sequence before you Windows task bar; choose Start > Programs start a build: > SLS System > Sinter, then... ` Start the chiller • The Sinter application window opens. ` Verify the SLS system compressed air • The RealMonitor utility starts, appearing as a RealMonitor button in the Windows ` Verify the SLS system nitrogen supply taskbar. (See Sinter Help for more the ` Verify the SLS system powder supply RealMonitor utility.) ` Put Sinter in Manual Operations (Man Ops) • After about one minute, the DSPIF mode application starts, appearing as a DSPIF ` Load the RCM button in the Windows taskbar. (Sinter uses ` Move the part piston to its Home position DSPIF to control SLS system heaters and ` Move the roller to its Home position motion, and to communicate with the laser ` Move the piston back to its Start position scanning system.) 3 When you see the dspif button in the Instructions for each step in this sequence are taskbar, the Sinter application is ready to start described next. a build—but the SLS system machine still is If you’re starting the SLS system from not. its powered-off state, do not attempt to start a build before you perform the SLS system machine startup sequence. Also, never attempt to start a build if the dspif button is not shown in the taskbar. It takes at least 45 seconds for the dspif program to initialize after you run Sinter. (Putting Sinter in Build mode then opening a build packet starts a build.) SLS process 63 PREPARE TO BUILD user’s guide starting the equipment

4 Start the Chiller. 6 Verify SLS system nitrogen supply. For chiller instructions, a Press the power see the separate Chiller L Skip Step a if you have a nitrogen dewar or (I/O) button on Installation, Operations, bulk tank connected to your SLS system the chiller front and Maintenance Guide instead of a nitrogen generator. panel. that came with your a Open the compressed air supply valve at b Check chiller system. the bottom of the N2 generator. COOLANT b Make sure the NITROGEN INLET ball valve INLET pressure gauge at the SLS system on SLS system gauge panel is open. gauge panel. Verify coolant inlet pressure c Verify that the REGULATED N2 PRESSURE of ~400 kPa (58 psi) on this gauge. gauge on gauge panel reads 140 kPa c Check COOLANT FLOW meter on gauge (20psi). panel. Verify coolant flow of 4-5 lpm. 7 Verify the SLS system powder supply. 5 Verify SLS system compressed air supply. a Open the POWDER INLET ball valve at the a Verify that facility compressed air is on and SLS system gauge panel. connected to the gauge panel AIR INLET. b Verify that the lower and upper powder b Verify the readings for low air pressure, level sensor lights on the Hopper Feed high air pressure, and (for model 230 only) Module are both on. RCM lift air pressure on the SLS system gauge panel. The air pressure gauge labels 8 Check pressure and flow gauges. indicate their correct readings. These are: sPro 140 lowh air pressure 350 kPa (51 psi) highv air pressure 350 kPa (51 psi) sPro 230 lowh air pressure 350 kPa (51 psi) highv air pressure 500 kPa (72 psi) SLS process 64 PREPARE TO BUILD user’s guide starting the equipment

Verify the target pressure and flow settings 6 When the display says Integrated Recycling on the SLS system gauge panel: System Standby Mode, press . Display says Ready. TARGET TARGET GAUGE PRESS. FLOW 7 IRS will commence automatic operation; (...it Laser Window N2 105 kPa 7 lpm may be blending or transporting powder to the sPro on demand). N2 Makeup Flow 105 kPa 0 lpm IR Sensor Flow N/A 200 ccm BOS start-up Laser Coolant 420 kPa 9 lpm L The BOS must have some used powder in its powder transport hopper before it can respond IRS start-up to IRS requests to send used powder. If you have not performed a breakout yet, and you If the IRS is off, turn it on as follows: have some new or used (non-waste) powder in 1 Verify the IPC umbilical is connected to base, a container, you can pour it into BOS powder that safety sensor is securely connected to transport hopper. If you have no used powder, you and you want to run with all virgin powder the lid on the IPC, and that the ground cable at first, you must change the Percent Virgin is connected to the IPC band clamp. process parameter through your IRS operator 2 Verify IPC has sufficient powder panel menu. 3 Verify that the Used powder bin has sufficient If the BOS is off, and you plan to use recycled material. (Check the Idle Used Powder Bin powder during your build, start the BOS on as weight on the Idle display). If it doesn't, turn follows. on the BOS so it can feed recycled part cake 1 Switch on the POWER on/off switch on the powder into the Used powder bin BOS operator panel. 4 Power on the IRS with the rocker on/off 2 Allow the BOS to initialize at least 30 seconds. switch on the operator panel. The green lamp on the BOS Stacklight will 5 Allow the IRS to boot up. flash while the BOS initializes. SLS process 65 PREPARE TO BUILD user’s guide unloading the IPC

3 When the green light is on steady and the Unloading the IPC BOS operator panel display says Breakout The IRS Blender bin Station Standby Mode, press . must be full before the See Loading Virgin Powder on page 167 for 4 When display says Breakout Station Ready, IRS can transfer more details on IPC turn the POWDER TRANSPORT switch on powder to an SLS features and functions. the BOS operator panel to the RECYCLE system. When the position. Blender is low, the yellow lamp on the IRS stacklight is on. 5 While in RECYCLE mode, if there is powder in the BOS powder transport hopper, the BOS When you are ready to unload the IPC, move will respond to IRS requests for to send it. 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. Pressure sense line connection (available at the IPC crate access Umbilical opening) Pulse air

Powder dilute air Ground wire Powder connects to Bulkhead IPC band connection clamp with RFID tag reader IRS umbilical connections on IPC SLS process 66 PREPARE TO BUILD user’s guide unloading the IPC

Connecting an IPC to an IRS After the pressure sensor line, umbilical, and Connect the IRS umbilical (powder convey line, ground wire are connected to the IPC, put the IRS pulse air line, and ground wire) and the in Ready mode and use the IRS operator panel to overpressure sensor line to the IPC in the order indicate that an IPC has been attached. described below. (Refer to figure on the previous page): IPC batch unload sequence IPC ground wire Connect the ground wire on the Do not unload powder from the IPC IRS umbilical to the IPC band clamp before unless the IRS umbilical ground wire unloading. is connected to the metal IPC band clamp. Do not unload powder from the IPC unless the IRS umbilical ground wire Powder is unloaded from the IPC into the Virgin is connected to the metal IPC band bin in batches of roughly 5 kg. The unload clamp. sequence below repeats until the Virgin bin is full or the IPC is empty. Pulse Air top connection under the spring- L If you stop unloading manually before a entire loaded cover; inflates the IPC during powder batch (5 kg) unloads, the IPC continues until it unload and delivers short, high-volume air pulses unloads 5 kg. If the IPC empties before a batch to fluidize the powder. completes, the IRS will shut it down after 8 Overpressure sensor line tap located on the top minutes. lid, under the IPC cover; press in to connect/pull 1 Powder line purge. The IRS supplies both to remove. continuous and pulsed air to the IPC to purge Bulkhead (powder convey) line bottom two the powder line and fluidize any powder near connections under the spring-loaded cover. The the outlet that may have settled during large molded connector terminates two shipping. umbilical lines; the small air line used to dilute 2 IPC inflation. The IRS inflates the IPC to the powder flow and the larger powder flow line. minimum pressure using continuous and The connector also contains a radio frequency pulsed air. If minimum pressure is not identification tag (RFID) reader used to identify reached within a set time period, the IRS the powder contained in the IPC. assumes the IPC is empty and shuts it down. SLS process 67 PREPARE TO BUILD user’s guide unloading the IPC

3 Powder flow. To ensure smooth powder flow, light and display a message on the LCD. It will the IRS keeps the IPC inflated above still continue to feed powder to the Sinterstations minimum pressure with both continuous and during this time, but no blending cycle will be pulsed air streams. The IRS monitors the time initiated until a sufficient amount of powder is that the IPC pressure falls below the present in both the Used and Virgin powder bins. minimum pressure and above the maximum To load Virgin powder the Intelligent Powder pressure setpoints. If either time limit is Container (IPC) is first connected to the system. exceeded, or if the IRS Virgin bin is full, the IRS Second, the UI panel menu option "IPC Status" is shuts down the IPC; i.e., shuts off air flow to used to start the unloading process. Once the IPC and powder flow to the IRS. started, it will automatically continue until the 4 Shutdown. The IRS lets the pressure in the IPC IPC is empty, although it may be interrupted by a drop below minimum. As soon as it does, the blending cycle from time to time. IRS blows pulsed air in the IPC to clear the powder line. This prevents the powder line How the IPC RFID works from clogging when the next unload batch When the IPC is first connected, the IRS starts. communicates with the RFID reader to determine the type and amount of powder contained in the IPC overpressure safety shutdown IPC. The type must be the same as what the IRS The pressure sensor line at the top of the IPC already contains. If the tag indicates that the connects to an overpressure sensor inside the powder type is valid, the IRS will begin to unload. IRS. This sensor is completely independent of the After each "batch" of powder is unloaded from IPC batch unload air flow controls. If the sensor the IPC, the IRS will write out the amount of detects air pressure in the IPC greater than 1.8 psi powder loaded from the IPC to keep the tag above the maximum IPC pressure setpoint, the current. In addition, the IRS tracks the amount of IRS shuts down the IPC and air cannot enter the powder unloaded from each IPC. Once the IPC IPC from any source. RFID tag indicates that all powder has been L Minimum and maximum IPC pressure setpoints unloaded, the IRS will not unload any further are set at the factory and must only be changed powder and will shut down until the empty IPC is by a certified 3D Systems Customer Support disconnected from the system. Technician or Authorized Service Provider. SLS process 68 (empty) user’s guide (empty) SLS process 69 PREPARE TO BUILD user’s guide docking the RCM in the SLS system

Docking the RCM in the SLS System After you (optionally) Before you start your preheat the RCM and For complete RCM build, you will need to See Loading the RCM on you’re ready to build, loading instructions, see run Sinter and “load” page 75 follow these basic Loading and Unloading the RCM in the SLS steps to dock the RCM the RCM on page 129 system; i.e., raise it up until the rim of the part in the SLS system. After cylinder seals against the underside of the you dock the RCM, it’s ready for loading. process chamber floor. 1 Unlock the RCM wheels and remove the insulated RCM lid. Check for small pieces of lid insulation on the RCM after you remove the lid. If you see any, put on insulated gloves and vacuum them off before you dock the RCM.

2 Open the SLS system’s RCM bay door, then, with both hands on the RCM handle, roll the RCM over to the SLS system and center it in the bay opening. L Preheating does not heat the RCM handle. Dock preheated RCM in SLS system 3 Slowly and carefully roll the RCM into the SLS before build 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. SLS process 70 PREPARE TO BUILD user’s guide pre-build checklist

Pre-Build Checklist This topic summarizes the pre-build checklist. ✓ Enough powder in the IRS Blender bin. See your Sinter application online Help for See Verifying Sufficient Powder on page 71. details. ✓ Verify that the gas flow rates are set properly. ✓ Powder availability/flow (IPC/IRS) See Monitoring and Adjusting Gauges on the ✓ Nitrogen availability/flow (if no N2 Gauge Panel on page generator) ✓ Air pressure/flow ✓ Coolant flow ✓ Hard drive space Check the following items before starting a build: ✓ At least 50 MB of hard-disk space on the SLS system computer. ✓ Enough nitrogen available (if you’re not using the 3D 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 nitrogen tanks. Some materials require less nitrogen, and some require no nitrogen. Consult the Material Guide for more information. SLS process 71 PREPARE TO BUILD user’s guide verifying sufficient powder

Verifying Sufficient Powder You need to make sure You can start a build if... the SLS system feed See Sinter Help for a ✓ both material sensor lights are ON, or, hopper contains complete description of enough powder before upper and lower ✓ the lower sensor light is ON and the upper material sensor light you start building. Do sensor light is OFF. states. this by checking the When the upper material sensor stops sensing status lights on the powder, its light switches OFF and the SLS system feed hopper’s material sensors as described requests more powder from the IRS. If the IRS has below. powder in its blender bin, it refills the feed hopper and the upper material sensor light To verify sufficient powder before you switches ON again. build This automatic refill from the IRS only takes a few Open the SLS system's left side access door and minutes, so the upper material sensor light note the states of the upper and lower material should not stay OFF for long. If it does, this likely sensor lights on the feed hopper. indicates that the IRS blender is empty. (See ` Sensor light ON: powder at or above the next.) sensor level ` Sensor light OFF: powder below sensor level. IF BOTH MATERIAL SENSOR LIGHTS ARE OFF... You cannot start a build, because either... Feed hopper Sensor light Upper sensor ` The IRS blender bin is empty because the IPC empty. Replace the IPC and load more virgin powder in the IRS. See Loading Virgin Powder Lower sensor on page 167. ` The powder inlet tube from the IRS is clogged. See IRS & IPC Troubleshooting on page 172. SLS process 72 PREPARE TO BUILD user’s guide verifying sufficient powder

Preparing the chamber The following steps are a suggested guideline for 10 Pay attention to the O2 level in the machine. preparing the system to build parts: Once it has reached the set-point of 5.5%, open the Heater control function and 1 Prepare the RCM for loading. activate all of the heaters. 11 Once the powder has been leveled, and if the 2 Roll the RCM into the void under the next build has not yet been set-up, minimize sPro. Be sure that the RCM is fully seated in the Sinter application and all of the sub- the void. functions (DO NOT CLOSE), open Build Set- 3 Connect the power umbilical from the Up (see section on Performing Build Set-Up), machine to the RCM. complete the Build Set-Up, and close the 4 Close the front access panel. function. 12 5 Open Sinter>ManOps>Piston Control and Open Sinter back up. Select the blue Exit select Load. button and continue selecting until you are back in the main Sinter screen. 6 Once the RCM has loaded, select Home Piston and home the part piston in the RCM. 13 Select Build>Start Build, confirm the correct material is loaded, and select Start. 7 Once the piston has homed, open Roller and home the roller. 14 When the prompt appears on the Sinter screen to Push Start Button, physically push 8 Once the roller is homed, open Inert and the green Start button on the machine. activate the inerting process. 15 Once the O2 level and pre-heat set-points for 9 While the machine is inerting, begin leveling the heaters have been reached, the roller powder. Open Level Powder. Set the Roller should begin adding powder layers. Rotation 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. SLS process user’s guide

BUILD PARTS This section covers the tasks involved in building parts. Many of the procedures in this section are summaries of more detailed instructions in your Sinter application online Help.

Before you build parts, you must perform the procedures described in Prepare to Build starting on 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 ` Restarting a Terminated Build ...... 82 ` Loading the RCM...... 75 ` Viewing a Build In Progress ...... 83 ` Homing the Part Piston and Roller ...... 76 ` Changing Heater Setpoints In-Build . . . . . 84 ` Messages in the Sinter Application...... 77 ` Calibrating the IR Sensor...... 85 ` Selecting the Display Language ...... 78 ` Pausing a Build...... 86 ` Adding & Leveling Powder ...... 79 ` Modifying a Build in Progress ...... 87 ` Running a Build ...... 81 ` When a Build Ends ...... 89 SLS process 74 BUILD PARTS user’s guide running Sinter

Running Sinter L You must start the SLS equipment before c After about one minute, the DSPIF running Sinter on the SLS system computer. application starts, appearing as a DSPIF To run Sinter (after your SLS system is started): button in the Windows taskbar. (Sinter uses DSPIF to control SLS system heaters and 1 Login to Windows. motion, and to communicate with the laser Sinter should already be scanning system.) 2 Start the Sinter running if you started application: from the SLS system as 3 When you see the DSPIF button in the the Windows task described in SLS system taskbar, you can start a build. bar; choose Start > start-up starting on Do not attempt to start a build Programs > SLS page 61, Sinter is until you see the DSPIF button in System > Sinter, already running. the taskbar. It takes at least 45 then... seconds for the DSPIF program to a The Sinter start up completely. Selecting the application Main Sinter has three modes; Build toolbar button then mode window Main, Build, and opening a build packet starts a Manual Operations. opens. build. See Modes in the b The RealMonitor Application in your utility starts, Sinter Help for indicated by the descriptions of these RealMonitor modes. button in the Windows taskbar. (See Sinter Help for RealMonitor utility instructions.) SLS process 75 BUILD PARTS user’s guide loading the RCM

Loading the RCM Before you load the RCM, verify that: Click the Man Ops button on the main Sinter window toolbar, or select Machine > Manual ✓ The SLS system is started and Sinter is Operations. running. See SLS system start-up on page 61. Be sure to 2 Load (raise) the RCM: verify that the chiller is on and that compressed a Click the Piston Control button on the air, nitrogen, and powder are all being supplied to Man Ops toolbar. the SLS system. b In the Piston Control window, click the ✓ The RCM is clean, preheated (preferably), Load button. plugged into the SLS system, and properly docked in the RCM bay with the RCM door If the Load button is dimmed, the RCM closed. might not be in a safe loading position in the RCM bay. Open the RCM door and push See Preheating the RCM on page 68; Docking the the RCM forward until you hear and feel it RCM in the SLS System on page 69, and Load RCM in SLS system before a build on page 129. contact the back of the SLS system frame. Close the door and try the Load button To load the RCM again. 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 See the Manual Manual Operations Operations topic in mode. Sinter Help for SLS process 76 BUILD PARTS user’s guide homing the part piston and roller

Homing the Part Piston and Roller After you load the RCM, 2 After piston home, click Start Position you must “home” (reset The part piston button the reference limit moves up and down 3 To home roller, click Home Limit in the Roller position of) the part inside the RCM cylinder. The roller Control window. piston and the roller. moves back and forth Before you can do either, inside the process To home the roller these dependencies chamber, rolling out must be met: powder with each The roller must be at its left or right limit position. ✓ SLS system start-up pass. Before you can move the roller, you must meet is complete and the following dependencies: Sinter is running. ✓ The RCM must be loaded. See SLS system start-up on page 61. ✓ The part piston must be stationary. ✓ The RCM is loaded. ✓ The Add Powder Layer dialog box cannot be See Loading the RCM on page 75. open. ✓ The Add Powder Layer window is closed. After roller home, click Under feed hopper button. See Loading the RCM on page 75.

To home the part piston Starting up other machines while you wait Before you can move the part piston to any You can startup the IRS and BOS as described in position other than the home limit, the piston IRS Start-up on page 154and BOS Start-up on must be successfully homed. All the buttons page 220 while you wait for part piston to finish except for Home Limit are dimmed for a piston homing. that needs to be homed. 1 To home piston, click Home Limit in Piston Control window. SLS process 77 BUILD PARTS user’s guide messages in the Sinter application

Messages in the Sinter Application When Sinter is running various types of messages appear in the Message List window (described below). Alarm and warning messages also appear in pop-up windows you must acknowledge. Message Types in Sinter

TYPE COLOR SOUND DEFINITION Informational only or tells of a minor error. These generally occur when Message Black None you enter different data than the system expects or when a dependency is not met. Something occurred that can turn into an alarm condition if not Advisory Yellow Pulsing horn corrected in a specified time. Something serious may occur that you should attempt to correct; does Warning Yellow Pulsing horn not terminate the build. Indicates something occurred that will halt the current operation and Alarm Red Steady horn return the SLS system to a safe state.

About the Message List window New messages appear at the top of the window; The Sinter application displays messages in a old messages scroll down as new ones appear. Message List window: Messages are color coded to indicate their type. You can select a message 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.

SLS process 78 BUILD PARTS user’s guide selecting the display language

Selecting the Display Language You can 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. SLS process 79 BUILD PARTS user’s guide adding & leveling powder

Adding & Leveling Powder Just before you run your build, use the Add To use the Add Powder Layer dialog box Powder dialog box in Man Ops mode to add and Change the settings for each parameter in the level powder at the bottom of part cake. Add Powder Layer dialog box to the settings you Adding power creates a smooth powder bed on want, then click the Add Layer button. the floor of the process chamber. It also insulates L Click the Stop button if you need to stop the the bottom of the part cake and creates a flat roller while it is adding a layer. If you do this, you base for subsequent layers of sintered parts. must move the roller back to a limit before continuing. Click the Move To Limit button to To add and level powder move the roller back to a limit. Use the Add Powder button to manually add a L Under some circumstances, the system may layer of powder to the part bed. Before you can not correctly update the Move to Limit, Stop, add a powder layer, all these dependencies must or Add Layer buttons; they may remain dim be met: when they should be enabled. If a button you need to use is dim when it should be enabled, ✓ The RCM must be loaded. close and reopen the Add Powder Layer ✓ The roller must be stopped at a limit. dialog box to enable the button. ✓ The Roller Control and Piston Control dialog The following parameters are available to set in boxes must not be open. the Add Powder Layer dialog: When you click Add Powder, the Add Powder L You cannot close the Add Powder Layer Layer dialog box appears: dialog box while the SLS system is adding layers. SLS process 80 BUILD PARTS user’s guide adding & leveling powder

Add Powder Layer Parameters

PARAMETER RANGE DEFAULT DEFINITION The number of revolutions the powder dispenser makes when dispensing powder on Powder Feed 0 to 500 rev. 0.6 rev. top of the roller. (The powder dispenser is at amount the bottom of the feed hopper.) Typical setting is 0.6 rev. (0.0 to 0.508) mm (0.0 to The distance that the part piston lowers each Layer Thickness 0.020) in layer. Layer Cycle The number of consecutive powder layers to 1 and 32,000 Count be added. The ratio of the roller’s counter-rotation Roller: Rotation angular velocity to its (linear traverse) speed. 0 to 10 Ratio The larger the ratio, the faster the counter- rotates. 76 and 305 mm per second Specifies the speed at which you want the Roller: Speed (3 and 12 inches per roller to travel. second) SLS process 81 BUILD PARTS user’s guide running a build

Running a Build Before you run a build, be sure you do everything 3 When the file Open dialog appears, choose a required on the Pre-Build Checklist on page 70. the build packet file you want to build. When you’re ready to start, do the following: If you are not using the default material, you will have to confirm the material choice 1 Click the Build button on the Sinter before you the build begins. application Main mode toolbar. The Build Parts and the Build Viewer Build Log File Archiving at Start of Build windows appear When you start a new build, the Sinter Live, actual values oxygen level and application automatically: temperature values are shown in the Build ` Renames States.blog, the most recent build Parts window. However, the setpoints used log file, for archiving. The archived build log in the previous build remain until you click file name matches the time stamp of its first Start Build, after which Sinter updates the entry. setpoints. ` Opens a new States.blog file to log the new L If any of the temperature labels are dim, build information. This is the only file deleted they will not be controlled during the if you choose to automatically delete the logs build. Although setpoints will not be when the system prompts you on exiting the updated, you will see actual values. Sinter application. 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. SLS process 82 BUILD PARTS user’s guide restarting a terminated build

Restarting a Terminated Build If you terminate a build before completion, you may be able to restart it. This depends on the material in use and the 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 layers bond properly. ` Make sure the powder is feeding properly SLS process 83 BUILD PARTS user’s guide viewing a build in progress

Viewing a Build In Progress During a build, the Build Viewer window Options on the Viewer Menu displays the slice that the system is currently While the system is in Build mode, you can set scanning. Click on a part to display its name at the following options for the Build Viewer. These the bottom of the main window. options appear on the Viewer menu in the main L NOTE: If you close the Build Viewer window window: when a build is not running, you exit Build mode. You cannot close this window while a VIEW OPTION DESCRIPTION build is running, but you can minimize it. This option displays a dialog box that lets you control the Set grid size Viewing options on the Toolbar size of the grid drawn on the While the system is in Build mode, the Build Build Viewer window. toolbar appears at the top of the main window as This option is the same as the Grid marks shown: Grid button on the toolbar. When this option is checked, the system erases the display Clear after every before drawing a new slice. slice Otherwise, the system draws Some of the buttons on the toolbar control new slices on top of old ones. options for the Build Viewer. You can toggle this option on Click the Grid button to turn the display of grid or off by selecting it. When Dark checked, the system displays a marks on or off. Click the zoom buttons to background expand or contract the scale of the Build Viewer dark background in the Build window. Viewer window. SLS process 84 BUILD PARTS user’s guide changing heater setpoints in-build

Changing Heater Setpoints In-Build During a build, you can change five critical heater setpoints in the Build Parts window. ` Left Powder Temp. Top and Bottom ` Part Bed Temperature ` Right Powder Temp. Top and Bottom L NOTE: 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 higher Z values for that stage. If you had ramped values, you may need to pause and re-profile the build, or continue to monitor the build. SLS process 85 BUILD PARTS user’s guide calibrating the IR sensor

Calibrating the IR Sensor L This is a summary. For IR calibration details, see To perform manual IR calibration Sinter Help. 1 Put the system in Manual Operations mode. The SLS system can recalibrate the IR sensor 2 Load the RCM, if needed. dynamically during a build. This calibration is a quick process which occurs multiple times during 3 Click the IR Cal button. a build to compensate for sensor drift and 4 The Manual IR Sensor Calibration dialog changing environmental conditions within the box appears. machine. 5 Click the Start button on the dialog box. L You must perform an initial manual IR calibration to enable automatic, real-time L During the calibration, an Abort button recalibration during the build. If recalibration appears; click it if you need to stop the requires too great an adjustment, a message calibration process for any reason. pops up advising you to perform offline L If the RCM is above room temperature or the calibration again when the build completes. blackbody is above 60 ° C, the software waits If you want the SLS system to do real-time IR until these cool to actually start the offline sensor recalibration during the build, perform a calibration. 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 calibration. See Disabling Realtime Calibration in Sinter Help. SLS process 86 BUILD PARTS user’s guide pausing a build

Pausing a Build

When the Pause Build button is active, click on it to stop the build and display options. Resume the build as soon as possible after you pause it to prevent material heat loss.

CLICK THIS PAUSE BUILD BUTTON... TO DO THIS... Resume Build Continue the build. Enter Next Stage Move from Warmup stage to Build stage, or Build stage to Cooldown. 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 Terminate Build any parts from the part bed and review the build packet in Build Setup. Make any changes that can improve the build. Modify a profile, add/delete parts, or run a prime cycle. See Modifying a Build Change Profiles/Prime Cycle in Progress on page 87. SLS process 87 BUILD PARTS user’s guide modifying a build in progress

Modifying a Build in Progress

Make changes during a build with the Build ` Settings for Z levels below the current are Modify dialog box shown above. yellow and cannot be changed. To display it, click the Change Parameter button; ` The current Z level is displayed as a green if the build is paused, click the Change Profiles/ vertical line in the parameter chart. Prime Cycle button in the Pause Build dialog ` In the Build Profile Editor, a new button box. appears, the button. Use this button to make a profile change at the current Z level. Modifying Part and Build Profiles Click the button and a new row appears in the current build stage. Click in the Value Click the Modify Build Profile or Modify Part column and enter a value, then click Apply. Profile button to display a profile editor dialog When the system applies the value, it box from the Build Setup application. Use the updates the row to the current Z level. Change Build Mode button to access the Change Build Mode dialog box. Modify ` If you make changes near the current Z, the parameters as described in the Build Setup Help. system may not be able to apply them. If you do not get the message The parameter L You can find definitions of the parameters in change has been applied after clicking the Build Setup Help. Apply, try again at a higher Z. (There is no In most respects these dialog boxes work just as message when the attempt fails.) they do in the Build Setup software, with the following differences: SLS process 88 BUILD PARTS user’s guide modifying a build in progress

Adding and Deleting Parts and Other Changes Click the Add/Delete Parts button in the Build Modify dialog (shown on page 87) to launch the Build Setup application. From here you can modify most aspects of your build packet during the build. 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 in the Build Modify dialog (shown on page 87) to spread powder across the part bed without moving the part piston, which can compensate for a short feed. SLS process 89 BUILD PARTS user’s guide when a build ends

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: SLS process user’s guide

BREAK OUT PARTS When a build completes, you need to remove the sintered parts from the RCM part cake and clean them. Removing parts from the part cake is called “breakout.” This section describes 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 ` Breakout Parts from Part Cake ...... 97 ` Unloading RCM (Removing the Part Cake)93 ` Dispose of Waste Powder...... 98 ` Part Cake Cooldown...... 93 ` Recycle Used Powder...... 98 ` Power-on the BOS and Dust Collector. . . 94 ` Part Finishing After Breakout ...... 99 ` BOS Start-up ...... 95 ` Shutdown BOS ...... 100 ` Load & Raise Part Cake ...... 96 SLS process 91 BREAK OUT PARTS user’s guide breakout overview

Breakout Overview When a build is complete, you need to remove Before breakout, you must: the sintered parts and used powder (called the ` Cool down the part cake then remove the “part cake”) from the RCM part cylinder. RCM from the SLS system—or vice-versa. Removing parts from the part cake is called “breakout.” ` Dock the RCM in the BOS; roll it into the RCM bay, apply the foot brake, lower the rim shield, then connect the RCM cable. ` Start the BOS, put it in Breakout Station BOS 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 part cake About part cake cooldown before parts breakout The part cake in the RCM needs to cool down RCM before breakout so you can handle it safely. Do not attempt to remove the part Performing breakout using the BOS cake from the RCM while it’s hot. You (Breakout Station) can burn yourself and ruin the parts. You must choose where and how to cool down the part cake after a build, specifically: • Where – inside or outside the SLS system • How – using a controlled or uncontrolled temperature rampdown SLS process 92 BREAK OUT PARTS user’s guide breakout overview

The table below summarizes your part cake

PART CAKE PART CAKE COOLDOWN METHOD COOLDOWN LOCATION CONTROLLED UNCONTROLLED Use the Cooldown Wizard in Build Setup to create a custom cooldown profile for RCM connected inside Leave the RCM loaded after the build your build. Leave the RCM loaded until the SLS system finishes. Do not remove it until the part the SLS system indicates that the build is bed temperature is at or slightly above complete. room temperature. Wear insulated Not available. gloves if you need to remove the RCM RCM disconnected before it cools down. outside the SLS system

cooldown options before breakout: Unloading the RCM after a build After a build and before breakout, you must WHERE TO COOL DOWN THE PART CAKE remove the RCM with the part cake from the SLS If you cool down the part cake inside the SLS system. You can remove it while it’s still warm or system, leave the RCM loaded until the part cake let it cool down inside the SLS system. reaches its final cooldown temperature. If you remove the RCM from the SLS system... SLS process 93 BREAK OUT PARTS user’s guide unloading rcm (removing the part cake)

` While it’s still warm – place the RCM lid on it ✓ If the core temperature of the part cake is immediately to prevent uneven cooling. greater than 60 ºC (140 °F), do not continue. Then let it sit in the room with the RCM lid L If you do not have a thermometer, insert a and cool down naturally. metal probe or breakout tool into the part cake for 15 seconds; if it is too hot to hold, do not ` After it cools down – you can move the RCM continue. Also refer to the Material Guide. into the BOS and begin breakout. ✓ Make sure the roller is at a limit. ✓ Put the SLS system software into Man Ops L You can find material-specific information mode. about breaking out and cleaning parts in your Material Guide.

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. SLS process 94 BREAK OUT PARTS user’s guide power-on the BOS and dust collector

Power-on the BOS and Dust Collector Before you turn on the BOS, make sure RCM cable is NOT connected to the RCM.

BOS Power-up Dust Collector Power-on 1 Turn the BOS 1 Open the Dust POWDER See BOS Operator Collector enclosure See the Dust Collector TRANSPORT Controls and Indicators and empty the Installation and switch to OFF. on page 202 to locate dust pail if Operation manual that switches. shipped with your necessary. 2 Turn the BOS system. POWER switch on. 2 Connect the flexible duct pipe to the air duct flange on The BOS displays Initializing, then the left or right outer wall of the BOS Establishing network connection... chamber. L The yellow stacklight lamp is on while the 3 Turn on the power switch on the upper right BOS establishes a network connection. The side of the Dust Collector cabinet. 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. SLS process 95 BREAK OUT PARTS user’s guide BOS start-up

BOS Start-up After you power up the BOS as described above, start-up the BOS as follows: 1 Turn the BOS POWDER TRANSPORT switch to: • RECYCLE if you want to send powder in the BOS hopper to the IRS Used bin, or, • DISPOSAL if you want to send powder in the BOS hopper 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 for powder. • In DISPOSAL mode, the BOS enters the Disposing Powder state and sends powder to the waste drum until the sifter stays empty for 2 minutes. SLS process 96 BREAK OUT PARTS user’s guide load & raise part cake

Load & Raise Part Cake Use the part piston jog switch on the left inside . wall of the breakout chamber to: Raise part piston ` Raise the part cake during breakout Stop ` Home (lower) the part piston after breakout (optional/recommended) Lower part piston Before you can move the part piston: ✓ Part piston jog switch inside breakout The BOS must be powered on. chamber. ✓ The RCM must be properly docked in the L When the part piston reaches its upper or lower BOS. limit, its up or down motion stops automatically ✓ The BOS’s RCM cable must be plugged into to prolong the life of the piston motor, even if the RCM. the switch is not in the Stop position. ✓ The BOS’s RCM seal must be down. After breakout, before you remove the RCM from Push up and hold the jog switch to raise the the BOS, use the part piston jog switch to home piston; pull down and hold to lower the piston. the part piston; i.e., lower it to its lowest position. The piston moves gradually until you release the Lowering the part piston has the following switch or move it to the middle (Stop) position. benefits: The jog switch returns to the Stop position when ` Makes it easier to clean the RCM before the you release it next build. ` Reduces delay at the start of a build because you don’t have to wait very long for the part piston to home before you can move it to Start position. SLS process 97 BREAK OUT PARTS user’s guide breakout parts from part cake

Breakout Parts from Part Cake The part cake can remain extremely hot for hours after a build. To prevent burns, allow sufficient time for cool down (up to 24 hours) before removing the part cake.

Raise the part piston and allow powder to fall away from the part as the part cake rises. As you raise the piston, remove surrounding powder from the outline of the 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. SLS process 98 BREAK OUT PARTS user’s guide dispose of waste powder

Dispose of Waste Powder 1 Connect BOS powder disposal See Disposing Powder outlet to waste on page 225 of the BOS drum spout. section for detailed instructions. 2 Set the POWDER TRANSPORT switch 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 See Recycling Powder switch on the BOS on page 225 of the BOS operator panel to section for detailed instructions. RECYCLE. 2 Press to go into Breakout Station mode and start powder transfer. SLS process 99 BREAK OUT PARTS user’s guide part finishing after breakout

Part Finishing After Breakout L Consult your DuraForm Material Guide for full details on part finishing. After breakout, you typically remove remaining the part cake powder 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 easier and faster. See your SLS Process Facility Guide for recommended third party suppliers. SLS process 100 BREAK OUT PARTS user’s guide shutdown bos

Shutdown BOS Shutting down the BOS stops the following To shut down the BOS properly operations: 1 If the BOS is currently transferring powder to ` Used powder transport to the IRS Used bin (in the IRS, wait until the BOS operator panel RECYCLE mode) says Powder Xfer Complete. ` Used powder transport to the waste drum in 2 Press repeatedly until the BOS operator (in DISPOSAL mode) panel displays In Standby. ` Part piston motion (if and RCM is connected 3 Turn off the POWER switch on the IRS and the part piston is being raised or operator panel. lowered) See IRS Operator Controls and Indicators on ` Sifting page 133. ` 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. SLS process user’s guide

RC M This section describes the RCM (Rapid part cake Change Module), 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 ` ` ` Cleaning the RCM ...... 129 ` RCM Safety ...... 112 ` Loading and Unloading the RCM...... 130 ` ` Troubleshooting ...... 132 SLS process 102 RCM & OTS user’s guide RCM & OTS overview

RCM Over view ` You dock and load the preheated RCM in the SLS system and run a build.

` After a build, you remove the RCM and part cake, and run an uncontrolled part cake cooldown.

After cooldown, you dock the RCM in the See BOS Overview on BOS for breakout. You page 210. use the BOS’s jog RCM (Rapid part cake Change switch to gradually raise the part piston in the Module) rolls on locking wheels for RCM as you remove parts from the part cake. docking, unloading, and breakout SLS process 103 RCM & OTS user’s guide RCM features

RCM Features ➊ ➋ ➌ ➑ ➍ ➐ ➎ ➏

➊ RCM lid ➌ RCM alignment tooling balls (9X) Insulated cover used during uncontrolled Three top balls and six side balls help ensure cooldown. safe and proper RCM alignment in SLS system and BOS RCM bays during RCM loading and unloading. ➋ Part cylinder See RCM part piston and part cylinder on Holds the part cake and powder. Three page 109 and Loading and Unloading the RCM on (model 140) or four (model 230) separately- page 129. controlled blanket heaters wrap around the ➍ Part piston (inside part cylinder) outer cylinder wall to heat part cake and Supports the part cake during build and powder during builds. The part cylinder rim expels the part cake during breakout. Piston seals against bottom of the process chamber. top plate has separately-controlled heater to See RCM part piston and part cylinder on heat part cake and powder during builds. page 109. See RCM part piston and part cylinder on page 109. SLS process 104 RCM & OTS user’s guide RCM features

➎ RCM control box Service access only; houses RCM heater and motion control electronics. ➏ RCM wheel foot brake / wheel lock Stops the RCM from rolling when you step on the lever. When fully depressed/engaged, it locks RCM wheels. To prevent equipment damage and injury, always engage the RCM wheel lock when you dock the RCM in the SLS system or BOS.

➐ 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. ➑ RCM handle Safe grip bar for pushing or pulling the RCM. Wear insulated gloves whenever you handle the RCM. The RCM might still be hot when you pull it out of the SLS system. SLS process 105 RCM & OTS user’s guide RCM specifications

RCM Specifications

Models RCM 140 - standard model RCM 230 - same X and Y dimensions as RCM 140, but 23 cm (9 in) taller in Z dimension Input powera from RCM cable on SLS system or BOS. MODEL-SPECIFIC RCM 140 RCM 230

H  W  D - overall (112  94  101) cm (135  94  101) cm (44  37  40) in (53  37  40) in Weight 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 (550  550  460) mm (550  550  750) mm (X  Y  Z) (22  22  18) in (22  22  30) in 140 liters 230 liters Heaters Four (total) Five (total) Cylinder heatersb Three: Four: •top •top • middle • upper-middle •bottom • lower-middle • bottom Piston heater One: under piston top plate One: under piston top plate a. The RCM is remotely powered by the SLS system or BOS through the RCM cable. b. blanket heaters that wrap around outside of part cylinder SLS process 106 user’s guide SLS process 107 user’s guide SLS process 108 RCM & OTS user’s guide RCM description

RCM Description This section describes the functions of each of The setpoints for these heaters depend on the the RCM heaters, part piston, and part cylinder. material you’re building with. The SLS system stored recommended heater setpoints as RCM Heaters material default parameter values. The RCM has four or five heaters, depending on the model. You can view live RCM heater temperatures and change RCM heater 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. SLS process 109 RCM & OTS user’s guide RCM description

RCM part piston and part cylinder When the RCM is loaded in the SLS system, the L Be sure to clean the RCM seal after every build. part cylinder and part piston form the SLS system See Cleaning the RCM on page 128 and SLS part bed. The top of the RCM cylinder seals System Service & Maintenance on page 196 against the bottom of the square hole in the middle of the process chamber floor. Process chamber floor The part piston moves up and down in the RCM RCM seal part cylinder. When a build starts, the part piston is at the top of the cylinder, or “Start” position. As a build progresses The piston descends in small RCM part cylinder rim 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. When RCM is loaded, the RCM part cylinder rim seals against the underside of process chamber floor SLS process 110 user’s guide SLS process 111 user’s guide SLS process 112 RCM user’s guide RCM safety

RCM Safety When you use any SLS equipment, follow all ` Do not try to open any panel or door while a general safety guidelines in Safety on page 9. machine is running. When you use the RCM, follow the guidelines in ` Do not access any area of the machine near this section as well. They are specific to the RCM the process chamber high-temperature- machines. material builds. Follow these safety guidelines when operating ` Do not use any material without first the RCM: reviewing its Material Safety Data Sheet ` Read and follow all operating instructions. (MSDS). ` Follow all safety rules in this section and heed ` Always disconnect the RCM cable before all hazard warnings in this guide. moving the RCM out of the SLS system or BOS. ` Do not try to do any equipment maintenance procedures you were not trained to do. ` Do not try to access, service, or adjust the laser system in any way. • Operators are trained to operate the system and perform all the necessary tasks ` Do not enter any area displaying posted to print a part. warning signs during open beam operations. Open beam operations refer to the laser, and • Certified service personnel are those they only occur during service procedures. who have completed 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. ` 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. SLS process 113 RCM & OTS user’s guide RCM & OTS safety

` If you hear an alarm, or if you see an error, ` To prevent injury and equipment damage, be alarm, or warning message on any sure to follow all handling guidelines in SLS equipment display, note the state of that Powder Safety on page 28 and Nitrogen/ machine’s Stacklight and refer to its Oxygen Safety on page 32. troubleshooting section in this guide. Clear ` To prevent crush injuries to the body, use the alarm, error, or warning message before extra caution when rolling the RCM into and resuming operation. (The SLS System out of the SLS system and BOS, and when Troubleshooting section might refer you to closing the BOS overhead door. Take note of the Messages and the Message List Window all crush hazard warning labels on the topic and/in your Sinter application online machines. Help.) ` Displayed error, alarm, or warning messages 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. SLS process 114 user’s guide SLS process 115 user’s guide SLS process 116 user’s guide SLS process 117 user’s guide SLS process 118 user’s guide SLS process 119 user’s guide SLS process 120 user’s guide SLS process 121 user’s guide SLS process 122 user’s guide SLS process 123 user’s guide SLS process 124 user’s guide SLS process 125 user’s guide SLS process 126 user’s guide SLS process 127 user’s guide SLS process 128 user’s guide SLS process 129 RCM user’s guide loading and unloading the RCM

Loading and Unloading the RCM Follow the instructions in this section to load and 2 Clean the part bed seal in the SLS system. The unload the RCM safely and properly during the seal is on the bottom of the process chamber SLS process. around the square part bed hole. Use a non- ignition vacuum to clean the seal. ` Load RCM in SLS system before a build ` Unload RCM from SLS system after a build To prevent excessive nitrogen loss from the process chamber ` Load RCM in BOS Pro before breakout and ensure an inert build ` Unload RCM from BOS after breakout environment, verify that part bed seal is clean before loading the Load RCM in SLS system before a build RCM in the SLS system. 1 (optional) Preheat 3 Remove the RCM the clean, empty For instructions, see lid just before For instructions, see RCM to shorten the Preheating the RCM on you’re ready to Cleaning the RCM on build Warmup page 115. start a build. page 128. stage in the SLS system. L After removing the lid, verify that the RCM is still clean L Keep the RCM lid on the RCM during before loading it in the SLS system. preheating to save energy. Vacuum up any lid insulation particles you After preheating, the RCM might see. cylinder and piston are both very hot! To prevent burns, always wear insulated gloves when handling a preheated RCM. SLS process 130 RCM user’s guide loading and unloading the RCM

BEFORE YOU LOAD THE RCM d Connect the SLS system’s RCM cable to the 1 Unlock the RCM wheels and remove the RCM connector insulated RCM lid. e Close the RCM bay door.

Check for small pieces of lid 4 Put the Sinter application in Manual insulation on the RCM after you Operations mode; click Man Ops on the main remove the lid. If you see any, put on Sinter window toolbar, or select Machine > insulated gloves and vacuum them Manual Operations. off before you dock the RCM. See the Manual Operations topic in Sinter Help for 2 Clean the RCM as described in Cleaning the instructions. RCM on page 128. 5 Load (raise) the RCM. Always clean the RCM before loading Display the Piston Control dialog box via the it in the SLS system. This ensure a Manual Operations toolbar, and click the tight seal between the RCM cylinder Load button. rim and the underside of the process chamber floor. See Piston Control under the Manual Operations topic in Sinter Help for instructions. 3 Dock the RCM in SLS system. a Open the SLS system’s RCM bay door. Then, with both hands on the RCM handle, roll the RCM over to the SLS system and center it in the bay opening. L Preheating does not heat the RCM handle. b Slowly and carefully roll the RCM into the SLS system. Push the RCM in as far as it will go. Tooling balls on the front and sides of the RCM help ensure proper placement. c Step down on the RCM wheel lock lever to lock the wheels. SLS process 131 RCM user’s guide troubleshooting

UnLoad the RCM from the SLS System Troubleshooting after a build Before you start your build, you need to run RCM Error Conditions Sinter and “load” the RCM in the SLS system; i.e., The RCM is held in place by air-powered jacks. If raise it up until the rim of the part cylinder seals the air pressure to the SLS system drops even against the underside of the process chamber briefly, the RCM will drop and the Chamber is floor. not inert warning message is displayed. 1 Power up and start the SLS system, See Starting the SLS then run Sinter. System (only) on page 191 and Starting 2 Put the Sinter the SLS System (only) on application in page 191. 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. 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. SLS process 132 user’s guide SLS process user’s guide

IRS & IPC Follow the instructions in this section to use the IRS and IPC safely. They tell you how to connect an IPC to the IRS and load the virgin (new) powder, setup the IRS to send powder to the SLS system and receive powder from the BOS, and what actions to take in response to IRS warnings and alarms. These instructions are covered in the topics below:

` About the IRS & IPC ...... 135 ` Using the IRS Diagnostics Menu ...... 160 ` IRS Features...... 136 ` Using the IRS Utilities Menu...... 161 ` IRS Specifications ...... 137 ` Loading Virgin Powder in the IRS ...... 164 ` IPC Features ...... 138 ` Transporting Powder – from IRS to SLS System ...... 166 ` IPC Specifications ...... 139 ` Blending ...... 167 ` How the IRS & IPC Work ...... 140 ` Loading Virgin Powder ...... 168 ` IPC Description ...... 148 ` Loading Used Powder ...... 171 ` IRS & IPC Safety ...... 151 ` Shutting Down the IRS ...... 171 ` IRS Operator Panel and Stacklight . . . . . 153 ` Maintenance ...... 172 ` IRS Start-up ...... 155 ` IRS & IPC Troubleshooting ...... 173 ` IRS Standby and Ready Modes...... 156 L If you have two RCMs and keep a full IPC on ` Using IRS Main Menu...... 157 hand, you can run builds continuously by hot- ` Using the IRS Setup Menu ...... 159 swapping RCMs and IPCs. SLS process 134 IRS & IPC user’s guide about the IRS & IPC

About the IRS & IPC The IRS and IPC SLS process machines work then sends the blended powder to the SLS together to supply powder for up to three SLS system feed hopper when it receives a hopper systems. The IRS draws virgin powder from the refill request. IPC, blends it with used powder from the BOS,

IRS Integrated Recycling System

IPC Intelligent Powder Cartridge SLS process 135 IRS & IPC user’s guide IRS features

IRS Features ➊ ➋ Virgin bin Receives and stores virgin powder from IPC. See IRS Umbilical connections on page 147.IRS Umbilical connections on page 167 ➌ Blender bin ➒ ➋ Blends virgin powder from the IPC with used powder from the BOS. ➌ See Blending on page 166. ➍ Power switch ➎ Operator panel ➍ Displays status and warning messages in ➎ Ready mode; enables setup, diagnostics, and manual powder transfers in Standby mode. ➏ See IRS Error Messages on page 172. ➏ Emergency stop button ➐ Umbilical (not shown) Connects IRS to IPC for unloading IPC. ➑ See IRS Umbilical connections on page 147 and Loading Virgin Powder on page 167 ➐ Overpressure safety line (not shown) ➐ Connects to top of IPC to detect excessive pressure in IPC. ➒ Used bin (used powder) Receives and stores used powder from the ➊ Stacklight BOS. IRS status indicator. See Loading Used Powder on page 170. See IRS Stacklight on page 153 SLS process 136 IRS & IPC user’s guide IRS specifications

IRS Specifications

Input power 208/240 VAC, 50/60 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) SLS process 137 IRS & IPC user’s guide IPC features

IPC Features ➏ ➎ ➊

➋

➍ ➌

➊ Shipping cover Top nozzle – pulse air line; air pulses Protects container during shipment. “fluidize” the powder in the container. ➋ Collapsible powder container Middle nozzle – transport air line; transport Holds 100 kg (220 lb) of DuraForm powder air conveys powder through the fill hose. material. Flattens when empty for easy Bottom nozzle – powder outlet hose shipping. Shipping weight of full container (bottom); carries powder to IRS virgin bin. plus pallet is 125 kg (276 lb). RFID tag – (in molded connector) verifies IPC ➌ Pallet powder matches powder in IRS. Permanently fastened to the powder See Loading Virgin Powder in the IRS on page 163 container; includes pallet jack channels. ➎ Fill cap (under shipping cover) L Empty IPCs are stackable; full IPC’s are not. Do not open. Factory use only. ➍ Umbilical connectors ➏ Pressure sensor tap (on fill cap) Three nozzles and one socket for the Connector for IRS overpressure safety air line. umbilical molded connector See Loading Virgin Powder in the IRS on page 163. SLS process 138 IRS & IPC user’s guide ipc specifications

IPC Specifications

Input power None (passive RFID tag on pallet) Weight • Full shipping weight 125 kg (276 lb) • Empty shipping weight 25 kg (54 lb) • Net weight of DuraForm PA plastic powder 100 kg (220 lb) Dimensions (H  W  D) (92  80  83) cm; (36  32  33) in

Radio Frequency Transmission

This product generates 13.56 MHz using an Inductive Loop System as a Radio Frequency Identification device (RFID). This RFID device complies with the requirements specified in FCC Part 15, Industry Canada RSS-210, European 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-CLDRCSTM

Access to the transmitter for service technicians is available through common enclosure access methods including use of common tools and removal of covers.

Note: Changes or modifications to this equipment not specifically approved by 3D Systems may void the user's authority to operate this equipment. SLS process 139 IRS & IPC user’s guide how the IRS & IPC work

How the IRS & IPC Work The IRS receives used powder from the BOS, Blender bin – (smaller bin in the right front blends it with virgin powder from the IPC in a corner) receives, blends, and stores powder from preset ratio (defined by the “Percent Virgin”), and the Used bin and Virgin bin before the IRS sends feeds the blended powder to up to three it to the SLS system(s) (maximum) SLS systems. Each SLS system sends a The IRS monitors the powder level and weight in separate refill request to the IRS when its feed the three bins and refills them continually (as hopper is low. soon as the drop below 95% full). Receiving and storing powder L The IRS tries to keep all three bins full. Used powder, virgin powder, and blended It also monitors the powder level in the IPC and powder are received and stored in three separate alerts you when it’s almost empty. bins on the IRS: Used bin – (in the left rear corner) receives and Blending and sending powder stores used powder from the BOS. The BOS sends When the IRS refills the Blender bin, it does so a message to the IRS when it has powder to send. one batch at a time using specific portions of The BOS waits for the IRS to reply “okay to send,” used and virgin powder. The Percent Virgin then it sends powder. The IRS replies “okay to setting controls these portions; for example, a send” to refill the Used bin. batch with 30 Percent Virgin is 70 percent used powder. Virgin bin – (in the right rear corner) receives and stores virgin powder from the IPC. You connect The IRS always tries to blend a full batch, but will the umbilical to the IPC to unload virgin powder blend a partial batch if there’s not enough used from the IPC to the Virgin bin. After the initial fill, or virgin powder to make a full batch. (A batch of the IRS draws powder from the IPC until the blended powder weighs about 5 kg.) Virgin bin is full. After Blending is the highest priority for the IRS. It must finish blending before it can send powder to the SLS systems or receive powder from the BOS. SLS process 140 IRS & IPC user’s guide how the IRS & IPC work

Used (part cake) powder bin Virgin powder storage bin The Used bin in the left rear corner of the IRS The Virgin bin in the right rear corner of the IRS receives used powder (part cake) from the BOS receives virgin powder from the IPC and stores it and stores it for blending. After the initial fill, the for blending. The IRS loads virgin powder from IRS keeps the Used bin full (based on powder the IPC until the Virgin bin is “full”; i.e., until the weight and level) while used powder from the bin weight and powder level are both above the BOS is available. factory “full” setpoint; typically. L A load cell under the bin and a material sensor L A load cell under the bin and a material sensor at the top of the bin read the powder weight at the top of the bin read the powder weight and level. Do not place objects on top of the and level. Do not place objects on top of the bin. This will make the IRS read the powder bin. This will make the IRS read the powder weight greater than it is. weight greater than it is. Used powder automatically flows from the BOS When the powder weight in the Virgin bin falls to the IRS until the Used bin is full if the BOS is... below the preset “empty” setpoint, the IRS automatically unloads virgin powder from the IPC ✓ powered up, until the Virgin bin is full. ✓ in RECYCLE mode, and ✓ Before the IRS can unload powder into the Virgin has used part cake powder available to send. bin, an IPC must be... If the BOS has no used ✓ connected to the IRS umbilical, powder to send, See Starting the SLS ✓ eventually, the Used System (only) on at the proper pressure, bin will get too low to page 191 and Starting ✓ sending a valid RFID reading to the IRS, and blend a full batch. the SLS System (only) on ✓ page 191. have powder to send (not empty). When this happens, the IRS blends a partial batch. SLS process 141 IRS & IPC user’s guide how the IRS & IPC work

Blender bin percent, it transfers a load of used powder. If This Blender bin in the right front corner of the below, it transfers a load of virgin. The weight of IRS blends a batch of powder and stores it until it powder transferred with each load varies is fed to the SLS system(s). A load cell and a level somewhat and it is different between the used sensor monitor the Blender bin level. When the and virgin bin due to the slightly different flow powder weight drops below the falls to a properties of each material. In addition, the predetermined low level, a blend cycle is desired ratio of virgin to used powder may not be initiated. All other operations cease during 1:1. Therefore, the powder proportioning does blending. This means that the IPC will not load, not always alternate one load of each powder the IRS will not accept used powder from the BOS type. and the LS machines will not be fed powder until At the end of the proportioning, the last load may blending is complete. be greater than the final weight of powder Blending will not start until a sufficient quantity needed to arrive at the percent Virgin needed for of both used and virgin powder is available to the entire batch. Therefore, it transfers only the satisfy the desired percent virgin (user-settable at required weight to the blender and returns the the IRS UI). Once this has been checked and excess powder in the transporter to the bin it was satisfied, the IRS will begin blending by originally fed from. This ensures that the final transferring a load of whichever powder makes blend will be the desired percent Virgin. up the majority of the batch. Following this, at Once the blender contains the desired amount of the end of each transfer (whether of Virgin or Used and Virgin powder, the bin contents are Used powder) the IRS calculates the current thoroughly mixed by circulating the powder from percent virgin based on weights transferred so the bottom to the top of the bin using the right far. If the percent virgin is above the final desired transporter system. Internals in the bin enforce a velocity profile in the bin that essentially fold the powder over itself as it flows through the bin. The number of circulation cycles is set in software. Blend cycling continues until the weigh cell and the level switch signal a full bin. SLS process 142 IRS & IPC user’s guide how the IRS & IPC work

Once blending is complete, the IRS resumes When the IRS blends a partial batch, it flashes the processing other transfer requests for loading yellow stacklight and Please Load Used Powder Virgin or Used Powders into their respective bins or Change Percent Virgin appears on the operator or supplying blended powder to the LS machines panel display. connected to the IRS. Please load WHEN POWDER SUPPLY IS LOW - BLENDING A used powder PARTIAL BATCH or change If the IRS does not have enough powder (virgin or Percent Virgin used) to blend a full batch with the specified percent virgin, it will blend a “less-than-full” Partial batch message partial batch with the same percent virgin as a L The percent virgin determines the blend ratio. full batch. The IRS does this by blending all the The percent used is derived from the percent limiting amount of powder with a proportionally virgin. smaller amount of the other powder. When the Blender runs out of powder, the IRS Example: If the percent virgin is 60% —3 kg virgin shuts down, its red stacklight illuminates, and to 2 kg used—and the used bin only has 1 kg left, Blender Empty appears on the operator panel the IRS will blend a partial batch using the entire display. 1 kg of used, but only 1.5 kg of virgin. This makes the partial batch blend ratio 1.5. Blender empty

Empty Blender message SLS process 143 IRS & IPC user’s guide how the IRS & IPC work

Transporter Systems TRANSPORTER The left and right transporter systems are similar. A conical stopper valve, operated by an air Powder flows from a bin by gravity into an cylinder, is opened while the transporter is filling L-Valve, which controls the flow into a collector and closes to pressurize the transporter and funnel. From the funnel, the powder flows by convey the powder. The transporter hopper has a gravity into a chamber that can be closed and high-level proximity switch, which signals when pressurized to force powder to the powder the transporter is full. An air line with a # 19 manifold and on to the intended destination. orifice provides air to clean adhered powder off the proximity switch after each transfer. L-VALVE AND COLLECTOR FUNNEL The bottom of the transporter or fluidizer is a The bottom of the L valve contains a permeable permeable membrane similar to that in the L- fabric that allows air to flow through it. Air, Valves. Flow to the fluidizer membrane is flowing through a #13 orifice and the permeable controlled by a #63 orifice. This flow fluidizes the fabric, provides the motive force to convey the powder and forces the powder out a side port. powder. Note that the number of an orifice is an From there, a second air stream dilutes the indication of the orifice hole size, i.e., a #13 orifice powder to limit the ratio of powder to air in the has a 0.013-inch diameter hole. A larger air flow powder conveying lines. If there is too much will result in a higher powder flow rate. If there powder, the lines will plug. are air leaks around the membrane or at the air connection, the powder flow rate might be too POWDER MANIFOLD low. The powder manifold is a series of “T” fittings The L-Valve empties its powder through the with the flow out each branch controlled by a collector funnel lid and into the collector funnel. pinch valve. A pinch valve is essentially a rubber It is important that the L-Valve not touch the sleeve contained within a cavity that can be Collector Funnel lid. If it touches here, the pressurized to “pinch” the rubber sleeve closed. resulting friction will influence the load cell The pinch valves may only be closed when the readings that determine powder weight in the powder flow line is empty or nearly empty. If bins. The dust collection fan will ensure that air closed when full of powder, the powder will be always flows into the gap around the outside to compressed into a firm agglomerate and will not capture dust. clear when the pinch valve is opened. SLS process 144 IRS & IPC user’s guide how the IRS & IPC work

The following table shows the destinations for 3 Turn off L-Valve: When the level sensor LVL-R both Powder Manifolds on the IRS. on the transporter senses that the transporter is full, valve N5_S7V2 closes and FROM... LOCATION TO... the IRS delays to allow the powder flow to stop. If a timeout period elapses without the Blender level sensor turning on, the transfer will also Left powder Rear of Used begin. manifold Services Powder Bin transporter Panel 4 Pressurize Transporter. Valve N5_S2 switches Auxiliary to actuate air cylinder N66 to close the Right Outlet Transporter plug valve. Note that N5_S2 is a Blender 4-way valve. After a short delay, valve Right powder Front of Virgin N5_S10V4 opens and the pressure in the line manifold Services Powder Bin is characterized using the pressure sensor transporter Panel SLS system mounted directly on the I/O board and Outlet sensed through line N302. 5 Transport Powder. Once the line has been OPERATION determined to be clear (not plugged), valve Each transfer follows the same sequence. Below is N5_S10V2 opens until the line pressure rises an example sequence when conveying powder to a setpoint and then opens and closes to from the Blender to the SLS system outlet: maintain the pressure at this setpoint. A certain backpressure corresponds to a given 1 Select Destination. Valve N5_S5V2 actuates line loading of powder. If the ratio of powder to open the pinch valve allowing powder to air gets too large, the line will plug. When flow to the SLS system outlet. the line pressure falls below a minimum 2 Load Transporter. Valve N5_S7V2 opens to conveying pressure for a certain length of turn on the Blender L-Valve to allow flow time, the IRS moves to Shutdown. from the Blender into the Right Transporter collector funnel. The plug valve is normally in an open position which allows the powder to flow by gravity directly into the transporter. SLS process 145 IRS & IPC user’s guide how the IRS & IPC work

6 Shutdown. Valves N5_S10V2 and N5_S10V4 2 Transfer Acknowledge: When ready to close. Valve N5_S8V4 then opens for a few transfer, the IRS sends the SLS system an seconds to clear the transporter level sensor acknowledge message. The SLS system then of any adhered powder. Finally valve N5_S2 sets its powder control valves to receive the actuates to open the Right Transporter plug powder and sends a Valves Complete valve and Valve N5_S5V2 actuates to close message to the IRS. the pinch valve allowing flow to the SLS 3 Transfer: the IRS transfers one transporter system outlet. load of powder. SLS system powder transfers 4 Transfer Completion: When the load of powder has transferred, the IRS sends the SLS During normal operation, when the SLS system system a Transfer Complete message. upper feed hopper sensor is no longer asserted (the level sensor LED is off) the SLS system will 5 Transfer Completion Acknowledge: When the call for powder. If the IRS is not in a blend cycle or SLS system has reset its powder control transferring powder to another SLS system, it will valves, it sends a Valves Reset message to the respond quickly. If the IRS is blending a powder IRS. batch, it will finish blending before responding. Each step has a maximum time associated with it. One transporter load will then be sent. The SLS If the maximum time is exceeded on any one system will continue to call for powder until the step, the sequence starts over. 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. SLS process 146 IRS & IPC user’s guide how the IRS & IPC work

BOS powder transfers The IRS is a server responding to requests from the BOS meaning that all powder transfer requests originate from the BOS. When the BOS operator wishes to send powder to the IRS, he places the BOS in Recycle mode. Provided there is powder to send and 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 sends IRS a Transfer Complete message. Each step has a maximum time associated with it. If the maximum time is exceeded on any one step, the sequence starts over. SLS process 147 IRS & IPC user’s guide IPC description

IPC Description The Intelligent Powder Cartridge (IPC) is a When your are ready to use the IPC, move it next DuraForm powder material delivery and storage to the IRS, connect the safety pressure sensor line container. It has two connections on its pallet to the top of the IPC, then connect the IRS base that are protected during shipment by a umbilical at the bottom as shown: spring-loaded cover. It also has one connection on the upper lid under the fabric cover.

Umbilical Pressure sensor line Pulse air connection under cover Powder dilute air Ground wire Powder connects to Powder IPC band connection clamp with RFID

IRS umbilical connections on IPC

Pressure sensor connection located on the top Powder Connection bottom two connections lid, under the IPC cover; press in to connect/pull under the spring-loaded cover. The large molded to remove. connector terminates two umbilical lines; the small air line used to dilute the powder flow and IRS UMBILICAL CONNECTIONS the larger powder flow line. The connector also Pulse Air top connection under the spring- contains a radio frequency identification tag loaded cover; inflates the IPC during powder (RFID) reader used to identify the powder unload and delivers short, high-volume air pulses contained in the IPC. to fluidize the powder. SLS process 148 IRS & IPC user’s guide IPC description

IPC ground connection Connect the ground wire IPC batch unload sequence on the IRS powder umbilical to the IPC band Do not unload powder from the IPC clamp before unloading virgin powder. unless the IRS umbilical ground wire Do not unload powder from the IPC is connected to the metal IPC band unless the IRS umbilical ground wire clamp. is connected to the metal IPC band clamp. Powder is unloaded from the IPC in batches of roughly 5 kg. The unload sequence below repeats After the pressure sensor line, umbilical, and until the Virgin bin is full or the IPC is empty. ground wire are connected to the IPC, use the IRS L If you stop unloading manually before a entire operator panel to indicate that an IPC has been batch (5 kg) unloads, the IPC continues until it attached. unloads 5 kg. If the IPC empties before a batch completes, the IRS will shut it down after 8 How the IPC RFID works minutes. When the IPC is first connected, the IRS 1 Powder line purge. The IRS supplies both communicates with the RFID reader to determine continuous and pulsed air to the IPC to purge the type and amount of powder contained in the the powder line and fluidize any powder near IPC. The type must be the same as what the IRS the outlet that may have settled during already contains. If the tag indicates that the shipping. powder type is valid, the IRS will begin to unload. 2 IPC inflation. The IRS inflates the IPC to After each “batch” of powder is unloaded from minimum pressure using continuous and the IPC, the IRS will write out the amount of pulsed air. If minimum pressure is not powder loaded from the IPC to keep the tag reached within a set time period, the IRS current. In addition, the IRS tracks the amount of assumes the IPC is empty and shuts it down. powder unloaded from each IPC. Once the IPC RFID tag indicates that 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. SLS process 149 IRS & IPC user’s guide IPC description

3 Powder flow. To ensure smooth powder flow, IPC overpressure safety shutdown the IRS keeps the IPC inflated above The pressure sensor line at the top of the IPC minimum pressure with both continuous and connects to an overpressure sensor inside the pulsed air streams. The IRS monitors the time IRS. This sensor is completely independent of the that the IPC pressure falls below the IPC batch unload air flow controls. If the sensor minimum pressure and above the maximum detects air pressure in the IPC greater than 1.8 psi pressure setpoints. If either time limit is above the maximum IPC pressure setpoint, the exceeded, or if the IRS Virgin bin is full, the IRS IRS shuts down the IPC and air cannot enter the shuts down the IPC; i.e., shuts off air flow to IPC from any source. the IPC and powder flow to the IRS. L Minimum and maximum IPC pressure setpoints 4 Shutdown. The IRS lets the pressure in the IPC are set at the factory and must only be changed drop below minimum. As soon as it does, the by a certified 3D Systems Customer Support IRS blows pulsed air in the IPC to clear the Technician or Authorized Service Provider. powder line. This prevents the powder line from clogging when the next unload batch starts. SLS process 150 IRS & IPC user’s guide IRS & IPC safety

IRS & IPC Safety When you use any SLS equipment, follow all IRS umbilical safety general safety guidelines in Safety on page 9. ` Disconnect IRS umbilical in Standby mode. When you use the IRS or IPC, follow these IRS- and IPC-specific guidelines as well. Always place the IRS in Standy mode before you disconnect the umbilical. Hazardous voltage exists inside the If you disconnect the umbilical with IRS enclosure. Injury or death from the IRS in Ready mode, there’s a electrical shock can result if you chance the IRS might be unloading remove external panels or attempt to powder from the IPC. If so, powder defeat safety interlocks. Panels can spray out and the airborne should only be removed, and particles could irritate your eyes. interlocks should only be defeated, There is also a remote chance that the by trained and certified 3D Systems airborne dust cloud will explode in Customer Support personnel. the presence of an ignition source.

` Before moving the IPC or attempting to load ` Connect the ground wire clamp on the end of the IRS with powder from the IPC, see IPC the umbilical to the IPC band clamp screw Handling Safety on page 37 of the “Safety” before unloading virgin powder. This will section. prevent potentially damaging electrostatic Do not attempt to move the IRS discharge, from the IPC to the IRS. without the assistance of a trained 3D Systems service technician. Use at IPC unpacking safety least two people, or a pallet jack, to ` Never use a blade to remove the shrink-wrap move an IPC. from an IPC. You could damage the vinyl container fabric and cause it to leak when the ` Some exterior IRS and IPC surfaces are warm IPC is pressurized during unloading. to the touch during operation, but not warm enough to pose a burn hazard. SLS process 151 IRS & IPC user’s guide IRS & IPC safety

` Before you unload powder from the IPC, IPC moving and storage safety verify that the safety overpressure air line is The IPC is designed to lifted and moved with a connected to the push-on fitting on the top pallet jack. Do not try to lift or move it manually, of the IPC container. (The safety overpressure especially when it is full. The IPC weighs 25 kg air line connects to two pressure switches in (54 lb) empty and 125 kg (276 lb) full. the IRS. These switches detect potential overpressure in the IPC during unloading.) Always follow standard lifting practices (one person per 23 kg (50 lb)) when moving any ` The pressure in the IPC normally cycles SLS equipment or material. If you are not between 0.7 psig and 0.8 psig while the IRS is accustomed to lifting this much weight, or if you unloading powder from it. When an unload have back problems, do any or all of the following cycle completes, the IRS clears the umbilical to protect yourself: use additional people to lift which raises the pressure in the IPC to about the items, remove mass to reduce weight, or use 1.25 psi. The overpressure switches close all a mechanically assistance such as a pneumatic lift the air valves for air flow from the IRS to the cart. IPC if the pressure in the IPC exceeds 1.8 psi. SLS process 152 IRS & IPC user’s guide IRS operator panel and stacklight

IRS Operator Panel and Stacklight Use the IRS operator panel and stacklight run the IRS and determine its operating status. LCD display E-Stop button

Integrated Recycling Station Standing By >Exit Stand-By Setup

POWER on/off switch Cancel/Exit button Enter/OK button Scroll buttons for choosing options

IRS Operator Panel TO DISPLAY ALARM AND WARNING MESSAGES You can switch power to the IRS on and off at the In IRS Ready mode, the See IRS & IPC operator panel. After you switch power on, use operator panel displays status, warning, and Troubleshooting on the operator display and buttons to setup, run, page 172. and troubleshoot the IRS. 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. SLS process 153 IRS & IPC user’s guide IRS operator panel and stacklight

When status changes, Occasionally the status IRS Stacklight message overwrites a warning or error message. The green, yellow, and red lights on the IRS To hide the current status message and scroll the stacklight indicate the IRS states described most recent warning and error messages, press below. (The blue light is not used.) repeatedly. The warning or error message is overwritten when the status changes again. If COLOR MODE IRS STATUS there are multiple warning or error messages, you can view each in turn by pressing . Off Normal IRS is stopped and is not Red servicing any transfer Steady requests. The cause appears on the operator panel display. Off Normal IRS has a warning condition as displayed on the LCD. It Steady will continue to provide Yellow blended powder to the SLS system(s) in this condition. Safety override during Flashing service by a Field Engineer. Off IRS not ready IRS is operating normally Steady and is waiting for a transfer Green request One or more transfers are Flashing in process as shown on the operator panel display. Blue not used SLS process 154 IRS & IPC user’s guide IRS start-up

IRS Start-up Before you turn on the IRS, make sure the IRS umbilical is connected to IPC base fittings with ground cable is connected to the IPC band clamp. Also verify that the IPC overpressure safety sensor is securely connected to the tap on the IPC lid.

1 Turn the IRS 3 When you are ready run the IRS; (i.e., ready to POWER switch on. See IRS Operator Panel begin transferring and blending powder), and Stacklight on choose Exit Standby, then press . The IRS displays page 152 to locate the Initializing... for power switch. The IRS enters Ready mode. The display you several seconds, see immediately after you enter Ready mode then the default Standby mode display depends on the states of the bins. appears along with menu options. 4 If all the bins are full, including the Blender Integrated Recycling bin, the Ready mode display appears showing the weights of all three bins and the Station Standing By IPC. >Exit Standby Setup Integrated Recycling Standby mode display with main menu Station Ready Blended: 25 IPC: 20 While in Standby mode, air flow in the IRS Virgin: 102 Used: 70 and IPC is off, and no powder transfers occur. Ready mode display showing current 2 If you’re not ready to run the IRS yet, press bin weights and IPC weight to choose Setup, Diagnostics, or When see the Ready mode display above, the Utilities from the Standy menu, then press IRS is doing its job; blending and transporting to display the chosen menu. powder. See Using IRS Main Menu on page 156 and for menu option descriptions and instructions. SLS process 155 IRS & IPC user’s guide IRS standby and ready modes

5 If one of the bins or the IPC is low, the IRS Default displays in Standby and Ready display prompts you to add more powder mode change the empty IPC. After you do, the IRS When you’re in Standby mode, the default returns to Ready mode and displays the bin display shows the menu options. However, in weights. Ready mode, the default display shows the live weights (in kilograms) of the three IRS bins and IRS Standby and Ready the IPC. Modes The IRS has two operating modes: Standby and So, if you’re in Ready mode, press to access Ready. When you power up the IRS, it starts in the Ready mode menu options. Standby. You can do everything in Standby except transfer powder—you must be in Ready mode to do that. (This is mainly because air flow in the IRS is shut off in Standby mode.) 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 only available in Standby mode, and IPC Status is only available in Ready mode. SLS process 156 IRS & IPC user’s guide using IRS main menu

Using IRS Main Menu Use the IRS main menu To select main menu options in Standby or Ready See Using the BOS Setup Menu on From Integrated Recycling Station Ready mode, mode— to view the press to enter Standby mode. IRS software version page 229 and Using the BOS Diagnostics Menu and to access Setup, The Standby mode display appears along with on page 232. and Diagnostics. (You the list of main menu options. must be in Standby to access Utilities.) Integrated Recycling Station Standing By L The IRS must be in Ready mode to transfer >Exit Standby powder. Powder cannot be transferred in Standby mode because air flow to the IRS (and Setup IPC) is off in Standby. Standby mode display with Main menu You can also access Setup and Diagnostics in IRS Ready mode, but you must be in Standby to Press to choose an option, then press . access Utilities. Some main menu options are mode-specific. For To view IRS software version example: From the Main menu, choose About, then press • The Utilities menu is only available when . the IRS is in Standby mode. The BOS software version number and date • The IPC Status menu option is only appears. available in the Ready mode. FW Ver: R13.03 MAC:0000000002 Build: 2005-10-18 About menu display Press to return to the Main menu. SLS process 157 IRS & IPC user’s guide using IRS main menu

To access IRS Setup or Diagnostics menus From the Main menu, choose Setup or Diagnostics, then press . The BOS Setup menu or Diagnostics menu See Using the BOS appears. Setup Menu on page 229 and Using the BOS Diagnostics Menu on page 232. SLS process 158 IRS & IPC user’s guide using the IRS setup menu

Using the IRS Setup Menu You can access the Setup menu in Ready mode or Setup Menu Options Standby mode. Process Parameters Menu To access the Setup menu IPC Pressure, L Pressure, and R Pressure ` From Standy mode display: Sens Gain Integrated Recycling Station Standing By Zero >Exit Standby Process Setup Percent Virgin Standby mode display with main menu Restore Saved Parameters Press to choose Setup from the main menu, then press . Save Parameters Restore Factory Parameters ` From Ready mode display:

Integrated Recycling Station Ready Blended: 25 IPC: 20 Virgin: 102 Used: 70 Ready mode display Press to display the main menu Press to choose Setup from the main menu, then press . SLS process 159 IRS & IPC user’s guide using the IRS diagnostics menu

Using the IRS Diagnostics Menu You can access the Diagnostics menu in Ready Diagnostics Menu Options mode or Standby mode. Blender Blender Load, Blender High Level To access the Diagnostics menu Virgin Powder Bin Virgin Powder Bin Load, Virgin Powder Bin High Level ` From Standy mode display: Used Powder Bin Used Powder Bin Load, Used Integrated Recycling Powder Bin High Level Station Standing By Left Transporter Left Transporter Load, Left >Exit Standby Transporter High Level Setup Right Transporter Right Transporter Load, Right Standby mode display with main menu Transporter High Level Press to choose Diagnostics from the IPC Transporter IPC Pressure, IPC Pressure Switch main menu, then press . ` From Ready mode display:

Integrated Recycling Station Ready Blended: 25 IPC: 20 Virgin: 102 Used: 70 Ready mode display Press to display the main menu Press to choose Diagnostics from the main menu, then press . SLS process 160 IRS & IPC user’s guide using the IRS utilities menu

Using the IRS Utilities Menu You can only access the Utilities menu in Standby 4 From Standy mode display: mode. Integrated Recycling To access the Utilities menu Station Standing By Skip to Step 4 of you are in Standby mode now. >Exit Standby Setup 1 Enter Standy mode from Ready mode by pressing twice, or until you see the Ready Standby mode display with main menu mode bin weights display: Press to choose Utilities, then press Integrated Recycling . Station Ready Blended: 25 IPC: 20 Utilities Menu Options Virgin: 102 Used: 70 Use the Utilities menu to empty the IRS bins, send powder to SLS system manually, or transfer Ready mode display powder between bins. The menu options are 2 Press to display main menu in Ready summarized below. Instructions for emptying mode. bins and transferring powder are in the next two sections. Integrated Recycling Station Ready OPTION DESCRIPTION >Exit to Stand-By Empty Blender Sends powder from the Setup Bin Blender to the POWDER OUTLET until the IRS is turned Ready mode display with main menu off. 3 Press to choose Exit to Stand-by, then Empty Virgin Bin Sends powder from the Virgin then press . bin to the POWDER OUTLET until the IRS is turned off. SLS process 161 IRS & IPC user’s guide using the IRS utilities menu

OPTION DESCRIPTION To empty powder bins Before you move the IRS or change Empty Used Bin Sends powder from the Used bin to the AUXILIARY OUTLET materials, empty all IRS powder bins. until the IRS is turned off. When you empty the Virgin bin or Blender bin, Manual LS Sends one transporter load of powder exits the POWDER OUTLET at the right Transfer powder to the SLS system. rear of the IRS. This option is for When you empty the Used bin powder exits the 3D CSE use only. Do AUXILIARY OUTLET at the left rear of the IRS. not attempt to use it. Before you empty the Used bin, uncap the outlet Improper manual and attach a spare powder line to it. transfer can clog powder line. 1 For Virgin bin or Blender bin: Disconnect Blender to Virgin Sends powder from the the powder supply line from the (first) SLS Blender bin to the Virgin bin system’s POWDER INLET. until the IRS is turned off. For Used bin: Remove the cap from the IRS AUXILIARY OUTLET and connect a spare powder supply line to it.

Auxiliary Powder Outlet Outlet (to (capped) SLS system) pull cap lock straps to release cap

Powder outlets inside IRS enclosure, (viewed from rear with rear panel off)

2 Place the open end of the powder line from the [POWDER or AUXILIARY] OUTLET in a large covered container. SLS process 162 IRS & IPC user’s guide using the IRS utilities menu

L The container should be large enough to hold all the powder in the bin you’re emptying. It should also be clean if you intend to reuse the powder you’re removing. 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.

Manual LS Transfer

Display after you select an Empty [Blender, Virgin, or Used] bin command

5 When powder stops flowing, turn off the IRS to stop emptying the powder bin. To empty another bin, repeat from Step 1. SLS process 163 IRS & IPC user’s guide loading virgin powder in the IRS

Loading Virgin Powder in the IRS To load virgin powder into the IRS Virgin bin, do Step 1: Connect a full (or partially full) IPC the following three steps: to the IRS 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 2 Put the IRS in Ready mode. side of the IRS. 3 Change the IPC status from Do not Unload to 2 If an empty IPC is currently connected, Unload. reverse Steps 3 and 4 below to disconnect it, Each of these three loading steps are detailed then move it out of the way. below. When loading is done, Press to exit 3 Connect the pulse air line on the IRS umbilical Standby and enter Ready mode. to the full IPC’s pulse air inlet on the front of L To ensure your builds never run out of powder, the IPC pallet. always replace an empty IPC with a full one as soon as possible. To ensure a good seal, press the lock button on top of the pulse air connector, push the connector onto the inlet, then release the button.

IPC pulse air inlet

IRS umbilical pulse air line connector SLS process 164 IRS & IPC user’s guide loading virgin powder in the IRS

4 Connect the bulkhead connector on the IRS Step 2: Put the IRS in Ready mode umbilical to the IPC’s powder outlet (also on 1 If the IRS power is off, switch it on. the front of the IPC pallet) and fluidizing air inlet. 2 Check the IRS display. If it shows Integrated Recycling Station Ready, the IRS is in Ready To ensure a good seal, press the lock tab on mode. the right side of the bulkhead connector, push the connector firmly onto the [air inlet/ 3 If the IRS is not in Ready mode, it’s in Standby powder outlet], then release the lock tab. mode. Press twice to exit Standby and enter Ready mode.

Step 3: Change IPC Status from Do Not Unload to Unload Fluidizing 1 Press to change the display from air inlet Integrated Recycling Station Ready to IPC status. IPC powder outlet 2 Change the IPC status on the display from from Do Not Unload to Unload via the operator. 3 Disconnect the IRS umbilical from a partially IRS umbilical powder line full or empty IPC. bulkhead connector Each unloading step is detailed in this section.

L The red (or blue) tube on the IRS umbilical To change the IPC status conveys “fluidizing air” to help keep the powder outlet from clogging. The grey wire connects The IRS must be in Ready mode change the IPC the RFID antenna in the bulkhead connector to status from Do Not Unload to Unload. the IRS RFID reader. The antenna receives If the IRS is in Ready mode, press to change information from the RFID tag embedded in the display from Integrated Recycling Station the IPC pallet. Ready to IPC status. SLS process 165 IRS & IPC user’s guide transporting powder – from IRS to SLS system

Transporting Powder – from IRS to SLS System During a build, an SLS system requests powder 3 Transfer: the IRS transfers one transporter from the IRS whenever its feed hopper gets low load of powder. on powder. “Low” means the powder level in the 4 Transfer Completion: When the load of feed hopper is below the upper level sensor. powder has transferred, the IRS sends the SLS When the feed hopper is low, the upper level system a “Transfer Complete” message. sensor’s LED switches off. 5 Transfer Completion Acknowledge: When When the IRS receives a powder request from an the SLS system has reset its powder control SLS system, it sends powder immediately— valves, it sends a “Valves Reset” message to unless it’s currently sending powder to another the IRS. SLS system, or in a blend cycle. Each step has a maximum time associated with it. The IRS sends powder one transporter-load at a If the maximum time is exceeded on any one time. The SLS system continues to request step, the sequence starts over. powder until its feed 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 receive the powder and sends a “Valves Complete” message to the IRS. SLS process 166 IRS & IPC user’s guide blending

Blending When the Blender drops below approx. 20 kg, it In addition, the desired ratio of virgin to used will attempt to blend a batch of powder. Blending powder may not be 1:1. Therefore, the powder will not start until a sufficient quantity of both proportioning does not always alternate one load Used and Virgin powder is available as measured of each. At the end of the proportioning, the last by the load cells supporting the Used and Virgin load may be greater than the final weight of powder bins. Once this has been checked and powder needed to arrive at the percent Virgin satisfied, the IRS will begin blending by needed for the entire batch. Therefore, it transfers transferring a load of whichever powder makes only the required weight to the blender and up the majority of the batch. returns the excess powder in the transporter to the bin it was originally fed from. This ensures Following this, at the end of each transfer that the final blend will be the desired percent (whether of Virgin or Used powder) the IRS Virgin. Once the blender contains the desired calculates the current percent virgin based on amount of Used powder and Virgin powder, it weights transferred so far. blends the powder within the blender to obtain a If the percent of virgin is... uniform batch. Once blending is complete, the ` above the final desired percent virgin (user IRS resumes processing other transfer requests settable at the UI on the IRS) it transfers a for loading Virgin or Used Powders into their load of used powder. respective bins or supplying blended powder to the Sinterstations connected to the IRS. ` below the final desired percent virgin, it transfers a load of virgin. The weight of View or Change the Used/Virgin Powder powder transferred with each load varies Ratio somewhat and it is different between the used and virgin bin due to the slightly different flow properties of each material. SLS process 167 IRS & IPC user’s guide loading virgin powder

Loading Virgin Powder When the IRS is low on Virgin powder, it will light up the When your are ready to use the IPC, move it next to the IRS, connect the safety pressure sensor line to the top of the IPC, then connect the IRS umbilical at the bottom as shown:

Umbilical Pressure sensor line Pulse air connection under cover Powder dilute air Ground wire Powder connects to Powder IPC band connection clamp with RFID

IRS umbilical connections on IPC

Pressure sensor connection located on the top Powder Connection bottom two connections lid, under the IPC cover; press in to connect/pull under the spring-loaded cover. The large molded to remove. connector terminates two umbilical lines; the small air line used to dilute the powder flow and IRS UMBILICAL CONNECTIONS the larger powder flow line. The connector also Pulse Air top connection under the spring- contains a radio frequency identification tag loaded cover; inflates the IPC during powder (RFID) reader used to identify the powder unload and delivers short, high-volume air pulses contained in the IPC. to fluidize the powder. SLS process 168 IRS & IPC user’s guide loading virgin powder

IPC ground connection Connect the ground wire IPC batch unload sequence on the IRS powder umbilical to the IPC band Do not unload powder from the IPC clamp before unloading virgin powder. unless the IRS umbilical ground wire Do not unload powder from the IPC is connected to the metal IPC band unless the IRS umbilical ground wire clamp. is connected to the metal IPC band clamp. Powder is unloaded from the IPC in batches of roughly 5 kg. The unload sequence below repeats After the pressure sensor line, umbilical, and until the Virgin bin is full or the IPC is empty. ground wire are connected to the IPC, use the IRS L If you stop unloading manually before a entire operator panel to indicate that an IPC has been batch (5 kg) unloads, the IPC continues until it attached. unloads 5 kg. If the IPC empties before a batch completes, the IRS will shut it down after 8 How the IPC RFID works minutes. When the IPC is first connected, the IRS 1 Powder line purge. The IRS supplies both communicates with the RFID reader to determine continuous and pulsed air to the IPC to purge the type and amount of powder contained in the the powder line and fluidize any powder near IPC. The type must be the same as what the IRS the outlet that may have settled during already contains. If the tag indicates that the shipping. powder type is valid, the IRS will begin to unload. 2 IPC inflation. The IRS inflates the IPC to After each “batch” of powder is unloaded from minimum pressure using continuous and the IPC, the IRS will write out the amount of pulsed air. If minimum pressure is not powder loaded from the IPC to keep the tag reached within a set time period, the IRS current. In addition, the IRS tracks the amount of assumes the IPC is empty and shuts it down. powder unloaded from each IPC. Once the IPC RFID tag indicates that 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. SLS process 169 IRS & IPC user’s guide loading virgin powder

3 Powder flow. To ensure smooth powder flow, light and display a message on the LCD. It will the IRS keeps the IPC inflated above still continue to feed powder to the Sinterstations minimum pressure with both continuous and during this time, but no blending cycle will be pulsed air streams. The IRS monitors the time initiated until a sufficient amount of powder is that the IPC pressure falls below the present in both the Used and Virgin powder bins. minimum pressure and above the maximum To load Virgin powder the Intelligent Powder pressure setpoints. If either time limit is Container (IPC) is first connected to the system. exceeded, or if the IRS Virgin bin is full, the IRS Second, the UI panel menu option “IPC Status” is shuts down the IPC; i.e., shuts off air flow to used to start the unloading process. Once the IPC and powder flow to the IRS. started, it will automatically continue until the 4 Shutdown. The IRS lets the pressure in the IPC IPC is empty, although it may be interrupted by a drop below minimum. As soon as it does, the blending cycle from time to time. IRS blows pulsed air in the IPC to clear the See Step 1: Connect a full (or partially full) IPC to powder line. This prevents the powder line the IRS on page 163 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 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 Technician or Authorized Service Provider. SLS process 170 IRS & IPC user’s guide loading used powder

Loading Used Powder To transfer used powder from the BOS sifter to See IRS Stacklight on page 153 for descriptions of the IRS Used bin, set the BOS POWDER IRS stacklight states. TRANSPORT switch to RECYCLE. The BOS will 3 Press repeatedly until the IRS operator send powder to the IRS unless or until the Used panel displays Integrated Recycling Station bin is full. Ready. If the Used bin is full; i.e., if its upper level sensor 4 Turn off the POWER switch on the IRS LED is on, the IRS will not accept powder from the operator panel. BOS. So, if the Used bin’s upper LED is on, turn the BOS POWDER TRANSPORT switch to DISPOSAL. L If the BOS can’t transfer powder to the 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 light means an internal transfer is in process, such as IPC unloading, blending, or transferring powder between bins.) SLS process 171 IRS & IPC user’s guide maintenance

Maintenance

Moving the IRS If you need to move the IRS after you fill the bins with powder, empty the bins first. Always empty the IRS powder bins before moving the IRS. Moving the IRS with powder in the bins can damage the machine.

To empty the bins, use the three Empty Bin command options on the IRS utilities menu. See To empty powder bins on page 161. SLS process 172 IRS & IPC user’s guide IRS & IPC troubleshooting

IRS & IPC Troubleshooting

IRS Error Messages

MESSAGE DESCRIPTION ACTION Input out of Bounds Floating point must be between Correct value to within range bounds. For example, the Percent Virgin must be greater or equal to 30% and less than or equal to 100% RFID Factory Tag Error RFID Tag information is corrupted. RFID Update Tag Error RFID Tag Updated Information not valid. Expired 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 Restore IPC originally used for unloading process unload. IPC Tag Read Failure Communications problem with RFID reader Machine Config Missing. Call Non-Volatile RAM storing sensor Reprogram NVRam. Service. parameters, tare weights, etc. is missing. Must re-program NVRam using Setup > Program Factory Default Parameters menu option. Blended Powder Empty The Blended Powder bin empty. Provide the Virgin and Used No powder will be sent to the Powder so a new batch can be Sinterstations until more powder prepared. is blended. SLS process 173 IRS & IPC user’s guide IRS & IPC troubleshooting

IRS Error Messages (continued)

MESSAGE DESCRIPTION ACTION Blender Weight Error The Weight of the Blender Bin Restore the previous Blender changed unexpectedly. No weight or use the Setup > Reset powder will be sent to the Bin Weight Error menu option. 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 screw in the load cell is adjusted Virgin Powder Bin Weight Error The Weight of the Virgin Powder Restore the previous Blender Bin changed unexpectedly. No weight or use the Setup > Reset powder will be sent to the Bin Weight Error menu option. 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 screw in the load cell is adjusted SLS process 174 IRS & IPC user’s guide IRS & IPC troubleshooting

IRS Error Messages (continued)

MESSAGE DESCRIPTION ACTION Used Powder Bin Weight Error The weight of the Used bin Restore the previous Blender changed unexpectedly. No weight or use the Setup > Reset powder will be sent to the SLS Bin Weight Error menu option. system until this is resolved. This See Reactivation after IRS Bin error will also occur if: Weight Error on page 176. • an external object, e.g., a toolbox, is placed on the bin • the bin tare weight is adjusted • the adjustment screw in the load cell is adjusted Insufficient Powder The Transporter did not fill within Check: the requisite time. • 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 Load Virgin Powder Virgin Powder is needed to mix Connect an IPC with sufficient another blended powder batch. Virgin Powder. The IRS will continue to feed the Sinterstations it services until the Blender is empty. SLS process 175 IRS & IPC user’s guide IRS & IPC troubleshooting

IRS Error Messages (continued)

MESSAGE DESCRIPTION ACTION Please Load Used Powder or Used Powder is needed to mix Load used powder into the IRS Change Percent Virgin another blended powder batch. using the BOS. The IRS will continue to feed the Sinterstations it services until the Blender is empty. Blender Unexpectedly Full The Blender High Level sensor Determine which is accurate and indicates a full bin, but the bin correct the situation. The blend weight does not. The IRS will blend will be incorrect, but close to the the contents proportioned up to desired percentage. Since it is this point and continue to feed the blended in with the prior contents Sinterstations it services. of the blender, it should not cause problems in the build.

Reactivating Powder Transfers REACTIVATION AFTER INVALID IPC RFID ERROR Follow the steps in this section to reactivate No powder can be transferred until powder transfers if they were disabled by the the IRS validates the RFID tag for the Powder Management System due to: currently connected IPC. ` Invalid IPC RFID tag After the IRS detects an invalid IPC RFID tag, you ` An IRS bin weight changes unexpectedly (at must do the following to reactivate powder anytime other than during a powder transfers: transfer). 1 Disconnect the IRS umbilical. Both of these conditions display error conditions 2 Connect the umbilical to a valid IPC that’s not on the IRS operator panel. If you suspect one of empty. these error occurred, but don’t see an error message, press repeatedly display and scroll the list of recent IRS error messages. SLS process 176 IRS & IPC user’s guide IRS & IPC troubleshooting

REACTIVATION AFTER IRS BIN WEIGHT ERROR 4 After you enter the code, navigate to the No powder can be transferred until Setup menu in either Standby or Ready the you reactivate the IRS and reset mode. the bin weights. 5 From the Setup menu, choose Reset Bin If the IRS detects an unexpected change in an IRS Weight Errors, then press . bin weight (anytime other than during a powder L If you do not see the Reset Bin Weight transfer), it will do the following: Errors option on the Setup menu, ask your Customer Support Representative for ` Display Bin Weight Error... along with the 3D Systems’ Customer Support phone number. After bin weight errors are reset, the IRS will resume powder transfers when you put it in ` Send a message to the APMU to stop all Ready mode. powder transfers. After a Bin Weight Error, SLS system(s) can IRS Stacklight states continue to run until their feed hopper(s) are See IRS Stacklight on page 153. empty. To reactivate powder transfers, do the following: 1 Write down the displayed deactivation code. L If the error message is overwritten, 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. SLS process 177 IRS & IPC user’s guide IRS & IPC troubleshooting

Clearing the IRS umbilical: Method 1 7 Reconnect the umbilical to the IPC. Be sure to 1 Disconnect the umbilical from the IPC. connect the umbilical ground wire to the IPC band clamp. 2 Place the umbilical bulkhead in a container to catch the powder when it comes out. Clearing the IRS umbilical: Method 2 3 On the IRS operator panel, navigate to the If the umbilical clogs near the end of IPC Diagnostics menu in either Standby or Ready unloading; follow the steps below to clear the mode. line:

4 From the Diagnostics menu, choose IPC Pulse air Transporter, then press . IRS umbilical 5 From the IPC Transporter menu, choose connection on IPC Powder Convey Line Clean, then press to change dilute air the setting from OFF to ON. Powder As soon as you switch this setting to on, 1 Verify that the IPC status on the IRS display is purge air should start flowing through the Do Not Unload. umbilical’s convey line at high rate. >IPC: Do Not Unload L If you do not see the Convey Line Clean Press OK to change option on the IPC Transporter menu, call 3D Systems’ Customer Support Hotline for assistance. 6 As soon as the convey line clears, switch the IPC status Do Not Unload display 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 for assistance. SLS process 178 IRS & IPC user’s guide IRS & IPC troubleshooting

2 Unplug the IRS umbilical’s pulse air 4 Carefully vacuum powder in the IRS umbilical connector at the IPC. Let the IPC vent any from the IPC bulkhead connector end. remaining pressure.

IRS umbilical pulse air connector (press vacuum button to release)

5 Pass the vacuum quickly over the IPC powder 3 When the IPC is done venting (i.e., when air outlet to loosen powder in the IPC internal flow out of the IPC stops), unplug the IRS piping. umbilical’s powder connection.

IRS vacuum umbilical powder connector (pull out) SLS process 179 IRS & IPC user’s guide IRS & IPC troubleshooting

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 SLS process user’s guide

SLS SYSTEM This section describes the SLS system and provides operating, maintenance, and troubleshooting instructions. It frequently 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 ` Starting the SLS System (only) ...... 192 ` SLS System Features ...... 183 ` Shutting Down the SLS System ...... 196 ` SLS System Specifications ...... 184 ` SLS System Service & Maintenance. . . . . 197 ` SLS System Description ...... 185 ` SLS System Troubleshooting...... 203 ` SLS System Safety ...... 191 SLS process 181 SLS SYSTEM user’s guide SLS system overview

SLS System Overview The SLS system builds parts in the removable A laser mounted on top of the SLS system scans RCM. It performs builds in a heated, nitrogen- the bed of powder. After scanning, the RCM, inerted internal process chamber the receives (under control of Sinter program running in the powder from the IRS. An feed hopper dispenses SLS system computer), drops the RCM part piston DuraForm powder material on a sweeper in the one layer height. process chamber. Powder is wiped off the sweeper, preheated, then a roller spreads the powder over the part bed. SLS process 182 SLS SYSTEM user’s guide SLS system features

SLS System Features ➊ ➋ ➒ ➌

➑ ➍

➎

➐ ➏

➊ Process chamber module (PCM) ➍ User Interface (UI) • Part Bed ➎ Emergency Stop button • Part bed heaters ➏ RCM bay • Roller ➐ Overflow Modules (OFM) • Feed heaters • Powder transport tubes • IR sensor and blackbody • Powder transport pumps • Laser window damper handle ➑ Hopper feed module (HFM) ➋ Image Processing Module (IPM) • Feed hopper • Laser window (removable) • Powder dispenser • Laser and optics • Powder inlets (From IRS & OFMs) ➌ Gauge panel (right side - not shown) ➒ Machine Services Module (MSM) (rear - not • Nitrogen generator port shown) • Oxygen monitor port • Machine power/control enclosures • Flow and pressure gauges • Application computer • Air and coolant valves SLS process 183 SLS SYSTEM user’s guide SLS system specifications

SLS System Specifications

Models sPro 140 - standard model sPro 230 - 23 cm (9 in) taller than model 140 Input powera 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 (220  184  185) cm (78  72  73) in (87  72  73) in • Stacklight height 36 cm (14 in) 36 cm (14 in) • door clearance (for left and 51 cm (20 in) on both sides 51 cm (20 in) on both sides right side process chamber access doors) •RCM cable length 132 cm (52 in) 132 cm (52 in)

Max. build volume (in RCM) (550  550  460) mm (550  550  750) mm (X  Y  Z) (22  22  18) in (22  22  30) in 140 liters 230 liters a. The SLS system must be connected to a separate, dedicated facility power circuit. SLS process 184 SLS SYSTEM user’s guide SLS system description

SLS System Description This is main SLS process machine. It builds solid Upper Process Chamber (UPC) 3-dimensional parts out of 3D Systems’ The UPC, or upper portion of the completely DuraForm laser sintering powder. This guide enclosed process chamber, houses chamber heat covers two SLS system models: the sPro 140 and and atmosphere control devices: the taller sPro 230. These two models are the same with one exception: frame risers installed ` Part bed heater rods on model 230 enable it to build taller parts in a ` Halogen chamber lights taller RCM. ` Blackbody and IR sensor on swing-out panel See RCM Description on page 108 for more about ` Chamber viewing window RCM models. ` Oxygen sensor The major sPro model 140 and 230 SLS system ` Nitrogen heater 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 SLS process 185 SLS SYSTEM user’s guide SLS system description

Lower Process Chamber (LPC) The LPC, or lower portion of the process chamber, Flexible thermal curtains on the inner side of contains devices that heat powder on the process each channel provide the isolation for the pulleys chamber floor, then spread it across the part bed. and belts. They also enable the mechanical These include: coupling of the roller to the guide rods. ` Counter-rotating powder bed roller with ` Two pairs of powder heaters; one on the right cover. side of the chamber and one on the left. Each ` Stepper motor to drive roller transverse pair has a top and bottom heater. The top motion and roller rotation. “radiant” heater is mounted above the ` Two thermally isolated channels housing chamber floor. The bottom “conduction” roller drive components. These components heater is below the chamber floor. These enable roller transverse motion with counter- preheat powder from above and below after rotation. They include: it is wiped off the roller cover onto the process chamber floor—and before it is Two roller driveshafts; one for transverse motion spread across the part bed. and the other for rotation; one shaft in each channel ` Square part bed hole in the middle of the chamber floor, directly below the laser Two roller guide rods mechanically coupled to window. The RCM cylinder rises up and seals the roller; one rod in each channel against the gasket around the bottom edges Two sets of pulleys, belts, and belt tensioners for of this opening. the roller; one set in each channel SLS process 186 SLS SYSTEM user’s guide SLS system description

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 SLS process 187 SLS SYSTEM user’s guide SLS system description

Gauge panel

2 Gauge Panel 1

sPro SLS system TOP VIEW

FRONT 3 456 1 Regulated N2 Pressure N2 inlet pressure gauge; set to 15 psi 2 Regulated N2 Pressure N2 inlet pressure 7 regulator 11 3 PC Pressure Process Chamber pressure 9 gauge 4 IR Window N2 Flow gauge/regulator 8 5 Laser Window N2 Flow gauge/regulator 10 6 Coolant Flow gauge 7 Nitrogen Inlet from N2 Generator or tank; N2 supply pressure: 400 to 600 kPa (60to90psi) 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 12 13 Coolant Return from laser cooling lines 15 back to Chiller 13 14 14 Coolant Inlet from Chiller to laser cooling lines 15 Powder Inlet from IRS SLS process 188 SLS SYSTEM user’s guide SLS system description

RCM bay Machine Services Module (MSM) Separate frame for loading and unloading RCM; At back of machine; main interface is gauge interlocked door; RCM cable. panel ` Electrical and control electronics enclosures Overflow Modules (OFM) ` Application computer Catch unused powder on right and left side of PCM. Overflows contain screens; powder falls User Interface (UI) and Application through screens and is pumped back into the Computer Hopper Feed Module. Computer display, keyboard, and trackball for SLS ` Powder transport tubes system application computer. Access to Sinter ` Powder transport pumps application and utilities, as well as Powder Management Network configuration. Hopper Feed Module (HFM) You control the SLS system through UI connected Hopper on the left side of SLS system receives to the application computer mounted in the rear powder from the IRS and overflow modules; of the SLS system (in the Machine Services powder dispenser at bottom of hopper deposits Module). The application computer runs the SLS fixed amount of powder on top of roller. When system software, which runs builds, build setup, the roller moves, a wiper suspended from the top and manual operations. of the process chamber slides it off the roller cover onto the PCM floor where it is preheated. System Enabled button and status indicator (green) indicates that the powder feed and part ` Feed hopper piston can move. If the RCM is loaded, the system ` Powder dispenser also allows roller motion. ` Powder inlets (From IRS and left/right OFMs) System Active status indicator (green) indicates you can use the heaters, laser, powder feed and part piston motion, and the roller motion. SLS process 189 SLS SYSTEM user’s guide SLS system description

3D Systems LS Software LS software includes 3D Systems’ software and To start the software, see Run Sinter application third-party software provided with the SLS on page 192. System SINTER UTILITIES BUILD SETUP APPLICATION SOFTWARE In addition to the software that controls the SLS The Build Setup application helps you create system, 3D Systems provides utility applications build packets from STL files. Build packets store with additional functions, such as reducing log all the data and instructions required to build SLS files or checking the status of the system from a parts. remote computer. For more information, see Sinter online Help. With Build Setup you verify your build packets, preview your build, and estimate build times—all before actually building the part(s). THIRD-PARTY SOFTWARE An STL file editor software package called See the Build Setup Help for more information. Materialise Magics RP is included with your SLS system shipment. See the Magics RP software SINTER APPLICATION SOFTWARE documentation for instructions. To start the The SLS system software controls the SLS system. Magics RP software, double-click the Magics RP With it, you can: icon on your Windows desktop. ` Run builds using the build packets you create Basic functions of the software are free. The in Build Setup. See “Running a Build” on page software’s advanced functions are free for 60 66 for more information. days, and then must be purchased. The 60-day ` Manually control the SLS system. See the evaluation period is activated by the 3D Systems “Manual Operations” topic in Sinter Help for representative who installs your system. If you do more information on manually controlling not purchase the activation password, advanced the system. functions are disabled. ` Access Build Setup directly to modify a build packet on the fly (while a build is in progress). SLS process 190 SLS SYSTEM user’s guide SLS system safety

If your company purchased the password at the same time that it purchased the SLS system, the software will be fully activated by the field service representative 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 this section as well. They are specific to the SLS system. SLS process 191 SLS SYSTEM user’s guide starting the SLS system (only)

Starting the SLS System (only) These instructions Perform the procedures below to start up the SLS describe how to power See Starting the system from its powered-off state: up and start the SLS Equipment on page 60 ` Power on the SLS system system only. In normal for instructions on how to start all other SLS operation, you start up ` Run the Sinter application process machines other SLS equipment ` Perform SLS system machine start-up as well. sequence L To save time, start preheating the RCM about 2 These three procedures are described next. hours before you plan to start a build in it. These instructions assume the SLS system main Power-on SLS system power disconnect switch on the AC box is off, but 1 Turn on the SLS that facility power is available. system’s main See SLS System Features power disconnect on page 182 to locate switch on the AC the switches in this SLS system start-up startup procedure. Also chassis door (at left Before you power on the SLS system see Starting the SLS rear of SLS system). or open the N2 generator air supply System (only) on valve, verify that the room O2 alarm 2 Turn on SLS system page 191. The SLS monitor is ON and that the O2 alarm UI monitor. The system connects to 208 cable is properly connected to the power button is at VAC, 50-60 Hz, 3-phase WYE facility power. SLS system gauge panel. top left rear corner of the monitor, L If the O2 alarm monitor is off (AC power light on along with the other display adjustment front is off), open the hinged panel to access buttons. the power switch, then switch power ON. For more information, see the separate Oxygen L The SLS system computer powers up when Alarm Monitor Operating Instructions that you turn on the main power disconnect. came with your system. You don’t need to turn it on separately. SLS process 192 SLS SYSTEM user’s guide starting the SLS system (only)

Run Sinter application 1 Login to Windows. ` Start the chiller 2 Start the Sinter application: from the ` Verify the SLS system compressed air Windows task bar; choose Start > Programs ` Verify the SLS system nitrogen supply > SLS System > Sinter, then... ` Verify the SLS system powder supply • The Sinter application window opens. ` Put Sinter in Manual Operations (Man Ops) mode • The RealMonitor utility starts, appearing as a RealMonitor button in the Windows ` Load the RCM taskbar. (See Sinter Help for more the ` Move the part piston to its Home position RealMonitor utility.) ` Move the roller to its Home position • After about one minute, the DSPIF ` Move the piston back to its Start position application starts, appearing as a DSPIF Instructions for each step in this sequence are button in the Windows taskbar. (Sinter uses described next. DSPIF to control SLS system heaters and motion, and to communicate with the laser If you’re starting the SLS system from scanning system.) its powered-off state, do not attempt 3 When you see the dspif button in the to start a build before you perform taskbar, the Sinter application is ready to start the SLS system machine startup a build—but the SLS system machine still is sequence. Also, never attempt to not. start a build if the dspif button is not shown in the taskbar. It takes at least 45 seconds for the dspif program to Start chiller and verify flow gauges initialize after you run Sinter. (Putting If you’re starting the SLS system from it’s Sinter in Build mode then opening a powered-off state, you must first perform the build packet starts a build.) following start-up sequence before you start a build: SLS process 193 SLS SYSTEM user’s guide starting the SLS system (only)

4 Start the Chiller. 6 Verify SLS system nitrogen supply. For chiller instructions, a Press the power see the separate Chiller L Skip Step a if you have a nitrogen dewar or (I/O) button on Installation, Operations, bulk tank connected to your SLS system the chiller front and Maintenance Guide instead of a nitrogen generator. panel. that came with your a Open the compressed air supply valve at b Check chiller system. the bottom of the N2 generator. COOLANT b Make sure the NITROGEN INLET ball valve INLET pressure gauge at the SLS system on SLS system gauge panel is open. gauge panel. Verify coolant inlet pressure c Verify that the REGULATED N2 PRESSURE of ~400 kPa (58 psi) on this gauge. gauge on gauge panel reads 140 kPa c Check COOLANT FLOW meter on gauge (20psi). panel. Verify coolant flow of 4-5 lpm. 7 Verify the SLS system powder supply. 5 Verify SLS system compressed air supply. a Open the POWDER INLET ball valve at the a Verify that facility compressed air is on and SLS system gauge panel. connected to the gauge panel AIR INLET. b Verify that the lower and upper powder b Verify the readings for low air pressure, level sensor lights on the Hopper Feed high air pressure, and (for model 230 only) Module are both on. RCM lift air pressure on the SLS system gauge panel. The air pressure gauge labels indicate their correct readings. These are: sPro 140 lowh air pressure 350 kPa (51 psi) highv air pressure 350 kPa (51 psi) sPro 230 lowh air pressure 350 kPa (51 psi) highv air pressure 500 kPa (72 psi) SLS process 194 SLS SYSTEM user’s guide starting the SLS system (only)

8 Check pressure and flow gauges. Verify the target pressure and flow settings on the SLS system gauge panel:

TARGET TARGET GAUGE PRESS. 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 SLS process 195 SLS SYSTEM user’s guide shutting down the SLS system

Shutting Down the SLS System Follow the procedures below to shut down the 5 Depressurize. Close the valves on SLS system safely and properly. The procedures compressed air lines that serve the cover three types of shutdown: SLS equipment below in this order: ` Normal shutdown a IRS ` Shutdown for service b BOS ` Emergency shutdown c SLS system Use an SLS system E-stop button to L Depressurizing stops all powder transport shut down the system only in an in and between the IRS, BOS, and SLS emergency. (See Emergency system. Shutdown on page 40.) Shutting down a machine with E-stop can result in data loss and material waste.

1 If you must shut down the SLS system See Pausing a Build during a build, pause on page 86 the build first, then terminate it. 2 If the RCM is loaded, unload the RCM using See Unloading RCM the Piston Control (Removing the Part window in Man Ops. Cake) on page 93 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. SLS process 196 SLS SYSTEM user’s guide SLS system service & maintenance

SLS System Service & Maintenance

About Service & Maintenance Laser Service and Maintenance SLS system service and maintenance WARNING! SLS system laser service procedures must only be performed and maintenance procedures must by 3D Systems-certified service only be performed by 3D Systems- technicians unless this guide certified service technicians. explicitly states otherwise. Attempts by non-3D Systems- certified personnel to perform laser If your SLS system needs service or maintenance, service or maintenance procedures contact 3D Systems’ Customer Support Hotline could result in serious injury. All SLS at: system users must observe the guidelines and warnings in the “Laser U.S.A. 800 793 3669 Safety” section of this guide. Asia-Pacific +852 2923 5077 The SLS system conforms to applicable Europe +49 (0) 6151 357-357 requirements of 21 CFR Subchapter J at date of manufacture. It is designated a Class 1 Laser ...or contact your local 3D Systems representative. Device by the Center for Devices and Radiological Health (CDRH). In normal operation, the laser beam is completely confined and the viewing windows in the process chamber block infrared radiation. 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 process 197 SLS SYSTEM user’s guide SLS system service & maintenance

Cleaning the Process Chamber The following steps are a suggested guideline for CLEAN THE LASER WINDOW cleaning the SLS equipment and preparing the 1 At the SLS system, raise the laser window process chamber for another build on the sPro door (top front of machine). Close the laser 140 or 230. window shutter by pushing the shutter handle up and to the right. AFTER THE BUILD COMPLETES 2 Loosen the two laser window retaining 1 Open Sinter then click the Man Ops toolbar thumb screws. button to enter Manual Operations mode. 3 Carefully pull the laser window straight out of 2 Click the Roller toolbar button to open the the IPM. Roller Control window 4 Clean the laser window on both sides using 3 In the Roller Control window’s Position warm water and a non abrasive liquid section, enter a New roller position between detergent. 28 inches and 30 inches (700 mm and 750 mm). 5 Rinse the laser window, then dry it thoroughly using compressed air (20-30 psi) 4 Close the Roller Control window, then click until ALL moisture is removed. the Piston Contr button to open the Piston Control window. 6 Once dry, clean both sides with Ethanol and an uncoated, lint free lens tissue. 5 In the Piston Control window’s RCM section, click the Unload button. 7 Reinstall the laser window in the IPM, tighten the retaining thumb screws, and open the 6 Open the SLS system’s RCM door and unplug laser window shutter by pulling the handle the RCM cable from the RCM. down and to the left. 7 Pull out the RCM and place the insulated RCM lid over the cylinder to keep the heat in. CLEAN THE ROLLER 1 Move the roller over the center of the part bed cavity (as described in Step 3 of After the build completes earlier). SLS process 198 SLS SYSTEM user’s guide SLS system service & maintenance

2 Carefully enter the RCM bay and wipe down 4 Reinstall both windows and tighten frame the exposed area with ethanol and a clean screws sufficient to ensure frame gasket towel or rag. compression. Wear eye protection to prevent CLEAN THE ROLLER BELT CHANNELS, IR SENSOR, AND ethanol from dripping in your BLACKBODY eyes. Vacuum the front and back roller belt tracking channels using the rubber hose attachment for CLEAN THE OVERFLOW SCREENS the vacuum. These are accessible from inside the 1 Loosen the captive thumbscrew on the [right RCM cavity and by opening the upper access or left] overflow chute access door, then open panels on the right side of the machine and the door. removing the heater panel. To remove the heater panel you must: L Overflow chute access doors are on the left and right sides of the SLS system behind 1 Unscrew the three (3) locking screws. the process chamber access doors. 2 Unplug the power wire going to the top of 2 Lift out the overflow screen and vacuum it. the panel. 3 Reinstall the overflow screen, then close and 3 Unscrew and remove the ground wire. fasten the overflow chute door. 4 Grasp the panel and lift, sliding the panel 4 Repeat for overflow screen on opposite side. toward you slightly as you lift.

CLEAN FEED HOPPER DISPENSER WINDOWS 5 While the panel is removed, clean the IR 1 Open the left process chamber access doors. sensor and black body. These can be accessed by releasing the two (2) locking 2 Remove the eight Torx screws on the two screws holding the IR panel in place and feed hopper dispenser windows. lowering the panel to it's full open position. 3 Remove the two windows; wash clean, and Swab the IR lens with Ethanol and then dry dry them thoroughly. using a clean, foam covered swab. Wipe the black body off using a clean towel or lens tissue. Replace the panel when finished. SLS process 199 SLS SYSTEM user’s guide SLS system service & maintenance

6 Replace the right side heater panel. To 6 Using lens paper and ethanol carefully clean replace, you must: optic. To do so drop ethanol on the lens paper and dragging it across the optic. 7 Align the three (3) locator tabs with their Repeat, as necessary until the lens is clean. respective slots. 7 Rotate window assembly over to clean the 8 Slide the panel forward into the slots, other side. lowering into place as you slide. 8 Once unit is clean, reinstall into machine. 9 Connect the ground wire back in place. 9 Tighten the finger screws 10 Plug the power wire back into the panel fitting. 10 Rotate the handle counterclockwise 11 Tighten the three (3) locking screws to secure the panel in place. Cleaning the IR sensor and blackbody The IR sensor should be cleaned before every Cleaning laser window build. Cleaning the sensor can be done through either method listed below. Clean the laser window before every build.

1 To remove the laser window lift the top panel METHOD 1 up. 1 Using a T20 driver, remove the two screws 2 Rotate the handle clockwise, this will trap located on the IR block. The IR block is warm air in the build chamber. located on the right side of the machine and houses the IR sensor. 3 Loosen the finger screws holding the window in place. 2 Using lens paper and ethanol carefully clean the optic of all material. 4 Grab the laser window with both hands and carefully slide unit out of system. 3 Reinstall IR blocks assembly and secure with T20 driver. 5 Place unit on flat surface with handle end up. METHOD 2 1 Unload and remove RCM. SLS process 200 SLS SYSTEM user’s guide SLS system service & maintenance

2 Entering the machine through the bottom 1 Exit Sinter, then wait for the SLS system to one can access the IR sensor window. cool down. 3 Using a lens cloth and alcohol clean lens 2 Open the (left or right) side access doors on carefully to remove all material. the SLS system enclosure. See SLS System Features on page 182 to locate the access METHOD 3 doors. 1 Using a standard screwdriver, open the right 3 Locate the hinged, sealed cleanout panel on side access panel to gain access to the IR the outer wall of the overflow chute. sensor optic. Loosen screws to open panel 2 Rotate panel out and clean the optic, using and remove/clean screen. ethanol and a lens cloth. Open Overflow hinged, chute 3 Rotate panel back into place and latch. sealed panel 4 We should probably go with Method 3, as to clean standard…this is sometimes hard to get to… screen and chute

To clean overflow chutes and screens 4 Use a flathead screwdriver to loosen the two The chutes below the overflow holes at the right captive screws on the cleanout panel. and left ends of the powder bed have screens to 5 Before you open the panel, put a garbage catch chunks of agglomerated powder and under it to catch any powder that falls out. broken part pieces. The screens prevent these chunks from clogging the SLS system’s powder 6 Lift out the screen and clean it off, then put it transporters and tubes. back in. L If you run out of powder unexpectedly, your 7 Close the panel, then press lightly as you overflow chute(s) and/or screen(s) might be retighten the two screws. (Pressing in helps clogged. seal the panel.) Periodically check and clean the overflow chutes 8 Check and clean the other overflow chute. and screens. The steps are the same for the right or left side overflow chutes. 9 Restart Sinter and continue. SLS process 201 SLS SYSTEM user’s guide SLS system service & maintenance

Cleaning roller Checking the SLS system gauge panel The roller should not need to be cleaned before Before you build, always check the gauge panel every build. If system is cold, the material will to ensure that the flow gauges read as follows: stick to the surface of the roller, however has IR WINDOW N2 FLOW (2 to 3) L/min temperatures increase material will be removed from the roller. Roller should only be cleaned if LASER WINDOW N2 FLOW (5 to 8) L/min system is cool. Time period between cleanings is COOLANT FLOW (4 to 5) L/min TBD. Cleaning of the roller should be done in the Nitrogen Generator Maintenance following manner: There are no user maintenance procedures for 1 Before removing a the RCM. the Nitrogen Generator. During scheduled preventive maintenance, your certified 2 Go to Man Ops and select the Roller button 3D Systems service representative will: on the tool bar. ✓ Replace the nitrogen generator filters as 3 Using the arrows, move the roller to the needed. These filters will typically not need center of the part bed and stop it. changing for one year 4 Unload the RCM, by going to the piston control button in Man Ops and selecting Nitrogen Generator Replacement Filters Unload. FILTERa PART NO. QTY 5 Remove the RCM from the machine. Carbon filter 100894-00 1 6 Having removed the RCM from the machine 01M BX filter 101313-00 1 you now have access to the roller. N2 membrane filter 101314-00 1 7 Using a rag and alcohol clean the roller. 1M DX filter 103886-00 2 Cleaning the RCM a. N2 filters ship in the Nitrogen Generator enclosure. Clean the RCM before preheating it. ✓ Recalibrate the Nitrogen Generator (if See Cleaning the RCM on page 128 necessary) for 98% pure nitrogen output. SLS process 202 SLS SYSTEM user’s guide SLS system troubleshooting

SLS System Troubleshooting

SLS system Stacklight states SLS System Failure Modes Your SLS System has a Stacklight, a pole with four If you are having problems with your SLS system, colored lights on it that can turn on or flash to refer to the table of SLS system failure modes indicate the states of the machine: below. To prevent injury and equipment COLOR MODE SLS SYSTEM STATUS damage, do not attempt to perform Off Normal any corrective action labeled Red Steady An alarm is active. 3D CSE Only in the table below. Any correction labeled 3D CSE Only Off Normal in the table below must only be Steady A warning is active Yellow performed by a 3D Systems Customer Safety override during Support Engineer (3D CSE) or Flashing service by a Field Engineer. Authorized Service Representative. SLS system is powered off or Off not ready. Green Normal. SLS system is okay; Steady operating normally Blue not used

L The red and yellow lights will both be See Using the lit if a warning and Stacklight in Sinter alarm are active at Help for Stacklight the same time. testing instructions. SLS process 203 SLS SYSTEM user’s guide SLS system troubleshooting

SLS System Failure Modes

FAILURE MODE OR ERROR POSSIBLE MESSAGE CAUSE WHY DID THIS HAPPEN? CORRECTION Time to add powder Part bed too hot Black body is drifting 3D CSE Only layer has been 1. RTD is bad – check exceeded against standard resistor 2. Check for electronics problem on CC board Time to add powder Part bed is too Temperatures not adjusted 1. Adjust part bed heater layer has been hot correctly offsets exceeded 2. Adjust part bed heater setpoints Time to add powder Part Bed is too Feeds too hot 1. Adjust bottom feed layer has been hot heaters so that some exceeded minor cracking occurs on the longest layers 2. Reduce duty cycle on top heaters 3. Lower the top feed heater duty cycle limit and the bottom feed setpoint. Also extend the warmup. 3D CSE Only 4. Move RTD from center of bottom heater to top heater to measure directly. SLS process 204 SLS SYSTEM user’s guide SLS system troubleshooting

SLS System Failure Modes (continued)

FAILURE MODE OR ERROR POSSIBLE MESSAGE CAUSE WHY DID THIS HAPPEN? CORRECTION Time to add powder Part bed is too IR sensor problem Contact Customer Support layer has been hot 3D CSE Only exceeded 1. Check cable connections 2. Verify IR sensor range settings Time to add powder Too much Agglomerated powder clogging Clean out overflows layer has been powder overflows exceeded Too much Agglomerated powder got past Contact Customer Support powder the overflow screen and is clogging the transport line. Short Feed Clean exhaust filter Feed roller gap Chunks in feed hopper are Clean out feed hopper and clogged clogging feed roller gap overflows IRS stalled/not feeding powder Replace empty IPC No powder in Proximity sensors adjusted Contact Customer Support feed hopper incorrectly 3D CSE Only Adjust proximity sensors Parts are weak Laser window is dirty Check window cleanliness Low laser power Laser power not calibrated Contact Customer Support Layer thickness Check layer thickness Laser is underpowered for too great layer thicknesses > 0.004 in Adjust layer thickness SLS process 205 SLS SYSTEM user’s guide SLS system troubleshooting

SLS System Failure Modes (continued)

FAILURE MODE OR ERROR POSSIBLE MESSAGE CAUSE WHY DID THIS HAPPEN? CORRECTION X,Y,Z – following Tuning has Laser scanning mirror servos are Contact Customer Support error drifted very sensitive to many factors Fatal DSP Error Bad connection Powder gets in connectors Clean connectors with ethanol and air. Inert lost Ran out of IRS stalled Contact Customer Support powder due to IRS ran out of powder Determine why IRS ran out IRS failure of powder and fix; e.g., connect full IPC Overflow pinch Worn durometer rubber Contact Customer Support valve leak 3D CSE Only Replace rubber Part bed is melting Uneven part bed Thermocouple short circuit Contact Customer Support heating tripped breaker 3D CSE Only Check breakers and thermocouples Part bed is too hot The piston is set Part bed IR sensor range not Contact Customer Support during warmup to 150 and the adjusted correctly 3D CSE Only (Setpoint=100 °C, Part bet is set to Adjust range IR sensor range Part bed=150 °C) 100 and the part to be 0-200 °C instead of bed IR is not 0-500 °C adjusted correctly SLS process 206 SLS SYSTEM user’s guide SLS system troubleshooting

SLS System Failure Modes (continued)

FAILURE MODE OR ERROR POSSIBLE MESSAGE CAUSE WHY DID THIS HAPPEN? CORRECTION Poor accuracy Wrong Building too close to the edge or Stay as close to the center as temperatures corners possible Wrong scale and Factory parameters are not Build scale parts offsets optimized Laser/scanner Laser scanner out of calibration Contact Customer Support problem Top part surface is Laser scanner Chiller not on Turn on Chiller. If that does rough problem solve problem, Contact Customer Support 3D CSE Only Make sure Chiller sensor is installed and working Roller is noisy, leaves Problem with Contact Customer Support chatter marks across stepper driver the part bed software Can NOT do offline Need new Contact Customer Support calibration; improved blackbody never blackbody reaches high end of heater 2-point calibration SLS process 207 SLS SYSTEM user’s guide SLS system troubleshooting

SLS System Failure Modes (continued)

FAILURE MODE OR ERROR POSSIBLE MESSAGE CAUSE WHY DID THIS HAPPEN? CORRECTION DSP fatal error 24 V drop when Noise coupled during contactor Contact Customer Support entering/exiting transitions 3D CSE Only Manual Ops or Clean DSP card contactors starting a build. Sometimes happens during a build. Do not have ability A dependency Software bug Check all interlocks, to start the inert has not been especially the laser lid process but no met. message Parts curling when Long layer times Use higher part bed setpoint scan time is long (1 (scanning) cause and extend warmup min) right heater duty cycle to go to 0 SLS process user’s guide

BOS 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 ` BOS Operating States...... 224 ` BOS Overview...... 211 ` Using the BOS Main Menu ...... 229 ` BOS Operator Controls and Indicators . 212 ` Using the BOS Setup Menu ...... 230 ` BOS Components ...... 215 ` Using the BOS Diagnostics Menu ...... 233 ` BOS Safety ...... 218 ` Using the BOS Work Platform ...... 239 ` BOS Power-Up Sequence ...... 220 ` Shutting Down the BOS ...... 240 ` BOS Start-up ...... 221 ` BOS Maintenance ...... 241 ` Breakout Station mode operations. . . . . 222 ` BOS Troubleshooting...... 242 SLS process 209 BOS user’s guide BOS features

BOS Features ➊ ➋ ➒ ➌

➑ ➍

➎

➐ ➏

➊ BOS Door ➍ Operator panel ➋ Air Curtain ➎ Emergency Stop button ➌ Powder Transport Hopper ➏ RCM bay Rotating auger in hopper can crush ➑ RCM raise/lower switch and cut. Do not operate with hopper ➐ Sifter grate removed. Follow lockout ➑ Waste bag procedure before removing grate for cleaning. SLS process 210 BOS user’s guide BOS overview

BOS Overview When a build is complete, you need to remove the sintered parts from the RCM part cake 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 recycled back to the IRS, or disposed of. L You can find material-specific information about breaking out and cleaning parts in your Material Guide. SLS process 211 BOS user’s guide BOS operator controls and indicators

BOS Operator Controls and Indicators Use the BOS operator controls and indicators BOS Operator Panel described in this section to run the BOS and Most BOS controls are located on the BOS determine its operating status. operator panel shown below.

POWDER TRANSPORT switch Selects: • RECYCLE (transport to IRS Used bin) •OFF • DISPOSAL (transport to waste) LCD display E-stop button

Main >About Setup Diagnostics

WORK LIGHT Cancel/Exit button on/off switch Enter/OK button POWER on/off switch Scroll buttons for choosing options The operator panel displays the most recent the status changes again. If there are multiple status. Occasionally the status will overshadow a warning or error messages, you can view each in warning or error message. You can view the turn by pressing . hidden message by pressing to hide the undesired status message. It will reappear when SLS process 212 BOS user’s guide BOS operator controls and indicators

BOS Stacklight The colored lights on the BOS stacklight and COLOR MODE BOS STATUS operator panel display messages indicate the BOS status. Off Normal BOS is transferring used Blue Steady COLOR MODE BOS STATUS powder to the IRS Used bin. Off Normal Flashing BOS is blending.

Red Stop/error fault; BOS trying Steady to re-establish lost network Powder Transport switch connection to IRS. The rotary POWDER TRANSPORT switch on the Off Normal BOS operator panel selects the BOS powder transport mode: BOS has a warning condition as displayed on RECYCLE – sends used powder to the IRS Steady the LCD. It will continue to Used bin when the BOS is in the Waiting for Yellow service IRS requests for used IRS state and the IRS requests powder. powder in this condition. OFF – Turns off all powder transfer Safety override during Flashing operations. service by a Field Engineer. Off BOS powered off DISPOSAL – sends used powder to the waste drum when the BOS is in the Disposing Normal. BOS in Standby Powder state. mode with network connection to IRS Steady established. BOS is ready to Part piston jog switch Green use and waiting for a Used Use the part piston jog switch on the left inside powder transfer request wall of the breakout chamber to: from the IRS. ` Raise the part cake during breakout BOS initializing (not ready – Flashing starting up) ` Home (lower) the part piston after breakout (optional/recommended) SLS process 213 BOS user’s guide BOS operator controls and indicators

Before you can move the part piston: After breakout, before you remove the RCM from the BOS, use the part piston jog switch to home ✓ The BOS must be powered on. the part piston; i.e., lower it to its lowest position. ✓ The RCM must be properly docked in the Lowering the part piston has the following BOS. benefits: ✓ The BOS’s RCM cable must be plugged into ` Makes it easier to clean the RCM before the the RCM. next build. ✓ The BOS’s RCM seal must be down. ` Reduces delay at the start of a build because Push up you don’t have to wait very long for the part and hold Raise part piston piston to home before you can move it to the jog Start position. switch to Stop raise the piston; Lower part piston pull down Part piston jog switch inside breakout and hold chamber. to lower the piston. The piston moves gradually 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. SLS process 214 BOS user’s guide bos components

BOS Components

BOS Door A motorized auger is at the bottom of the The BOS door helps keep dust in the breakout powder transport hopper. When the sifter is chamber from escaping into the room. Its rim seal empty, the BOS transfers powder from the helps the Dust Collector draw dust out of the hopper to the sifter by turning on the auger chamber efficiently. motor (along with the sifter motor). You can perform breakout with the BOS door The powder transport hopper has a level sensor closed, minimizing your exposure to dust. A mounted on its right side wall. When the hopper viewing window at eye level runs the full length is full, the light on the level sensor is on. To check of the door so you can see inside the chamber the level sensor light, remove the right side with the door closed. A rubber pleated air curtain access panel on the BOS and look on the hopper also runs the length of the door so you can reach wall near the back. in and work on your parts without opening the door. RCM bay The BOS door lifts open. Air props that help you Enter RCM Bay functional description. lift the door up and help hold it in the open position. Sifter Enter sifter and sifter transporter functional Powder Transport Hopper descriptions. 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. SLS process 215 BOS user’s guide bos components

Work Platform (for BOS Pro 230) Enter BOS work platform functional description. Before breakout, after you dock and lock an RCM in the BOS, place the work platform directly in The BOS work platform makes breakout easier. front of the BOS. To move the platform, lift the Standing on the 23-cm (9-in) high platform puts right side until the wheels on the left side touch everything on the BOS table within comfortable the floor, then roll it like a hand truck. reach reduces arm and back fatigue. The platform is designed to support one person weighing 113 kg (250 lb) max.

BOS Pro 230 Work Platform

The work platform provides a non- slip surface, however, care must be taken to prevent slipping, tripping, and falling. SLS process 216 BOS user’s guide bos components

Dust Collector The Donaldson-Torit VS-1200 3-phase Dust The flexible vacuum duct arm enables you to Collector removes airborne dust from the BOS remove glass media from SLS parts after you work chamber via a fixed duct hose. clean them in the optional Bead Blaster.

Dust Collector top view AIR Do not restrict clean air outlet

BOS top view

Dust Collector side view Fixed vacuum duct hose

The Donaldson-Torit® VS-1200 3-phase Dust Collector SLS process 217 BOS user’s guide BOS safety

BOS Safety When you use any SLS equipment, follow all Using the BOS work platform general safety guidelines in Safety on page 9. Center the work platform directly in front of the When you use the BOS, follow the guidelines in BOS and between the end panels this section as well. They are specific to the BOS. The BOS main door is designed for easy and Lifting and lowering the BOS RCM seal comfortable access to the breakout area. In order to accommodate some users, a work platform The RCM seal in the BOS is a sheet metal/ rubber may be acquired for easier access to the work seal assembly that seals the RCM cylinder during area. This platform is 228.9 mm (9 in.) high and part breakout. This seal is normally stored in its can accommodate a maximum 114 kg (250 lb). upward clip position out of the way of the RCM person. The installation of the platform does not entry point. It may not always be in this position. require any tools and is not physically connected In order to push the RCM into the BOS for part to the BOS. Two wheels are provided to roll one breakout, the BOS door should be lifted out of end of the platform across a floor. The hand-hold the way to see if the seal is in the clip near the is at the opposite end from the wheels. Hands are work light lens. If not, lift the seal until it clips into easily placed on the end support for lifting. As its stored position. The RCM may now be docked. with all lifting, proper lifting techniques must be used. Care must be taken for safety as in the use Be careful when handling RCM seal. If of any work platform. A non-slip surface is

Be the seal drops from its clip it can provided, but care must be taken to prevent injure your fingers or hands. Also, do slipping, tripping, and falling. not to place your hands on the entry side of the RCM when docking. A shear hazard exists for hands and fingers during docking. SLS process 218 BOS user’s guide BOS safety

BOS RCM safety The rapid change module (RCM) is usually a hot module. Care must be taken to honor the warning labels that exist on the module. Although it is recommended to completely cool the powder and parts in the RCM, they 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 inside the lower frame perimeter during RCM piston lifting operation—injury may result. SLS process 219 BOS user’s guide BOS power-up sequence

BOS Power-Up Sequence Before you turn on the BOS, make sure RCM cable is NOT connected to the RCM.

1 Turn the BOS POWDER See BOS Operator TRANSPORT Controls and Indicators switch to OFF. on page 211 to locate switches. 2 Turn the BOS POWER switch on. The BOS displays Initializing, then Establishing network 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. SLS process 220 BOS user’s guide BOS start-up

BOS Start-up After you power up the BOS as described above, start-up the BOS as follows: 1 Turn the BOS POWDER TRANSPORT switch to: • RECYCLE if you want to send powder in the BOS hopper to the IRS Used bin, or, • DISPOSAL if you want to send powder in the BOS hopper 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 for powder. • In DISPOSAL mode, the BOS enters the Disposing Powder state and sends powder to the waste drum until the sifter stays empty for 2 minutes. SLS process 221 BOS user’s guide breakout station mode operations

Breakout Station mode operations The BOS must be in “Breakout Station” mode 4 Transporter plug-valve closes before it can transfer powder to the sifter, then 5 Transport air turns on, does pressure check recycle or dispose of it. (solids control air is modulated to keep If the BOS is In Standby, make sure the powder transport pressure below its maximum limit). transport switch to on Recycle or Disposal, then Transport air remains on until low-pressure press . This does the following: setpoint is reached; transport air and solids control air turn off. If the sifter is empty (i.e., the level sensor at the top of the sifter is off), the sifter motor 6 Transporter plug-valve opens. runs until sifter is full; i.e., until the level sensor switches on—or for 2 minutes— Transport Sequence Complete whichever occurs first. When transport sequence is complete, the BOS If hopper is empty (i.e., the level sensor on checks the sifter level sensor: the hopper is off), air flows to the left air-slide ` If sifter level sensor is on (i.e. powder is until the hopper is full. When hopper is full present), the transport sequence runs again. (i.e, the level sensor switches on) air flow to ` If sifter level sensor is off, sifter motor starts the left air-slide stops. and runs for 2 minutes or until sifter level sensor switches on—whichever occurs first. Transport sequence begins Then transport sequence runs again. When sifter is full, the sifter motor shuts off and ` If the sifter level sensor stays off after sifter transport sequence begins. (The transport motor runs for two minutes, the BOS enters sequence takes about 2 minutes): the In Standby state and remains there until 1 Sifter air-slide air flow turns on. you press . 2 The transporter fills until its level sensor switches on. 3 Sifter air-slide air flow turns off SLS process 222 BOS user’s guide breakout station mode operations

BOS Operation Tips ` The sifter level sensor can be seen from the RCM bay. (See image below.) ` The hopper level sensor can be seen from the right rear side of BOS, with right side access panel removed. (See image at right.)

BOS hopper level sensor viewed from right side of BOS

` 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 BOS sifter level sensor viewed air-slide air flow is off In Standby mode, and from front of RCM bay. 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. SLS process 223 BOS user’s guide BOS operating states

BOS Operating States When the BOS is on, the display indicates the Powder Xfer Off state it’s currently in. Each operating state is described below. Powder Xfer Off In Standby

Powder Xfer Off state display In Standby If the you press when the POWDER TRANSPORT switch is OFF, the BOS enters the In Standby state display Powder Xfer Off state. If you turn the POWDER TRANSPORT switch to RECYCLE or DISPOSAL, After a network connection is established, the the BOS switches to the In Standby state. BOS enters the standby state and displays In Standby. It remains in standby until you press Xfer to Sifter , which switches the BOS to the Xfer to Sifter state. Xfer to Sifter

Xfer to Sifter state display 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 full (i.e., the level sensor switches on). If the sifter doesn’t fill in 2 minutes or less, the BOS returns to the In Standby state. SLS process 224 BOS user’s guide BOS operating states

If the sifter does fill in less than 2 minutes, the If the POWDER TRANSPORT switch is OFF, the BOS enters either the Waiting for IRS state (if the BOS remains in the In Standby state. POWDER TRANSPORT switch is set to RECYCLE), or, the Disposing Powder state (if the POWDER TRANSPORT switch is set to DISPOSAL). Xfer to Sifter state change summary

THE BOS STATE CHANGES FROM TO WHEN... AND THE SIFTER... In Standby Xfer to Sifter Is empty (sifter motor off) (sifter motor on) You press Xfer to Sifter In Standby Stays empty > 2 minutes You do nothing (sifter motor on) (sifter motor off) with sifter motor on. Xfer to Sifter Waiting for IRS POWDER TRANSPORT (sifter motor on) (sifter motor off) switch set to RECYCLE Xfer to Sifter Disposing Powder POWDER TRANSPORT Is full (sifter motor on) (sifter motor off) switch set to DISPOSAL (has powder to send) Xfer to Sifter In Standby POWDER TRANSPORT (sifter motor on) (sifter motor off) switch set to OFF SLS process 225 BOS user’s guide BOS operating states

Waiting for IRS ✓ Sifter is full (sifter level sensor on; there’s powder to send) Waiting for IRS ✓ POWDER TRANSPORT switch is set to RECYCLE ✓ BOS receives a powder request from the IRS Waiting for IRS state display The BOS remains in the Recycling Powder state The BOS enters the Waiting for IRS state from the while there’s powder to send. After the sifter stays Xfer to Sifter state when the: empty for more than 2 minutes, the BOS changes to the Stopping state, then the In Standby state. ✓ Sifter is full (sifter level sensor on; there’s powder to send) Disposing Powder ✓ POWDER TRANSPORT switch is set to RECYCLE It stays in this state and waits for the IRS to send a Disposing Powder request for powder. When the BOS receives a request, it enters the Recycling Powder state and sends the load of powder to the IRS. Disposing Powder state display

Recycling Powder The BOS enters the Disposing Powder state from the Xfer to Sifter state when the: ✓ Sifter is full (sifter level sensor on; there’s Recycling Powder powder to send) ✓ POWDER TRANSPORT switch is set to DISPOSAL Recycling Powder state display The BOS enters the Recycling Powder state from the Waiting for IRS state when the: SLS process 226 BOS user’s guide BOS operating states

The BOS remains in the Disposing Powder state BOS in EStop 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. BOS in EStop

Stopping BOS in EStop state display

Stopping 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 Stopping state display this state until the unsafe condition is removed and either the emergency stop button is reset or The BOS enters the Stopping state when: the safety interlock is enabled. ✓ The sifter stays empty for more than 2 After that, the BOS automatically returns to the In minutes while the BOS is any powder transfer Standby state. state, such as Recycling Powder or Disposing Never try to disable or override any Powder. BOS safety interlock. Operating the ✓ The sifter does not fill up in less than 2 BOS without all safety interlocks minutes after you press to perform a enabled can cause equipment manual powder transfer (from the hopper to damage, injury, or death. If you the sifter). suspect a safety interlock is not L Pressing turns on the auger and sifter working properly, do not operate the motors at the bottom of the hopper. When the BOS. Rather, disconnect power from BOS enters the Stopping state, it stops both the BOS and contact 3D Systems these motors. Customer Support Hotline for assistance. After the Stopping state, the BOS returns to In Standby. SLS process 227 BOS user’s guide BOS operating states

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

Recycling Error display

The BOS displays Recycling Error if it detected an error when transferring powder to the IRS. After you press to acknowledge the error, the BOS reverts to In Standby state.

Dispose Error

Dispose Error

Recycling Error display

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. SLS process 228 BOS user’s guide using the BOS main menu

Using the BOS Main Menu Use the BOS main menu to view the BOS software Press to return to the Main menu. version and to access BOS Setup or Diagnostics menus. To access BOS Setup or Diagnostics menus From the Main menu, choose Setup or To select Main menu options Diagnostics, then press . From In Standby mode, press twice. The BOS Setup menu The Main menu appears. or Diagnostics menu See Using the BOS appears. Setup Menu on Main page 229 and Using the >About BOS Diagnostics Menu Setup on page 232. Diagnostics Main menu display

Press to choose an option, then press .

To view BOS software version From the Main menu, choose About, then press . The BOS software version number and date appears.

FW Ver: R13.03 MAC:0000000002 Build: 2005-10-18 About menu display SLS process 229 BOS user’s guide using the BOS setup menu

Using the BOS Setup Menu From the BOS Main To access the Process Params menu menu, use the BOS See Using the BOS Main Menu on page 228 to Use the Process Params menu to view and Setup menu to access change the BOS RCM Com Mode and RCM Type the Process Params access the BOS Main menu process parameters. and Eng Params menus. From the Setup menu, choose Process Params, then press . Use these menus to view and change BOS process parameters or engineering parameters. The Process Params menu appears. BOS engineering parameters on the Process Params Eng Params menu should only be >RCM Com Mode changed by 3D Systems certified RCM Type service personnel.

Process Params menu display To select Setup menu options From the BOS Main menu, select Setup. Press to choose the process parameter you The Setup menu appears. want to set, then press .

Setup >Process Params Eng Params

Setup menu display

Press to choose an option, then press . SLS process 230 BOS user’s guide using the BOS setup menu

SET RCM COM MODE SET RCM TYPE Use the RCM Com Mode process parameter to set Use the RCM Type process parameter to specify the BOS/RCM communications mode to LVDS or which type of RCM is connected to the BOS; an SPI. RCM-140 or a (taller) RCM-230. 1 From the Process Params menu, choose RCM 1 From the Process Params menu, choose RCM Com Mode, then press . Type, then press . The currently selected RCM communications The currently selected RCM Type appears; mode appears; LVDS or SPI. 140 or 230.

RCM Com Mode RCM Type LVDS 140

RCM Com Mode display RCM Type display

2 Use to change the type to 140 or 230. 2 Use to change the mode to LVDS or Be sure to match the type of RCM actually SPI. connected to the BOS. 3 Press to save the mode setting, or press 3 Press to save the RCM Type setting, or to keep the setting as-is and return to the press to keep the setting as-is and return Process Params menu. to the Process Params menu. SLS process 231 BOS user’s guide using the BOS setup menu

To access the Eng Params menu SET MAXTIME PARAMETERS Use the Eng Params menu to view and change Use the MaxTime[operation_name] engineering the BOS MaxTimeTransLoad, parameters to set the timeouts for various BOS MaxTimeStopLVFlow, and MaxTimeConveying powder transfer operations. engineering parameters. 1 From the Eng Params menu, choose a BOS engineering parameters should MaxTime[operation_name] parameter, then only be changed by 3D Systems press . certified service personnel. The current value of the MaxTime[operation_name] parameter From the Setup menu, choose Eng Params, then appears; for example, 1000 for press . MaxTimeStopLVFlow. The Eng Params menu appears. MaxTimeStopLVFlow Eng Params >MaxTimeTransLoad 1000 MaxTimeStopLVFlow MaxTimeConveying MaxTimeStopLVFlowdisplay Eng Params menu display 2 Use to increase or decrease the L If you see an Access Denied display at this MaxTime[operation_name] timeout setting. point, you are not authorized to change BOS Insert note or caution. what engineering parameters. Press to return to the Setup menu and contact 3D Systems happens if set the Customer Support for assistance. MaxTime[operation_name] wrong? Press to choose the engineering parameter you want to set, then press . 3 Press to save the timeout setting, or press to keep the setting as-is and return to the Process Params menu. SLS process 232 BOS user’s guide using the BOS diagnostics menu

Using the BOS Diagnostics Menu From the BOS Main To select Diagnostic menu options See Using the BOS Main menu, use the BOS From the BOS Main menu, select Diagnostics. Diagnostics menu to Menu on page 228 to access the Input Status access the BOS Main The Diagnostics menu appears. menu. and Force Output menus. Diagnostics >Input Status Use these menus to if you need to test BOS Force Output operations or diagnose BOS problems. They enable you to manually change the status of BOS inputs and outputs; for example, from the Diagnostics menu display Diagnostics menu, you can manually test: Press to choose an option, then press . ` RCM part piston up/down motion ` Air and powder transport valves To access the Input Status menu ` Stacklight lights Use the Input Status menu to view and change the status of BOS inputs. Valve outputs on the Force Output menu should only be changed by From the Diagnostics menu, choose Input Status, 3D Systems certified service then press . The Input Status menu appears. personnel. Input Status >Move RCM Up Move RCM Down RCM Present Input Status menu display

Press to choose the input you want to view or change, then press . SLS process 233 BOS user’s guide using the BOS diagnostics menu

The inputs on the Input Status menu perform the BOS operations below.

BOS INPUT STATUS OPERATION Raises part piston while RCM Present input is ON, the RCM Power Relay ON Move RCM Up output is ON, and RCM is connected to BOS OFF Stops part piston from moving up Lowers part piston while RCM Present input is ON, the RCM Power Relay ON Move RCM Down output is ON, and RCM is connected to BOS OFF Stops part piston from moving down Enables part piston up or down motion while the RCM Power Relay output ON is ON and an RCM is connected to BOS RCM Present Disables part piston up or down motion while the RCM Power Relay output OFF is ON and an RCM is connected to BOS

L Before you can The Move RCM Up/Down inputs work like the change the See view or change RCM Part piston jog switch. Changing their status to status of the Power Relay and ON is like moving the jog switch to its RAISE or Move RCM Up/ Stacklight Outputs on LOWER position. Changing their status to OFF is page 236 for Down input, the like moving the jog switch to its STOP (middle) instructions on how to RCM Present position. input must be turn the RCM Power ON, the RCM Relay output on or off. When the part piston reaches its upper or lower Power Relay limit, the Move RCM Up/Down input status output must be ON, and an RCM must be changes to OFF automatically to prolong the life connected to the BOS. of the piston motor. SLS process 234 BOS user’s guide using the BOS diagnostics menu

VIEW OR CHANGE INPUT STATUS If you saved Move RCM Up or Move RCM Choose an input on the Input Status menu to Down input in the ON state, the piston will view or change. move to its upper or lower limit until you change the status back to OFF before it L You must connect the RCM to the BOS before reaches you can change the status of any BOS’s RCM inputs. To access the Force Output menu 1 From the Input Status menu, choose Move RCM Up, Move RCM Down, or RCM Present, Use the Force Output menu to view and change then press . the status of BOS outputs. The status of the selected input appears; OFF From the Diagnostics menu, choose Force or ON. Output, then press . The Force Output menu appears.

Move RCM Down Force Output OFF >Valves General Outputs Move RCM Down display Force Output menu display 2 Use to change the input status to OFF or ON. L If you see an Access Denied display at this point, you are not authorized to change BOS Keep hands and loose clothing outputs. Press to return to the Setup menu clear of RCM before part piston and contact 3D Systems Customer Support for motion is enabled. assistance.

3 Press to save the status, or press to Press to choose the output you want to keep the status as-is and return to the Input view or change, then press . Status menu. SLS process 235 BOS user’s guide using the BOS diagnostics menu

VIEW OR CHANGE VALVE OUTPUTS The outputs on the Valves submenu (under the Use the Valves menu to view the status of valve Force Output menu) perform the BOS operations outputs, or to manually switch valve outputs off below. or on.

BOS OUTPUT STATUS OPERATION ON Opens the BOS’s air cylinder valve Air Cyl Valve OFF Closes the BOS’s air cylinder valve Same as moving the operator panel rotary switch to RECYCLE ON Opens the BOS’s horizontal IRS pinch valve on the used powder transport line between BOS and IRS; IRS Pch Valve Horz Same as moving the operator panel powder transport switch to OFF OFF Closes the BOS’s horizontal IRS pinch valve on the used powder transport line between BOS and IRS Same as moving the operator panel rotary switch to DISPOSAL ON Opens the BOS’s vertical dispose pinch valve on the used powder transport line between BOS and waste powder drum. Dispose Pch Valv V Same as moving the rotary switch to OFF OFF Closes the BOS’s vertical Dispose pinch valve on the used powder transport line between BOS and waste powder drum.

To view or change valve outputs on the Valves 2 From the Valves menu, select an valve menu: output; for example Air Cyl Valve, then press . 1 From the Force Output menu, select Valves, then press . The Valves menu appears. SLS process 236 BOS user’s guide using the BOS diagnostics menu

3 Use to switch the Air Cyl Valve ON or VIEW OR CHANGE RCM POWER RELAY AND OFF, then, press . STACKLIGHT OUTPUTS Use the General Outputs menu to view the status of the RCM Power Relay and Stacklight lamp Air Cyl Valve outputs, or to manually switch the RCM Power OFF Relay or individual Stacklight lamps off or on. The outputs on the General Outputs submenu Air Cyl Valve display (under the Force Output menu) perform the BOS operations below. 4 Press to save the status, or press to keep the status as-is and return to the Valves menu.

BOS OUTPUT STATUS OPERATION Switches on (closes) the RCM power relay, supplying power to the part piston ON motor on the RCM connected to the BOS RCM Power Relay Switches off (opens) the RCM power relay, removing power from the part OFF piston motor on the RCM connected to the BOS ON Switches on the Color Stacklight lamp where Color is Red, Yellow, Green, Lamp Color OFF Switches off the Color Stacklight lamp or Blue SLS process 237 BOS user’s guide using the BOS diagnostics menu

To view or change valve outputs on the General If you saved a Lamp output in the ON Outputs menu: state, the corresponding color Stacklight lamp will remain lit until you change the 1 From the Force Output menu, select General output status back to OFF. Outputs, then press . The General Outputs menu appears. If you saved the RCM Power Relay output in the ON state, the you will be able to move the General Outputs part piston subject to the state of the BOS’s >RCM Power Relay RCM inputs. If you saved this output in the Lamp Green OFF state, you will not be able to raise or Lamp Yellow lower the part piston.

Valves menu display

2 From the General Outputs menu, select an output option; for example Lamp Green, then press .

Lamp Green OFF

Lamp Green display

3 Use to switch the Lamp Green output ON or OFF, then, press . 4 Press to save the status, or press to keep the status as-is and return to the General Outputs menu. SLS process 238 BOS user’s guide using the BOS work platform

Using the BOS Work Platform

BOS Pro 230 Work Platform

Use the BOS work platform to make breakout The platform is designed to support one person easier. Standing on the 23-cm (9-in) high weighing 113 kg (250 lb) max. platform puts everything on the BOS table within The work platform provides a non- comfortable reach reduces arm and back fatigue. slip surface, however, care must be Before breakout, after you dock and lock an RCM taken to prevent slipping, tripping, in the BOS, place the work platform directly in and falling. 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. SLS process 239 BOS user’s guide shutting down the BOS

Shutting Down the BOS Shutting down the BOS stops the following To shut down the BOS properly operations: 1 If the BOS is currently transferring powder to ` Used powder transport to the IRS Used bin (in the IRS, wait until the BOS operator panel RECYCLE mode) says Powder Xfer Complete. ` Used powder transport to the waste drum in 2 Press repeatedly until the BOS operator (in DISPOSAL mode) panel displays In Standby. ` Part piston motion (if and RCM is connected 3 Turn off the POWER switch on the IRS and the part piston is being raised or operator panel. lowered) See IRS Operator Panel and Stacklight on ` Sifting page 152. ` 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. SLS process 240 BOS user’s guide BOS maintenance

BOS Maintenance

Cleaning the BOS powder transfer hopper 3 After servicing the machine, replace the grate Moving parts can crush and cut. Do and make sure the grate is flush with the not operate with hopper grate table top. Tighten the two captive screws removed. Follow lockout procedure until completely engaged. Look into the before removing grate for cleaning. hopper to be sure no tools or any foreign objects other than powder are left inside. Before you attempt to clean the powder transfer Disengage the e-stop by rotating the button hopper, remove the hopper grate following the top until it releases. Plug the BOS power instructions below. cable back into the power source. Continue operation. 1 Before removing the powder transport hopper grate, press the BOS E-stop button to deactivate the BOS auger, machine power Replacing the sifter waste bag cable removed from its source. The trash bags inside the front lower door need to be replaced, maybe often, depending on the 2 In the course of BOS operation, the auger usage. The HEPA filter, 103230-00, on the may get jammed or an object may fall into auxiliary/disposal drum will need to be changed the powder transport hopper. The first action when needed. No other maintenance is required. should be to push the E-stop button. next, Just clean-up as needed. the power cable needs to be removed from its source. Acquire a flat bladed screw driver and remove the two captive screws holding the grate to the hopper/table surface. Remove the grate and set aside. Do not operate the machine while the grate is removed. SLS process 241 BOS user’s guide BOS troubleshooting

BOS Troubleshooting

BOS error messages

MESSAGE DESCRIPTION ACTION Input out of Bounds Value entered is outside valid Enter value that is within range. range. For example, the Percent Virgin must be greater or equal to 30% and less than or equal to 100%. 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 SLS process user’s guide

CONTACTING 3D SYSTEMS If you have questions about your SLS equipment, auxiliary machines, or DuraForm materials— or to request service—please contact 3D Systems at the appropriate number or address below.

Sales and Service

3D SYSTEMS CORPORATION 333 Three D Systems Circle FRANCE ITALY Rock Hill, SC 29730 USA tel +33 1 69 35 17 17 tel +39 39 68 904 00 tel 803.326.4080 fax 803.324.4311 GERMANY JAPAN email [email protected] tel +49 6151 357 0 tel +81 3 5451 1690 web www.3dsystems.com HONG KONG UK NASDAQ TDSC tel +852 2923 5077 tel +44 1442 28260 Customer Support Hotline About 3D Systems Toll free in U.S.A. 800.889.2964 Founded in 1986, 3D Systems provides solid imaging products and solutions that help reduce Outside U.S.A. 803.326.4080 the time and cost of designing products and Asia-Pacific + 852 2923 5077 facilitate direct and indirect manufacturing. Its systems utilize patented technologies that create Europe + 49 6151 357 0 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. SLS process user’s guide

LEGAL NOTICES Copyright and Corporate Identity © 2006 by 3D Systems, Inc. All rights reserved. Licensed User also undertakes to notify Subject to change without notice. This document 3D Systems promptly in the event that it is copyrighted and contains proprietary considers any of the data contained in this information that is the property of 3D Systems, document to be incomplete or erroneous in any Inc. The licensed user, in the name of whom this respect, in connection with Licensed User's document is registered (the “Licensed User”) particular use or generally. does not have the right to copy, reproduce, or translate this document in any way or to any FCC Notice media without the prior written consent of This equipment has been tested and found to 3D Systems, Inc. No copies of the document may comply with the limits for a class A digital device, be sold or given to any person or other entity. pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection Improvements against harmful interference when the 3D Systems may (but shall not be obligated to) equipment is operated in a commercial make improvements to this document from time environment. This equipment generates, uses, to time. However, the Licensed User and can radiate radio frequency energy and, if acknowledges that at any time after the not installed and used in accordance with the expiration of the date of issuance, 3D Systems instruction manual, may cause harmful may institute a periodic charge or fee payable by interference to radio communications. Operation the Licensed User in return for ongoing receipt of of this equipment in a residential area is likely to improvements. It is the responsibility of the cause harmful interference in which case the user Licensed User to provide 3D Systems with current will be required to correct the interference at his information as to its name and address. The own expense. SLS process 244 LEGAL NOTICES user’s guide limitations of warranty and liability

Changes or modifications not expressly approved IN NO EVENT WILL 3D SYSTEMS BE by 3D Systems could void your authority to RESPONSIBLE FOR DAMAGES OF ANY operate this equipment. NATURE, INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES, RESULTING Limitations of Warranty FROM THE USE OF OR RELIANCE UPON THIS and Liability INFORMATION. THE CUSTOMER ASSUMES ALL This information is provided by 3D Systems RISK RESULTING FROM THE USE OF THIS for the convenience of its customers. It is INFORMATION. Customers use of the materials believed to be reliable, but NO that follow is an acknowledgment of its REPRESENTATIONS, GUARANTEES OR agreement to the foregoing. Any customer not WARRANTIES OF ANY KIND ARE MADE AS TO ITS wishing to be bound should return this material ACCURACY, FITNESS FOR A PARTICULAR USE OR to 3D Systems. Nothing contained herein is to be THE RESULTS TO BE OBTAINED THEREFROM. The considered as permission, recommendation, nor information is based in whole or in large part on as an inducement to practice any patented laboratory work and does not necessarily invention without permission of the patent indicate performance in all conditions. owner. Notwithstanding any information provided by 3D Systems or its affiliates, the customer remains Trademarks and fully responsible for determining which federal, Registered Trademarks state or local laws or regulations, or industry 3D Systems, the 3D logo, Sinterstation, sPro, SLS, practices are relevant to activities in which it and DuraForm are registered trademarks of engages, as well as assuring that those laws, 3D Systems, Inc. Other trademarks are the regulations or standards are complied with under property of their respective owners. actual operating conditions, and 3D Systems undertakes no responsibility in these areas. SLS process user’s guide

A B GLOSSARY C D E A advisory A type of Sinter See also message, F AC box Electrical AC power cabinet on the lower application message (color code yellow). You warning, alarm, G left side of the SLS® system MSM. The AC box and the Message contains facility electrical power terminals, must acknowledge an H advisory. It can turn into List Window topic wiring, circuit breakers, and fuses. The in Sinter Help. I SLS® system’ s main power switch is on the an alarm if the cause it is J not corrected. AC box door. K Add Powder Layer sequence The steps an airslide Air-assisted gravity powder conveying L SLS® system performs to add one layer of chute on the BOS. The BOS has two airslides; M one conveys powder from the work table to powder to the part bed. Depending on your N the auger, the other conveys powder from build geometry and your current build stage, O a layer might or might not be scanned. For the sifter to the recycled powder transporter. example, at the start of a build, several A permeable membrane separates the P unscanned layers are added as a thermal airslide’s upper and lower channels. Q barrier for the parts in a part cake. During an Pressurized air in the lower channel R “fluidizes” powder in the upper channel, Add Powder Layer sequence, the SLS® system S enabling it to flow down the chute at much does the following: spreads a powder wave T and heats it to feed temperature; feeds shallower angle that it would without air powder to a new layer, heats powder on the assist. U part bed to process temperature, and then V holds the part bed temperature constant W while the layer is scanned. X Y Z SLS process 246 GLOSSARY user’s guide B

alarm A type of Sinter B See also message, A application message batch One unit of blended warning, advisory, (color code red). You See also partial B and the Message virgin powder and used must acknowledge an powder stored in the IRS batch C alarm when the alarm List Window topic in Sinter Help. Blender bin. A batch has D dialog box that pops up a specific Percent Virgin and weight (e.g., 5 kg then correct the cause. E for DuraForm PA). The IRS blends one batch F An alarm shuts down your current operation, at a time. motion, heating, and scanning in the G SLS® system. beam See laser beam. H APMU (Application Powder beam delivery system All the optical I Management Unit) See also Powder components of the SLS® system, including J Database management Management the laser, mirrors, lenses, galvanometers, and K System. application that logs power modulators. L powder transfer data it beam shaft The channel at the top of the M receives from the IRS. APMU resides on a process chamber, below the laser window PowderNet client SLS® system computer and N and above the part bed heaters, through helps ensure powder supply integrity in the O which the laser beam travels. The beam shaft SLS process. is centered over the part bed. P auger Screw mechanism at the bottom of the Q beam width The smallest diameter of the powder transport hopper under the middle R focused laser beam; ideally located in the grate on the BOS work table. The auger S part bed image plane. grinds part cake powder to be recycled T before it dropping it into the BOS sifter. U V W X Y Z SLS process 247 GLOSSARY user’s guide B

blackbody A temperature reference device BOS Breakout Station. The machine used for mounted on a hinged panel beside the breakout in the SLS process. The BOS can be A infrared sensor on the right wall of the set to recycle or dispose of used powder after B process chamber in sPro SLS® systems. breakout. When set to RECYCLE, the BOS sifts C The IR sensor measures the blackbody used powder, then sends it to the Used bin D temperature during IR sensor calibration. on the IRS. When set to DISPOSAL, the BOS sends used powder to the waste powder E container. F blackbody heater The device that heats the G blackbody to its reference temperature bounding box In the Build Setup application, an setpoint. imaginary box that defines the 3-dimensional H space in which the part fits. I blend n. A mix of used powder and virgin J powder in the IRS Blender bin with a specific .bpf build packet file: the file name extension for K Percent Virgin. build packet files. L v. To make a batch of powder in the IRS .bpz build packet (zipped) archive: the file name M Blender bin. extension for compressed build packet N archive files. Blender bin (On IRS top O right front corner) See also Virgin bin breakout Removing parts from the part cake, P and Used bin receives and blends typically (and most easily) done in the BOS. Q used powder (from the Breakout is the last step of the SLS process. Used bin) and virgin powder (from the Virgin R bin) in proportions specified by the Percent Breakout Station mode S Virgin. It stores the powder blend until the The BOS mode in which T See also Standby SLS® system requests a refill. air flow is on and powder transfers are mode U enabled. (Similar to V Ready mode mode in IRS.) W X Y Z SLS process 248 GLOSSARY user’s guide B

build 1. The three stage of part fabrication on an build packet archive A SLS® system. The three stage are (in order) compressed (Exported See also import A Warmup stage, Build stage, and .bpz) file containing a (build packet) and B Cooldown stage. 2. One or more parts set up build packet and its Export (build packet) C to be built in the same part cylinder. associated files. A build D packet archive can also Build mode A state of the contain the sorted facet file and attached E See also Main Sinter application in notes for a build packet. You must import a F which options to start mode and Manual Operations mode build packet archive before you can use the G and stop a build are build packet it contains in a build. available. H build parameter A I build packet A file property of a build with See also part J containing 3-D part See also Import parameter (build packet) and a default profile you can K build geometry data, change in Build Setup. build parameter values, Export (build L and part parameter packet) build preparation Things you do to prepare a M values. The data in a set of 3-D CAD parts for a build on an N build packet is required to build a set of parts SLS® system. During build preparation you O mainly use the Build Setup build preparation on an SLS® system. You must set up a build P packet in Build Setup before you can run a application. Build preparation is the first step build. To run a build, run Sinter on an of the SLS process. Q SLS® system, click the Build button to enter R Build mode, then click the Start Build button build profile The table of See also part S to select a build packet (.bpf) file. build parameters vs. Zheight in a build profile; T packet. Each build stage U has a separate profile. Together, they V comprise the build profile. W X Y Z SLS process 249 GLOSSARY user’s guide C

Build Setup The 3D Systems application that C A creates build files you can run on an CC box Chamber Controller electrical/ SLS® system using the Sinter application. electronics cabinet on the upper left side of B Build Setup is installed when you install your the SLS® system MSM. The CC box controls C LS software. (You can optionally install it on a motion, sensors, and atmosphere in the PCM. D separate computer, create a build packet, then transfer the .bpz file to the SLS® system certified service personnel E computer for building.) Anyone who has F completed the See also operator. G Build stage The second of 3D Systems’ field service See also H three SLS® system build training and is certified to perform corrective Warmup stage I stages. Defines the service tasks on the SLS® system. build profile for the and J Cooldown stage layers during an actual Chiller cools, filters, and recirculates coolant in K build. the SLS® system IPM. L Build Viewer When running a build in Sinter, CO2 laser The power M displays a top view of the layer that source for the SLS. The See also laser N SLS® system is currently scanning. For more beam is invisible and O can cause serious burns. information, see “Viewing a Build While In P Progress” in your Sinter Help. cooldown The ramp-down of part cake Q build volume The maximum X-Y-Z space a build temperature after a build. The rampdown can R be controlled or uncontrolled. In a controlled can occupy inside the part cylinder. The build S volume is slightly less than the part cake cooldown, the RCM heaters remain under volume. This prevents the laser beam from active control for a specific time, or until the T contacting the part cylinder walls and leaves part cake reaches a final temperature. In an U room for unsintered layers at the top and uncontrolled cooldown, all RCM heaters are V bottom of the part cake. Unsintered layers off and the part cake cools by convection. W form a base for parts in a build and thermally You can do a controlled cooldown in the X insulate the top and bottom of the part cake. SLS® system. Y Z SLS process 250 GLOSSARY user’s guide D

Cooldown stage The third D See also A of three SLS® system damper The hinged metal plate below the laser build stages. The build Build stage and B Warmup stage window at the top of the process chamber profile for the beam shaft. When closed, it blocks the laser C unscanned layers added beam from entering the process chamber, D after the last scanned Build stage layer. and helps keep powder out of the IPM. E configuration file See material configuration file. Always close the damper lever on F contactor An electro-mechanical power relay. the front of the IPM before you G The SLS® system machine contains several remove the laser window for H contactors. cleaning—and before you open I any door or panel on the Cross Fill Scan An advanced part profile SLS® system. Open the damper J parameter that alternates the scanning before you start a build. K direction between X and Y every layer. You L must purchase a Sinterscan license to use this default Response or M parameter. conditions used by a See also Default N computer unless the Values and curl an SLS part defect; part warping due to user commands it to use Dependencies O uneven heating or cooling. There are two something else. topic in Sinter P Help types of curl: “in-build curl” and “post-build Q curl.” In-build curl happens when the hot dependency In the R laser beam hits a cold (or insufficiently SLS® system, a condition See also Default preheated) part bed. Post-build curl happens that must be met before Values and S when different regions of a part cool down at a command can be Dependencies T different rates. Controlled cooldown helps executed. topic in Sinter U Help prevent post-build curl. V curling See part curling. W cylinder See part cylinder. X Y Z SLS process 251 GLOSSARY user’s guide E

dialog box A subordinate window that opens in E A the LS software. It either presents E-stop button (EMERGENCY STOP button) Any information or asks you to provide one of several large red buttons mounted on B information. the SLS® system. Pressing any E-stop button C dspif digital signal processor interface: the shuts down the SLS® system immediately. For D software and hardware Sinter uses to control safety, all energized components are de- E SLS® system heaters and motion, and to energized when E-stop is pressed. F communicate with the laser scanning system. Export (build packet) A G After you start Sinter, you must wait about 45 Build Setup File menu See also import H seconds for dspif to initialize before you (build packet command that I attempt to start a build. compresses a build archive) J duty cycle For SLS® system heaters, the percent packet (.bpf) file and its K (from 0% to 100%) of maximum available associated files into a single build packet heating power currently being applied. Duty archive (.bpz) file. You can optionally include L cycle varies to maintain a heater setpoint or the build packet’s sorted facet file in the .bpz M temperature parameter profile. file, and any notes attached to the build N packet during build setup. DuraForm (DuraForm® powder material.) Brand O P name for our family of specially formulated F powder materials for building SLS parts in Q SLS® systems. facets Triangular areas in an STL model that represent the exterior and interior surfaces of R Dust Collector Auxiliary machine with a vacuum a part. Three vertices and a normal define a S air duct and removable filter used in the facet. Facets are sorted in Z-axis order in a T SLS process. The Dust Collector connects to sorted facet (.sff) file. U the BOS and removes airborne powder from V the area above the BOS work table. W X Y Z SLS process 252 GLOSSARY user’s guide G

powder heaters The two G See also part bed A pairs of top and bottom galvanometer A small motor that moves one of heaters heaters on the left and the two (X- and Y-axis) scanning mirrors that B right sides of the deflect the laser beam. The motorized C process chamber. Feed heaters warm the scanning mirrors are often referred to as D powder wave before the roller spreads it “galvos.” across the part bed. E galvo See galvanometer. F feed hopper Powder storage dispenser G mounted on the left side of the SLS® system gauge panel Cluster of gauges, hose fittings, process chamber. The feed hopper receives and valves at the right rear of the sPro SLS® H blended powder from the IRS Blender bin system for controlling I and SLS® system overflow modules (OFMs). the supply of nitrogen, compressed air, J During a build, at the start of each Add powder, and coolant. K Powder Layer sequence, the feed hopper’s growth See part growth. L powder dispenser dispenses powder on top M of the roller in precise amounts. When the feed hopper is low, it signals the IRS to send H N more blended powder. heaters See powder heaters, part bed heaters, and O part cake heaters. P feed roller The roller inside the powder dispenser at the bottom of the feed hopper. HFM Hopper Feed Module. See feed hopper and Q powder dispenser. R fill Overlapping parallel S vectors that make up See also outline home limit The lowest part the horizontal surface of piston position—or See also homing T a slice in a part build. leftmost roller U position—from which other part piston and V Fill Scan Spacing (also laser scan spacing) On roller limit positions are measured. the part bed, the distance between adjacent W scan lines. X Y Z SLS process 253 GLOSSARY user’s guide I

homing Moving the part piston or roller to its inerting Lowering the oxygen level and raising home limit to reestablish the SLS® system’s the nitrogen level in the process chamber. A ability to track the device’s position. You must Inerting occurs in the Warmup stage of a B home the part piston or roller before you can build. Before the build can advance to the C command the SLS® system to move either Build stage, the process chamber must be D device. The part piston and roller must be re- inert. While inerting, the SLS® system delivers homed (a) if the RCM is unloaded for any maximum nitrogen flow (“purge flow”) to the E reason, and (b), if the dspif process is closed. process chamber until the oxygen F (Exiting the Sinter application does not close concentration inside reaches the inert G the dspif process.) setpoint. H interlock A device that makes or breaks a circuit, I I depending on the condition it should satisfy. J import (build packet In the SLS® system, interlocks serve as safety K archive) Extracting a See also Export devices. Unless interlocks are in place, certain L build packet (.bpf) file, (build packet) operations cannot run. M its associated files, and any attached notes, from a build packet infrared sensor See IR sensor. N archive (.bpz) file. To import a build packet IPC Intelligent Powder Cartridge. A factory- O archive, open a .bpz file, either through Build refillable powder container that supplies up P Setup’s File > Open command or the Build to 100 kg of virgin powder to the IRS. The IPC Q Packet Browser. is a sealed canvas bag fastened to rugged R inert Atmospheric state plastic pallet. The pallet has three nozzles for S inside the process See also inerting connecting the powder and compressed air lines in the IRS umbilical. When the IRS’s T chamber during a build U characterized by low oxygen and high Virgin bin gets low, the IRS draws virgin nitrogen concentrations. The SLS® system powder from the slightly pressurized IPC V keeps the atmosphere in the process through the IRS umbilical. W chamber inert (5.5% oxygen or less, X depending on the material) to prevent Y powder oxidation and combustion. Z SLS process 254 GLOSSARY user’s guide L

IPM Image Projection Module. Contains the IRS umbilical Flexible 5-meter harness of laser, laser focusing and scanning optics, and powder tubing, compressed air lines, and A removable laser window. The IPM is mounted electrical cables from the IRS that connects to B on top of the SLS® system, above the process the IPC when the IRS unloads virgin powder C chamber. from the IPC. D IR calibration Iteratively measuring of the IRS Ready mode IRS “run” E blackbody (reference) temperature with the state in which powder See also IRS F Standby mode IR sensor, then adjusting the IR sensor output transfers occur. In IRS G to match the reference temperature. IR Ready mode, the IRS calibration can be done automatically every n can unload an IPC, blend powder, send H layers during a build, or manually using the powder to SLS® system(s), and receive I IR CAL button in Man Ops. If you change the powder from a BOS. J type of material in the SLS® system, you must K perform a manual (“offline”) IR calibration IRS Standby mode IRS See also IRS Ready L using the IR CAL button in Man Ops before “idle” state in which no mode M starting your first build with the new powder transfers occur. material. IRS Standby mode is N mainly for IRS setup, diagnostics, utilities, and O IR sensor A noncontact part bed temperature IPC swapping. P measuring device mounted on a hinged Q panel beside the blackbody on the right wall L of the process chamber. The IR sensor detects R the emissivity of infrared energy at the part laser An electronic device that converts S bed and maps it to part bed temperature electrical energy into a narrowly-focused intense beam of visible or infrared light. In T based on the most recent IR sensor U calibration. the SLS® system, laser refers to a 30- or 70- watt Chiller. V IRS Integrated Recycling Station. Mixes new laser beam The focused laser light that sinters W virgin powder from the IPC with used powder X (from a part cake) and transports it to the the powder in the SLS® system. SLS® system feed hopper on demand. Y Z SLS process 255 GLOSSARY user’s guide M

laser scan spacing (also Fill Scan Spacing) On LS software Laser Sintering software. the part bed, the distance between adjacent Applications (including Build Setup and A scan lines. Sinter), utilities, and data files you install on B the SLS® system computer. You use the laser scan speed The speed at which the laser C LS software to setup and build sets of 3-D D travels in a scan line across the part bed. Scan parts on 3D Systems’ SLS equipment. Some speed is measured in inches per second or LS software features and utilities are licensed. E millimeters per second. F LVDS Low-Voltage G laser spot size See beam width. Differential-Signaling. See also SPI H laser window The removable crystalline window One of two BOS/RCM I above the process chamber through which communications modes set using the BOS the laser beam is directed onto the part bed. RCM Com Mode process parameter. J K layer A single layer of powder that may contain a L slice of one or several parts. M Main mode The initial state for the Sinter M leveling See powder leveling. application software. From Main mode, you N log files As you use the can switch to Build mode or Manual O Operations mode, or start Build Setup. SLS® system it See also Using Log P Files in Sinter automatically creates manual operations Q files in the \dtm\logs SLS® system actions you R folder. These files record events that occur See Manual perform in Sinter that S while the Sinter application is operating. Each are not part of a build, Operations in time you access the Sinter, it records such as lowering the Sinter Help for T information in these files, continually adding part piston and moving instructions. U new information as the application runs. the roller. V LPC Lower Process Chamber; see process chamber. W X LPM Liters Per Minute; the unit of coolant and nitrogen flow in the SLS® system. Y Z SLS process 256 GLOSSARY user’s guide N

Manual Operations mode message A brief color- The Sinter application coded text notification See Messages and A software state in which See also Build that appears in the the Message List B Window in Sinter you can perform mode and Main Sinter application’s C manual operations. mode Message List window. Help for more information. D Messages keep you Man Ops See Manual Operations mode. informed about E material The powder used in the SLS process. SLS® system activity. New messages always F appear at the top of the list. The message G material configuration file colors are black-information; yellow-advisory H In the LS software, a file or warning; red-alarm. I that specifies the See the DuraForm defaults and ranges for Material Guide for mode An operating state of the Sinter J the build parameters for more information application software. Sinter has three modes: K a particular material. Main mode, Build mode, and Manual L Operations mode. The available commands M material safety data sheets Published differ in each mode. information that provides details about N safety, usage, and handling for different MSDS See material safety data sheets. O materials. MSM Machine Services Module. The enclosed P MD chassis Mirror Driver electronics enclosure rear portion of the SLS® system that houses Q at the top of the SLS® system MSM. The MD the LS software, application computer, and R box controls laser power and image scanning gauge panel. S devices in the SLS® system IPM. T N U Nominal Hazard Zone (NHZ) An area (such as a V room) with limited access in which potentially hazardous maintenance W procedures can be performed.Nominal X Hazard Zone Y Z SLS process 257 GLOSSARY user’s guide O

Nitrogen Generator Provides a continuous outline The process of supply of nitrogen to the SLS® system by sintering the perimeter See also fill A removing the oxygen from ambient of a part before or after B compressed air input. sintering the fill of the part on each layer of C powder. Outlining increases accuracy in the D part's surface finish; but takes more time. O E OFM (right and left) Overflow Module. Powder overflow chutes (right and left) Catch-bins with F overflow chutes with powder transporters hinged cleanout doors on the right and left G below the right and left sides of the process side of the process chamber. Overflow chutes chamber. The OFM overflow chutes catch catch powder the part bed does not deposit H powder not deposited on the part bed on the part bed during an Add Powder Layer I during an Add Powder Layer sequence. The sequence. Screens in both overflow chutes J OFM powder transporters below the chutes catch chunks of powder before they enter the K pump powder back up into the feed hopper. OFM powder transporters. L Screens in both OFM overflow chutes catch M chunks of powder before they enter the oxygen alarm See Room Oxygen Monitor N powder transporters. oxygen monitor See Room Oxygen Monitor O open beam operations When the laser is in an oxygen sensor Detects the percentage of P unhoused condition, which occurs only oxygen inside the process chamber. during service procedures. Q R operator A person trained by 3D Systems to S operate the SLS® system and all other SLS equipment, and to perform all tasks T associated with build preparation, building U parts, and breakout. Also called a user. V W X Y Z SLS process 258 GLOSSARY user’s guide P

P partial batch A proportionally smaller batch of A parameter 1. (SLS system) virgin powder and used powder with the A property of a part or See Parameters in same Percent Virgin as a full batch. For B example, if a full batch is 60% virgin, the an entire build with a Build Setup Help. C default value you can partial batch is also 60% virgin. The IRS only D blends a partial batch when there is change. You change part and build E parameter values in Build Setup using profile insufficient (virgin or used) powder for a full F editors. 2. (IRS, BOS) A machine or process batch. It makes the largest partial batch setting with a default value you can change possible, using all the limiting amount of G through menus on the operator panel powder. H display. part cake The block of hot, loose, used powder I part The output of the SLS process; a solid object and parts in the part cylinder after a build. J described by an STL file made of sintered SLS After the part cake cools, parts are removed K powdered material in an SLS® system. from it in breakout. The BOS can be set to L recycle or dispose of used powder from the M part bed The area on part cake after breakout. The RCM-140 part process chamber floor, See also part bed cake measures (550 x 550 x 460) mm. The N bounded by the edges heaters taller RCM-230 part cake measures O of the part cylinder, that (550 x 550 x 750) mm. P contains both the powder being sintered and Q the sintered part(s). part cylinder heaters The band heaters wrapped around the part cylinder that heat R part bed heaters The four heaters mounted the sides of the part cake. S above the part bed. These heaters raise the T temperature of the part bed to just below the U powder’s melting point before the laser scans part cross-section(s) on the layer. V W X Y Z SLS process 259 GLOSSARY user’s guide P

part cylinder The rectangular steel vessel part piston Heated mounted in the RCM that holds the part cake. platform that supports See also homing A The part cake sits on top of the part piston the part cake and B During a build, the part cake is lowered into moves up and down inside the part cylinder C the part cylinder by one layer thickness after during builds and breakout. D each Add Powder Layer sequence. After a build, the part cake cools in the part cylinder. part piston heater The heater under the part E During breakout, the part cake is removed piston top plate that heats the bottom of the F from the part cylinder as the BOS raises the part cake. G part piston. part profile A table of part H parameter values vs. See also build I part curling A part deformity caused when the profile powder becomes too cool during a build. The Zheight for a part in a J build packet. The part part bows and is not perfectly flat. If curling K profile editor in Build Setup lets you save becomes a problem, consult your DuraForm L Material Guide for ways to resolve it. part slice In a part build, a single sintered layer M of powder; a horizontal cross-section of a part growth An defect that occurs when the N part. powder bed is too hot. Unsintered powder O may start to adhere to the sintered layers and pause build Temporarily P cause the part to exceed its designed See also terminate stopping a build to Q dimensions. change profiles or to build terminate a build. The R part parameter A part S scanning property with See also build system maintains the inert state, the heaters a default profile you can parameter; scale stay on, and you can resume the build. Only T change in Build Setup’s parameter the scanning and roller motion stop. U Part Profile Editor. PCM Process Chamber Module. See process V chamber. W X Y Z SLS process 260 GLOSSARY user’s guide P

Percent Virgin (IRS process parameter) The Powder Management System specified proportion of virgin powder in a (PMS) network and A batch (or partial batch) in percent. database application See also B that enables powder PowderNet and C PMS Powder Management System. See Powder transfers between SLS APMU. Management System. D equipment, logs data E powder bed The powder spread across the about every transfer, and helps prevent bottom of the process chamber by the roller. contamination of the SLS® system powder F supply. G powder dispenser H Mechanism at the PowderNet 3D Systems’ bottom of the See also powder proprietary network See also APMU I SLS® system’s feed feed amount that interconnects SLS and Powder J hopper. The powder equipment and carries Management K System. dispenser rotates to dispense a quantity of powder transfer L messages and data. powder on top of the roller at the start of M each Add Powder Layer sequence. PowderNet uses the IRS as its server, or hub. All powder transfer N powder feed amount The messages go through the IRS to client BOS O quantity of powder See also feed and SLS system(s). The IRS sends powder P dispensed on top of the hopper transfer data over PowderNet to the APMU Q roller at the start of the database in an SLS process for logging. Add Powder Layer sequence. Specifically, the R number of revolutions (0 to 500) the powder powder transporter An air-driven powder S dispenser makes when dispensing powder. pump in the IRS, BOS, or SLS® system at the T head end of a powder transport tube. powder leveling The process by which the roller U transports and levels powder from the feed powder transport hopper Chute below the V hopper across the powder bed. middle grate on the BOS work table for W depositing part cake powder to be recycled. X The auger is at the bottom of this hopper. Y Z SLS process 261 GLOSSARY user’s guide R

powder transport tube Flexible pipe through profile The set of values which powder flows between SLS assigned to a parameter See Using the A equipment. based on Zheight or X, Profile Editors and B How Parameters Y, Z location. A build C prime cycle Adds a layer of powder to the part packet contains profiles Work in Build Setup Help. Also D bed without dropping the part piston. This for part parameters, see part profile, allows you to compensate for powder short build parameters, and E feeds. build profile, and F scale parameters. scale profile. process chamber The stainless steel chamber Profiles can be saved to G inside an SLS® system where part builds disk for reuse in H occur. The SLS® system performs the Add multiple builds. I Powder Layer sequence inside the process purge See inerting. J chamber. The process chamber contains the K powder heaters, part bed heaters, roller, blackbody, IR sensor, powder bed, part bed, R L and the damper. Before a build, the RCM Rapid Change Module. Heavy-duty M SLS® system raises the RCM up and seals it wheeled cart with heated part piston and N against the square part bed hole in the floor part cylinder that holds the part cake. With O multiple RCMs, you can remove a part cake of the process chamber. During a build, the P atmosphere inside the process chamber is from an SLS® system, then immediately load inert and warmed by the heaters. The IPM an empty RCM. The RCM connects to the Q delivers the laser beam through the laser BOS for breakout. The RCM is currently R window, then down to the part bed. available in two models/sizes: RCM-140 with S a (550 x 550 x 460) mm part cylinder, and the T taller RCM-230 with a (550 x 550 x 750) mm U part cylinder. V W X Y Z SLS process 262 GLOSSARY user’s guide S

RCM Com Mode (Service use only.) BOS process roller The device in the process chamber that parameter that defines how the BOS spreads and levels powder across the powder A communicates with the RCM; in LVDT mode bed and part bed. In each Add Powder Layer B or SPI mode. sequence, the powder dispenser dispenses C powder on top of the roller cover. The roller D RCM Type BOS process parameter that defines moves under a scraper, which scrapes what type of RCM is connected to the BOS; powder off the cover and deposits it between E RCM model 140 or 230. the powder heaters. It then spreads the F Ready mode The IRS mode heated powder across the part bed. G See also Standby in which air flow is on Room Oxygen Monitor Detects the H and powder transfers percentage of oxygen in the SLS process I are enabled. (Similar to Breakout Station room. If the room oxygen concentration J mode in BOS.) drops to an unsafe level, the Room Oxygen K resizing In SLS, changing Monitor sounds and alarm and shuts down L the SLS® system and the nitrogen supply to it. the desired final part See also scaling M dimensions. N RFID tag (Radio Frequency IDentification tag) S O scale profile A set of scale Small wireless data storage device in the IPC P parameters that vary See also profile that is continually read and written to by a Q magnetic reader in the IRS umbilical based on the X, Y, and Z bulkhead connector. The IPC RFID tag location of parts. R S contains encrypted Powder Management scale parameter A part System data such as IPC serial number, scaling property with a See also part T expiration date, IRS machine ID, current IPC default value you can parameter; build U weight, etc. change in Build Setup’s parameter V Scale and Offset editor. W X Y Z SLS process 263 GLOSSARY user’s guide S

scaling In SLS, adjusting for scanning mirrors Mirrors, moved by the part shrinkage during a See also resizing; galvanometers, that direct the CO2 laser A build. (Scaling does not scale parameter beam during selective laser sintering (SLS). B change the desired final C part dimensions.) scrapers Blades that clean the powder from the roller as it travels across the part bed. D scan line The path where the laser sinters a line E selective laser sintering See SLS. of powder across the part bed. F scanner The components in the IPM that work setpoint A value for a particular parameter G together to deflect the laser beam onto the established by a configuration file or by the H user and which the SLS® system attempts to target. I achieve. For example, a feed heater setpoint scanner correction table A table of values the is the temperature that the system attempts J scanner uses to compensate for laser beam to achieve for the feed heater. The actual K targeting error. The scanner correction table temperature may fluctuate around the L enables the scanner to accurately target the setpoint value as the SLS® system attempts to M laser beam anywhere on the part bed. Each stabilize the temperature at the setpoint. N SLS® system has a unique scanner correction table. Sinter 3D Systems’ licensed O application software See also P LS software scanner parameters The parameters that that creates a set of 3-D Q control the laser beam. parts starting with a build packet file created in 3D Systems’ Build R scanner timeout The length of time the Setup application. S LS software gives the scanner to complete T one scan of a part layer. sintering Physical process in which particulates form a solid mass through the application of U scanning The process by which the laser beam is external energy. V deflected onto the part plane in order to W sinter a part. sinter See sintering. X Y Z SLS process 264 GLOSSARY user’s guide S

Sinterscan 3D Systems-licensed software SLS Selective Laser Sintering: A thermodynamic feature that enables you use the Cross Fill process in which directed laser energy heats A Scan advanced part profile parameter. particulates in a defined pattern, fusing them B into a solid mass. SLS is one of several sPro The SLS® system machine C 3D Systems’ rapid manufacturing and D that builds parts in 3D Systems’ SLS prototyping technologies. SLS is and integral process. sPro 140 has a maximum part cake part of 3D Systems’ SLS process that creates E volume of 140 liters; solid parts from 3-D CAD files. It makes parts F (550 x 550 x 460) mm. sPro 230 has a by rolling a thin layer of powdered material G maximum part cake volume of across a part bed, heating the part bed to just H 230 liters; (550 x 550 x 750) mm. below melting, then scanning a cross-section I of the parts with a high-power (up to slice See part slice. J 100-watt) infrared laser. The scanned cross- slicing Software process in Build Setup that section “sinters” (partially melts, then K generates part cross-section data for one or solidifies), adhering to the scanned cross- L more parts in a build. section on the layer below it. Unscanned M areas remain loose, solid powder. After a layer SLS® system Selective Laser Sintering system. N is scanned, the part bed drops one layer Machine for building parts using 3D Systems’ O thickness and the cycle repeats until the part SLS technology. The two latest SLS® system build is complete. At the end of the build, the P models are the sPro 140 and sPro 230. loose powder is removed from the layered Q part cake. R S T U V W X Y Z SLS process 265 GLOSSARY user’s guide S

SLS process (SLS™ process) 3D System’s process stage One of three for creating 3-D models and end-use parts separate, consecutive See also A from powdered materials starting with a 3-D states of a build. Each Warmup stage, B CAD file. The SLS process proceeds in three stage has a separate Build stage, and Cooldown stage C steps: build preparation, build, and breakout. build profile. D The following 3D Systems SLS equipment play major roles in the SLS process: IRS, IPC, Standby mode The mode E (in both the IRS and See also Ready F RCM, SLS® system, Nitrogen Generator, and mode and BOS. Auxiliary machines include: Chiller, BOS) in which air flow is G shut off and powder Breakout Station Room Oxygen Monitor, Dust Collector, Bead mode H Blaster, and Non-ignition Vacuum Cleaner. transfers are disabled. All other functions, such I sort To arrange facets in an as setup and diagnostics, are available in J STL file in ascending Z See also sorted Standby. K order. facet file STL file A file produced by a CAD system. The L sorted facet file A file that contains the facets in SLS® system computer uses this file to M the STL file sorted in ascending Z order. The generate a build. It is composed of triangles N software creates the sorted facet file when connected at vertices that represent exterior O and interior surfaces. It can be either ASCII or you verify parts in the Build Setup P application. You can display sorted facet files binary. Users can read ASCII files, but in in Build Setup. A build requires a sorted facet general, binary files provide better space Q file. conservation and system performance. R S SPI Serial Peripheral Stop See E-stop button Interface. One of two See also LVDS T BOS/RCM stray vectors A build defect where U communications modes set using the BOS unintentional scan lines distort the part V shape. RCM Com Mode process parameter. W SYSTEM SECURE light When this green UI X console light is on, all SLS® system safety Y interlocks are satisfied. Z SLS process 266 GLOSSARY user’s guide T

SYSTEM ENABLE light When this green UI Used bin (On IRS top left console light is on, you can load an RCM, then rear corner) receives See also Virgin bin A use the heaters, laser, part piston, and roller. used powder from the and Blender bin B The SYSTEM ENABLE light turns on BOS when the BOS is in C automatically after you run Sinter and the RECYCLE mode, and stores it for blending D dspif program initializes. with virgin powder. The IRS transfers used powder from the Used bin to the Blender bin E F T one batch at a time. The Percent Virgin process parameter determines how much G terminate build To stop a used powder is withdrawn from the Used bin See also pause H build in progress. each batch. Terminating a build build I turns off the heaters used powder Powder that has been through a J and does not maintain an inert state. build. Used powder is recycled or disposed of K Depending on the material and the elapsed after a build. Used powder surrounds parts in L time, you can restart a terminated build. the part cake. During breakout, the BOS sifts M used powder, then (in RECYCLE mode), N U sends it to the IRS’s Used bin, or (in DISPOSAL mode) sends it to the waste O UI User Interface. The adjustable console powder drum. Used powder cannot be P mounted on the front of the SLS® system. The recycled indefinitely. See your DuraForm UI includes the computer display, keyboard, Q Material Guide for material-specific recycling R and trackball, as well as the SYSTEM ENABLE instructions. light, SYSTEM SECURE light, E-stop button, S LASER ON light, CHAMBER LIGHT button, user See operator. T two USB (Universal Serial Bus) ports, and U service access keyswitch. V UPC Upper Process Chamber - part bed heaters W and IR sensor w/blackbody; O2 sensor X Y Z SLS process 267 GLOSSARY user’s guide V

V warning A type of Sinter application message A Virgin bin (On IRS top right (color code yellow). You must acknowledge a rear corner) receives See also Used bin warning. An warning can turn into an alarm if B virgin powder when the and Blender bin the condition that caused it is not corrected. C IRS unloads an IPC, and For more information, see the Messages and D stores it for blending with used powder. The the Message List Window topic in Sinter Help. See also message, advisory, and alarm. E IRS transfers virgin powder from the Virgin F bin to the Blender bin one batch at a time. The Percent Virgin process parameter X G determines how much virgin powder is X-axis The left-right fill scanning direction on the H withdrawn from the Virgin bin each batch. SLS® system part bed. I virgin powder New powder that has never been J used in a build. Virgin powder is shipped and Y K stored in an IPC. The IRS unloads virgin Y-axis The front-to-back fill scanning direction L powder from the IPC and stores it in the on the SLS® system part bed. M Virgin bin until it is ready to blend it with N used powder in Blender bin. Z O P W Zheight The part piston position during a build. The values of profiled part parameter and Q Warmup stage The first of build parameter change at specified Z See also R three build stages. The heights. The Z heights in part profiles can be warmup stage defines Build stage and S Cooldown stage part-relative or build-relative. The Z heights the first portion of the in build profiles are relative to stage heights. T build profile which U applies to unscanned layers added before the V Build stage. W X Y Z SLS process user’s guide

A B INDEX C D E service & maintenance SYMBOLS F ✓ button (operator panel) 6 laser 196 G X button (operator panel) 6 SLS system 196 3D Systems SLS equipment 49 H about 242 SLS system 184 I Customer Support this User’s Guide 2, 3 J contacting (Hotline) 242 About menu option view software version for K returning facility checklist to 51 L Sales and Service 242 BOS 228 IRS 156 M N A adding SLS process capacity 53 O about air valves, BOS, manually testing 232 P 3D Systems 242 Air Cyl Valve, on BOS Diagnostics menu 236 BOS 210 APMU 52 Q hazard warnings 5 R installation and facility requirements 51 B S IRS & IPC 134 T laser safety and classifications 20 bin Message List window (in Sinter Blender 65, 70, 71, 135, 139, 141 U application) 77 status 159 V part cake cooldown 91 capacity W Powder Management System 52 safety Blender 136 X 9 Used powder 136 Virgin powder 136 Y Z SLS process 269 INDEX user’s guide B

overflows (SLS system) 182 RCM Com Mode 230 Used powder 64, 95, 100, 135, 139, 140 RCM Type 230 A status 159 safety 217 B Virgin powder 66, 67, 135, 137, 139, 140 Setup menu 229 C status 159 accessing 228, 229 D Blender 65, 70, 71, 135, 139, 141 shutdown 100, 239 bin capacity 136 software version, display 228 E status 159 stacklight lamp test 237 F blending powder 166 stacklight states 212 G BOS troubleshooting 241 H about 221 Valves menu 235, 237 I Breakout Station mode 221 work platform 238 J Diagnostics menu 232 breakout accessing 228, 232 fininshing parts after 99 K open/close valves manually 235 overview 91 L testing valves 232 parts from part cake 97 M features 209 Breakout Station. See BOS N functional overview 210 Breakout Station mode operations 221 O loading part cake for breakout 96 build Main menu 228 changing heater setpoints during 84 P accessing 228 modifying 87 Q accessing Diagnostics from 228, 232 packet, setting up 56 R accessing Setup from 228, 229 starting (in Sinter application) 72 S display 228 when finished 89 T maintenance 240 Build Profile parmeters, editing 57, 87 noise level 19 during a build 87 U operating states 223 Build Setup V operator controls and indicators 211 application (BuildSetup.exe) 3, 7, 45, 56 W powder transport 146 editing parameter profiles in 57 X POWDER TRANSPORT switch 6 how to run 56 Y power-up sequence 94 review build packet 86 Z SLS process 270 INDEX user’s guide C

setting up a build packet in 56 contacting 3D Systems standalone 56 Customer Support 242 A to run from Sinter application 7 Sales and Service 242 B Workspace (build volume) 57 curl, post-build (reducing) 49, 102 C online Help (in application) 3, 7, 45, 56, 87, Customer Support 242 D 88, 189 buttons E E-stop locations and functions 40 D F operator panel. See operator panel Diagnostics menu G H BOS 228, 232 C manual tests 232 I cable IRS 157 J See also RCM cable K ground, IPC 30, 37, 65, 66, 148, 150, 154, DISPOSAL mode, BOS 170 L 168, 177 dispose of used powder 98 M socket, for RCM cable 104, 106, 110 docking the RCM calibration, IR sensor N about 85 O disabling automatic 85 in BOS 217 P manual 85 in SLS System 69 Q checking SLS equipment 59 documentation, other 7 R Chemtrec phone numbers 36 classifications, laser (safety) 20 S cleaning T overflow chute screens, SLS system 59 U RCM 128 V SLS equipment 59 W the IR sensor, SLS system 59 the process chamber, SLS system 59 X the roller, SLS system 59 Y Z SLS process 271 INDEX user’s guide E

DuraForm exhaust, SLS system 204 handling safety 36 HEPA, on waste powder drum 240 A Material Guide 8 Nitrogen Generator 201 B Material Safety Data Sheet. See MSDS, Force Output menu option C DuraForm BOS Diagnostics menu 234 D PA powder 68 open/close valves 235 package handling safety 36 stacklight lamps on/off 237 E Dust Collector F noise level 19 G safety features 14 H I E G J editing parameters gauge panel K Build Profile 57, 87 AIR INLET (for compressed air) 63 L Part Profile 57 COOLANT FLOW meter (setting) 63, 193 M electrical safety 17 COOLANT INLET pressure gauge 63, 193 emergency shutdown diagram 182, 187 N SLS equipment 40 IR WINDOW N2 FLOW 59, 201 O Eng Params menu, BOS 231 LASER WINDOW N2 FLOW 59, 201 P environmental issues, SLS process facility 18 low and high air pressure readings 63, 193 Q E-stop nitrogen and coolant flow settings 59, 201 R button locations 40 NITROGEN INLET ball valve 63, 193 what it does... 40 on SLS system 182 S Exit button, X 6 oxygen alarm cable connection 60, 61 T powder inlet ball valve 193 U F POWDER INLET ball valve 63 V REGULATED N2 PRESSURE gauge W Facility Guide, SLS process 3 reading 63, 193 Facility Layout, SLS process 3 target pressure and flow settings 64, 194 X feed hopper, SLS system 50, 134 Y filters Z SLS process 272 INDEX user’s guide H

ground Intelligent Powder Cartridge. See IPC cable, IRS umbilical to IPC 30, 37, 65, 66, 148, A 150, 154, 168, 177 IPC B electrical safety 17 connecting to IRS 163 C guidelines, safety 10 description 147 D features 137 E H ground cable 30, 37, 65, 66, 148, 150, 154, 168, 177 F hazards safety 150 G mechanical motion, locations 34 receiving inspection 36 H warning symbols 5 status 67, 169 I transporter status 159 heaters unloading 65 J setpoints, changing during a build 84 IR sensor K calibration 85 L disabling automatic calibration 85 M Help, online manual calibration 85 N for Build Setup application 3, 7, 45, 56, 87, IR WINDOW N2 FLOW, on gauge panel 59, 201 O 88, 189 IRS for Sinter application 11, 113, 189, 202 connecting an IPC 163 P homing description 139 Q part piston 76 Diagnostics menu 159 R roller 76 error messages 172 S hot surfaces and powders, safety 35 features 135 T L-valve 143 I Main menu U IEC 60825, laser safety 20 accessing 156 V Integrated Recycling Station. See IRS accessing Diagnostics from 157 W maintenance 171 X noise level 19 Y operation 144 Z SLS process 273 INDEX user’s guide J

powder manifold language, display (selecting) 78 about 143 laser A left/right 144 certification label 24 B powder transport systems 143 classifications 20 C powder transport to SLS system 188 radiation safety 20 D powder transporter 143 safety 20 power on 154 Class IV 20 E safety 14, 36, 150 service and maintenance 26, 196 F service 150 LASER WINDOW N2 FLOW, on gauge panel 59, G Setup menu 158 201 H Setup menu, accessing 157 load I shutdown 170 RCM 129 software version, display 156 in BOS for breakout 96 J stacklight states 153 in SLS system before build 75, 129 K start-up 154 used powder from BOS (into IRS) 170 L virgin powder (in IRS) from IPC 65 M J virgin powder (into IRS) from IPC 163, 167 N L-valve, powder (on IRS) 143 O LVDS, RCM COM mode. See also SPI 230 P K M Q Kanban light. See stacklight R Main menu BOS S L accessing 228 T label Diagnostics from 228, 232 U laser certification 24 Setup from 228, 229 V machine I.D. 24 display 228 W IRS labels, safety X locations 22, 23, 34 accessing 156 types 15 Diagnostics from 157 Y Z SLS process 274 INDEX user’s guide N

MSDS, DuraForm 3, 7, 13, 28 A N B Nitrogen Generator C maintenance cables and filters 201 D BOS 240 maintenance 201 E IRS 171 service 201 F laser 26, 196 nitrogen/oxygen safety 32 G RCM 128 noise level BOS 19 H SLS system 196 I Man Ops (in Sinter.exe) Dust Collector 19 loading RCM IRS 19 J manifold, powder (on IRS) 143, 144 SLS system 19 K Manual Operations. See Man Ops L Material Guide, DuraForm 8 O M Material Safety Data Sheet. See MSDS, DuraForm open beam operations 11, 112 N menus, operator panel operator panel O buttons 6 P ✓ button 6 X button 6 Q R Message List window, Sinter application 11, 113 S Mode T Standby, BOS 94, 219, 228 U modifying build in progress 87 V W X Y Z SLS process 275 INDEX user’s guide P

overflow chutes, SLS system 182 A cleaning screens 59 B modules, SLS system 188 C powder transport 188 D E P F parameters G Build Profile, editing 57, 87 Part Profile, editing 57 H part cake I cooldown 93 J load & raise in BOS 96 K part piston, homing 76 L Part Profile parmeters, editing 57 M pausing a build 86 Pist I and I1-I4, output current, RCM heater 108, N 126 O Piston Control (in Sinter.exe) 72 P platform Q BOS work 238 R platforms, SLS 56 powder S blending 166 T L-valve (on IRS) 143 U manifold (on IRS) 143, 144 V safety 28 W storage guidelines 36 transfer hopper, BOS 240 X transport Y Z SLS process 276 INDEX user’s guide R

from BOS to IRS 146 R A from IRS to SLS system 188 radiation safety, laser 20 in BOS 146 RCM B in IRS 143 build heights 49, 184 C IRS to SLS system 165 cable D overflow modules, SLS system 188 disconnect before moving 10, 112 valves, manually testing BOS 232 E on SLS system 108, 130 F transporter remote RCM heater power 105 IPC, status 159 G socket (RCM) 104 106 110 IRS 143 , , cooldown H IRS, status 159 controlled 119 I used Profile End Temp 119 disposing of 98 J Profile Length 119 recycling 98 K description 108 POWDER TRANSPORT switch, BOS 6 L docking PowderNet network 52 in BOS 34, 217 M power on in SLS system 69 N IRS 154 docking safety 10 34 O SLS System 191 , SLS system 191 door safety interlock (SLS system) 13 P features 103 Q functional overview 102 pre-build checklist 70 R handling safety 10 preheating RCM 68, 115, 129 S process parameters (BOS) T RCM Com Mode 230 RCM Type (BOS parameter) 230 U Process Params menu, BOS 229 V lid 129 profiles W build parameters, editing 57 X cooldown (on RCM) 119 Y part parameters, editing 57 Z SLS process 277 INDEX user’s guide S

loading in SLS system 69, 75, 129 S A maintenance 128 safety part piston motion test 232 electrical 17 B preheating 68, 115, 129 E-stop locations and effects 40 C process parameters (BOS) general guidelines 10 D RCM Com Mode 230 hot surfaces and powders 35 RCM Type (BOS parameter) 230 E IPC 150 F safety handling 36 about 112 IRS 14, 36, 150 G interlocks on SLS system 13 labels on SLS equipment 15 H service 104 laser 20 I specifications 105 Class IV 20 unload, from SLS system 131 J nitrogen/oxygen 32 K RCM heaters powder 28 temperatures RCM 112 L setpoints 123, 124 warning symbols 5 M targets 116 service 195 N 3D Systems O test manually 126 Authorized Service Provider 67 P recycle used powder 98 Certified Service Personnel 10 restarting a terminated build 82 contacting 242 Q roller areas 13 R homing 76 facility electrical 17 S running IRS 150 T a build 81 laser 11, 25, 26, 196 U the Sinter application 74 safety guidelines 26 V Nitrogen Generator 201 open beam operations 11 W RCM 104 X Y Z SLS process 278 INDEX user’s guide S

safety override (flashing yellow lamp) 132, after dspif initializes 62, 74 153, 202, 212 to load RCM 69 A shutdown SLS system for 195 running 47, 48, 58, 61 B SLS system 196 running Build Setup from 7 C software activation by 190 starting a build in 72 D set up build packet 56 utilities 189 setpoints, heater SLS equipment E changing during a build 84 checking 59 F Setup menu cleaning 59 G BOS 229 emergency shutdown 40 H accessing 228, 229 environmental issues 18 I IRS 158 safety J accessing 157 features 12 labels 15 K shutdown starting 60 L SLS process 3 M BOS 100, 239 adding capacity 53 N emergency 40 environmental issues 18 O SLS equipment 40 overview 45 IRS 170 SLS Process Facility Guide 7 P SLS system 195 SLS Process Facility Layout 3, 7 Q SLS system 14 R Sinter application (Sinter.exe) features 182 S about 3, 4, 189 maintenance 196 T exiting 48 noise level 19 homing part piston and roller 76 power on 191 U Manual Operations (Man Ops) 62, 72 safety 190 V to load RCM 75 service 196 W online Help (in application) 3, 8, 11, 46, 70, shutdown 195 X 113, 189, 202 software 189 Y run 62, 74 stacklight states 202 Z SLS process 279 INDEX user’s guide T

start-up 191 SLS equipment 60 troubleshooting 202 SLS system 191 A software STL file 45, 56 B activation 190 storage guidelines 36 C BOS version, display 228 support D IRS version, display 156 contacting 3D Systems 242 SLS system 189 E F T Sinter utilities 189 G Sinter.exe 189 third-party software 189 transporter, powder H third-party 189 I sorted facet file 58 IRS 143 SPI, RCM COM mode. See also LVDS 230 status, IPC 159 J stacklight status, IRS 159 K alarm indication 11, 113 transporting powder (IRS to SLS system) 165 L troubleshooting 131 BOS 237 M states N BOS 212 U O IRS 153 unload P SLS system 202 IPC 65 RCM 93, 129 Q testing lamps, BOS 232, 237 Used bin (IRS) 64, 95, 100, 135, 139, 140 R standalone Build Setup 56 capacity 136 S Standby mode, status 159 T BOS 219, 228 used powder U starting dispose of 98 loading 65, 170 V a build 72 recycling 98 W BOS 220 X IRS 154 Y Z SLS process 280 INDEX user’s guide V

V A view build in progress 83 Virgin bin (IRS) 66, 67, 135, 137, 139, 140 B capacity 136 C status 159 D virgin powder E loading 163, 167 F G W H I J K L M N O P Q R S T U V W X Y Z