english version of the german original operating...

Straumann® CARES® P series by Rapid Shape

English Version of the German Original Operating Instructions

P20 Straumann® CARES® P series

These operating instructions must be read and understood before operating the machine.

Contents

1 Safety information ........................................................................................................................... 5

1.1 Symbols .................................................................................................................................................................. 5

1.2 Safety instructions.................................................................................................................................................. 6

2 General Information ....................................................................................................................... 10

2.1 Conformity declaration ........................................................................................................................................ 10

2.2 Area of application of the operating instructions ................................................................................................ 10

2.3 Intended use ........................................................................................................................................................ 10

2.4 Duties ‐ operator (the operating company)/ person working on the machine (machine operator) ................... 11

3 Technical data ................................................................................................................................ 11

3.1 Dimensions ........................................................................................................................................................... 11

3.2 Weight .................................................................................................................................................................. 11

3.3 Prescribed ambient conditions ............................................................................................................................ 11

3.4 Interfaces ............................................................................................................................................................. 12

3.5 Calibration value .................................................................................................................................................. 12

3.6 Conversion / spare parts / repair ......................................................................................................................... 12

3.7 Delivery scope ...................................................................................................................................................... 12

3.8 Components ......................................................................................................................................................... 13 3.8.1 Front view.......................................................................................................................................................... 13

3.8.2 Rear view ........................................................................................................................................................... 14

3.8.3 Side view ........................................................................................................................................................... 15

4 Transport ........................................................................................................................................ 15

4.1 General instructions ............................................................................................................................................. 15

4.2 Transport damage ................................................................................................................................................ 15

5 Preparations ................................................................................................................................... 16

5.1 Room requirements ............................................................................................................................................. 16

5.2 Additional absolutely needed equipment ............................................................................................................ 16

5.3 Materials .............................................................................................................................................................. 17

5.4 IT requirements .................................................................................................................................................... 17 5.4.1 PC hardware ...................................................................................................................................................... 17

5.4.2 PC software ....................................................................................................................................................... 17

5.4.3 IP address .......................................................................................................................................................... 18

5.4.4 Internet access / TeamViewer port ................................................................................................................... 18

6 Getting started ............................................................................................................................... 18

6.1 Unpacking the machine ....................................................................................................................................... 20

6.2 Setting up the machine ........................................................................................................................................ 20

6.3 Connecting up the machine ................................................................................................................................. 20

6.4 Starting the machine ............................................................................................................................................ 21

6.5 Printing the first test job ...................................................................................................................................... 21

6.6 Installation and set up of software ...................................................................................................................... 22 6.6.1 Installation of netfabb ....................................................................................................................................... 22

6.6.2 netfabb settings ................................................................................................................................................ 22

6.6.3 Adding/ changing a machine in netfabb ........................................................................................................... 23

6.6.4 Adding a material in netfabb ............................................................................................................................. 24

7 Operation ....................................................................................................................................... 27

7.1 Controls overview ................................................................................................................................................ 27

7.2 Menu „Start Job“ (Process: Print components) ................................................................................................... 28 7.2.1 Loading the stl file ............................................................................................................................................. 29

7.2.2 Select machine .................................................................................................................................................. 30

7.2.3 Select material ................................................................................................................................................... 30

7.2.4 Slicing ................................................................................................................................................................ 31

7.2.5 Transfer of print data via network .................................................................................................................... 31

7.2.6 Transfer of print data via USB stick ................................................................................................................... 32

7.2.7 Preparing the material reservoir and build platform ........................................................................................ 33

7.2.8 Starting a job ..................................................................................................................................................... 34

7.2.9 Removing the build job ..................................................................................................................................... 34

7.2.10 Cleaning the component ................................................................................................................................... 35

7.2.11 Post‐processing ................................................................................................................................................. 36

7.3 Menu "Calibration“ (LED calibration) ................................................................................................................... 37

7.4 Menu "Info" ......................................................................................................................................................... 38

7.5 Menu "More Functions“ ...................................................................................................................................... 38 7.5.1 Verifying/setting parallelism ............................................................................................................................. 39

7.5.2 Cleaning the reservoir of particles .................................................................................................................... 40

7.6 Menu „Show Image“ ............................................................................................................................................ 40

7.7 Menu „Settings" ................................................................................................................................................... 40

8 Cleaning and maintenance .............................................................................................................. 41

8.1 Cleaning ................................................................................................................................................................ 41

8.2 Regular maintenance by the customer ................................................................................................................ 41

8.1 Yearly maintenance .............................................................................................................................................. 42

9 Shutting down the machine ............................................................................................................ 43

10 Disposal .......................................................................................................................................... 43

Straumann® CARES® P series RS_0001_B_en/012018 / 43

Publication details

Document Type: English version of the original German operating

instructions Product: Serie P20 Revised: RS_0001_B_en Status: 2018/01 Original

language : German

Copyright © Manufacturer

Address: Rapid Shape GmbH Generative Production Systems Römerstraße 21 71296 Heimsheim, Germany

Telephone: Fax:

+49 (0) 7033 309878 0 +49 (0) 7033 309878 40

Email: Internet:

[email protected] www.rapidshape.de

Distribution: Address: Institut Straumann AG Peter Merian‐Weg 12 4052 Basel, Switzerland

Telephone: Fax:

+41 (0) 61 965 11 11 +49 (0) 61 965 11 01

Email: Internet:

[email protected] www.straumann.com

Note: The product markings (P20, D20II) used in this operating instructions are equivalent to each other and identify the same product.


1 Safety information

1.1 Symbols

These operating instructions contain information which must be observed for your

own personal safety as well as to avoid material damage. The instructions comprise

the following explanations according to degree of risk.

Danger Non‐observance leads to serious injury or even death. High risk of hazard.

Warning Non‐observance can lead to serious injury or even death. Medium risk of hazard.

Caution Can lead to minor or moderately serious injuries. Low risk of hazard.

Caution Non‐observance of the precautionary measures can lead to material damage of the equipment as well as the environment.

Attention Indicates important information concerning the operation of the product or the respective work stage.

Instruction It is essential to wear UV protective goggles.

Instruction It is essential to wear protective gloves.


1.2 Safety instructions

Only specially trained personnel are permitted to perform/execute work with/on a Rapid Shape machine.

For further information on the topic of training, please consult the Rapid Shape Support Team. Rapid Shape

is not liable for damage of any kind resulting from incorrect use or from the actions of non‐authorized

personnel.

Risk of electric shock

Danger Non‐observance leads to serious injury or even death. High risk of hazard.

Only trained personnel trained for the purpose are permitted to work on the 230 V

power network. It is essential to observe the relevant safety and Association of

German Engineers regulations (VDE).

Improper installation can cause material damage and personal injury for which the

installer is liable.

Connect the power cable to the socket closest to the machine.

Machines with damaged power cables must be separated from the power network (remove the mains plug) and be repaired by a qualified electrician before being put back into operation again.

Only operate the machine with the supply voltage intended for the machine.

Only connect the machine to an authorized earthed socket. Should there be doubts about the suitability of a socket, consult the customer services team or a qualified electrician.

The complete separation of the machine is effected in an emergency by unplugging the mains plug from the power supply. As a result, this must be located near the machine and easy to access.

In the event of prolonged absence or bad weather always switch off the machine with the power switch and separate it from the power supply by removing the mains plug.


Warning against dangerous optical radiation


Only trained personnel are permitted to carry out work on this machine. The printing

process as well as calibration is subject to the influence of UV radiation and as a result

it is essential that the stipulations given in the warnings are followed.

Improper use during calibration as well as the printing process can cause material

damage and personal injury for which the operator alone is liable.

The protective hood of the machine must remain closed during the printing process to protect against UV radiation.

When calibrating the machine protective goggles must be worn as there is an acute risk of injury to the eyes caused by UV radiation.

Warning against hand‐related injuries


Machines of this type have easily accessible moving parts which can cause slight

crushing injuries. This is why the corresponding warnings are to be observed and

adhered to when working on the machine.

Non‐observance of these warnings can cause material damage and personal injury for

which the operator alone is liable.

During the printing process the protective hood must remain closed as there is a risk of crushing when running the build platform.

It is to be ensured that personnel do not have any hands in the build area during every movement of the build platform.


Warning against environmental influences


The electrical and mechanical components of the machine are only configured for

certain environmental influences. This is why the warning instructions are to be

observed and adhered to when putting into and during operation.



Protect the machine against moisture, dripping water and splash water.

Do not place any filled objects, such as drinks for example, in the immediate vicinity of the machine.

Do not position the machine near heating.

Do not position the machine in direct sunlight.

Do not operate the machine in damp rooms.

Only use the machine in temperate climates and not tropical climates.

Do no place any naked flames, such as candles for example, on or near the machine.

Warning against overheating


The electrical and mechanical components of the machine are only configured to

operate up to a limited ambient temperature. This is why the warning instructions are

to be observed and adhered to when putting into and during operation.




‐ Never install the machine in a cupboard or a shelf unit with insufficient ventilation.

‐ Never cover the ventilation vents of the machine.

‐ Maintain a distance of at least 20 cm on every side as well as behind the machine so that the heat generated can dissipate unhindered.

Warnings against corrosive/toxic substances


Chemicals required for the manufacture, maintenance and care must be handled

correctly and under observance of the relevant regulations and instructions for use

applicable to them. In this respect, it is essential to observe the stipulations of the

manufacturer. Please consult the safety data sheet of the manufacturer for more

detailed information.

Appropriate protective clothing must be worn and the metering stipulations of the

respective manufacturer are to be precisely observed.

Incorrect use of chemicals can cause material damage and personal injury for which

the operator alone is liable.

Irrespective of the details given by the material manufacturer, we recommend that

users wear at the very least protective goggles and protective gloves.

Read the safety data sheet of the manufacturer!

Warning against harmful vapors


Materials used for printing can emit vapors which irritate the respiratory paths and/or

can lead to dizziness. This is why appropriate protective clothing is to be worn and a

sufficient fresh air supply is to be assured when working with the materials.

Incorrect use of materials can cause material damage and personal injury for which the

operator alone is liable.

Read the safety data sheet of the manufacturer!


2 General Information

2.1 Conformity declaration

With the EC conformity declaration accompanying the machine, the manufacturer, Rapid Shape GmbH,

declares that the designated machine was developed, constructed and produced in accordance with the

relevant directives and their standards.

2.2 Area of application of the operating instructions

These operating instructions are valid for the following machines

Machine Type Prod. Date

Rapid Shape 3D printer system P20 from 03.2017

2.3 Intended use

The Rapid Shape 3D printer system is intended for the manufacture of 3 dimensional components made of

plastic as part of the digital workflow.

Digital workflow (schematic representation):

These operating instructions detail the process up to stage 3 and 4.

Stage 1, 2, 5 and 6 as well as the photosensitive print materials for stage 4 are not covered by the delivery

scope of the 3D printing system, but can all be acquired from Rapid Shape or its partners.

Should you have any queries, please contact our sales team.

1) Generation of the 3D data

2) Processing of the 3D data (optional)

3) Preparation of the 3D data for the printer system

4) Print of the 3 dimensional component

5) Post‐processing6) Use of the component


2.4 Duties ‐ operator (the operating company)/ person working on the machine

(machine operator)

It is essential to observe the instructions given in these operating instructions ‐ It is essential to observe the fundamental safety instructions in order to assure perfect as

well as safe operation of the machine. ‐ These operating instructions contain all the important information required for a safe

operation of the machine. ‐ All persons that operate/work on this machine must have read and understood these

operating instructions. Responsibility of the operator (the operating company) The operating company is obliged to ‐ to instruct the person working on the machine in its operation. ‐ inform the person working on the machine about safety in the workplace as well as the

generally applicable accident prevention regulations. ‐ to provide the person working on the machine with the operating instructions. ‐ A brief cleaning of the machine must be undertaken after every printing operation. See

Chapter 8.

Responsibility of the person working on the machine (the machine operator) Persons who operate this machine are obliged to ‐ observe safety in the workplace as well as the generally applicable accident prevention

regulations. ‐ to observe and follow the instructions and safety information given in these operating

instructions. We accept no liability for machine damage or injury to the operating personnel if these operating instructions are not observed.

3 Technical data

3.1 Dimensions

Standard system: 541x335x349 (closed hood) (HxWxD in mm) 779x335x349 (open hood)

3.2 Weight

Weight: 33kg

3.3 Prescribed ambient conditions

Ambient temperature: 15‐40°C Air humidity: max.60% Storage: The machine is only to be stored in dry, temperature‐

controlled rooms. (‐15‐70°C)


Operation: The machine is only to be operated in dry, temperature‐controlled rooms. (15‐40°C)

Explosion‐proof environment: It is generally forbidden to operate the machine in rooms with a potentially explosive atmosphere.

3.4 Interfaces

Electrical: Mains plug cable on the rear of the machine. 110/230VAC; 50/60Hz

Ethernet: Ethernet connection on the rear of the machine. 10/100 Mbit/s

Media: USB port on the front and rear of the machine USB 2.0

3.5 Calibration value

The following value is to be set when calibrating the machine. Should several values exist, all values are to be

calibrated.

Machine Type Calibration value

Rapid Shape 3D printer system P20 Set point low: 10.1 W/m² (tolerance ‐0.1/+0.4 W/m²) Set point high: 20.1 W/m² (tolerance ‐0.1/+0.9 W/m²)

Note: The calibration value does not correspond to the maximum performance of the machine.

3.6 Conversion / spare parts / repair

Every technical alteration of whatever kind to the machine is forbidden.

Only trained Rapid Shape GmbH personnel are permitted to carry out repairs to the machine. If repair is

required, please contact the Rapid Shape service team.

3.7 Delivery scope

Quantity Article

1 3D printer system 1 Starter kit

Optional Accessories pack (is offered and sold separately)

The starter kit contains tools and consumption parts required for operating the machine (please consult the

offer for details).


3.8 Components

3.8.1 Front view

Figure 1

1 Button „Left“ 2 Button „Entry/Confirmation“ 3 Button „Right” 4 USB port 5 Display

1 2 3

45


3.8.2 Rear view

Figure 2

1 110/230V connection incl. main switch 2 Ethernet connection 3 USB port

1

2

3


3.8.3 Side view

4 Transport


4.1 General instructions

The machine is only permitted to be transported in the packaging supplied and if sufficient protection against

tilting over is assured.

It is essential to keep the transport packaging for future use (for removals, maintenance, repair, ...). Returns

without the supplied transport packaging cannot be accepted.

Two persons are always to be employed to lift and carry the machine!

4.2 Transport damage

After receipt of the delivery carefully check the transport packaging as well as the product supplied for any

damage that could have occurred during transport. Transport damage is to be reported to the forwarding

agent and Rapid Shape immediately.


5 Preparations

5.1 Room requirements

To ensure a smooth, trouble‐free operation of the 3D printer system, please observe the following

stipulations:

‐ Set up in a room separated from other permanent work ‐ Set up only in a dust‐free area Beware of milling dust ‐ A sufficient supply of fresh air is to be assured in the room

In this respect, also always observe the stipulations of the respective material manufacturers (safety data sheet)

‐ The machine as well as the materials are to be protected from exposure to direct sunlight

‐ The room is to be equipped with UV‐protected lighting ‐ Windows are to be UV protected / shaded or fitted with UV protective film ‐ A strong foundation for setting up the machine ‐ Room requires LAN network and internet connection for service purposes ‐ Optional: Room with fresh water supply and sink unit ‐ Optional: Room with compressed air supply ‐ Optional: Set up in a temperature‐controlled room with constant temperature

±2°C (optimal) In this respect, also always observe the stipulations of the respective material manufacturers

5.2 Additional absolutely needed equipment

To ensure a smooth, trouble‐free operation of the 3D printer system, you require the following items:

‐ Post exposure unit for hardening the components In this respect, also always observe the stipulations of the respective material manufacturers! Observe safety data sheets! Observe biocompatibility requirements!

‐ Isopropanol or ethanol (at least 10l) In this respect, also always observe the stipulations of the respective material manufacturer! Observe safety data sheets! Observe biocompatibility requirements!

‐ Disposable gloves in different sizes ‐ Standard glass cleaner (streak‐free) ‐ Roll for paper toweling ‐ Waste containers for paper toweling (sealable to prevent odor) ‐ Closable, light‐proof cabinet for material reservoirs and material containers. ‐ Table workplace measuring approx. 100 cm in width to remove the components

from the platform as well as to carry out any post‐processing ‐ Optional: Protective gas supply with corresponding gas fixtures for the post

exposure unit In this respect, also always observe the stipulations of the respective material manufacturer! Observe safety data sheets! Observe biocompatibility requirements!

‐ Optional: Ultrasound cleaning unit. For several materials with several cleaning containers as required In this respect, also always observe the stipulations of the respective material manufacturer! Observe safety data sheets! Observe biocompatibility requirements!

‐ Optional: Table‐magnifier lamp ‐ Optional: Compressed air supply with compressed air pistol, incl. upstream

pressure reducer to 2 bar


5.3 Materials

Current information on materials as well as safety data sheets can be obtained direct from the material

manufacturers.

As regards Rapid Shape materials, our contact details are as follows:

Company name: Rapid Shape GmbH Address: Römerstraße 21 Town: 71296 Heimsheim Telephone: +49 (0) 7033 309878‐0 Fax: +49 (0) 7033 309878‐40 Internet: http://www.rapidshape.de Email: [email protected]

5.4 IT requirements

A computer is required to generate the print data for the machine. The following points are to be observed in

this respect.

5.4.1 PC hardware

In order to use the slicing software from netfabb, you require a computer that fulfils the following

requirements.

‐ Computer for CAD design, nesting and slicing Quad core CPU (Intel Core i5 or i7) @ 2.50 GHz At least 4GB main memory (8GB recommended) 1GB+ free hard disc memory Windows 7 32‐bit/64‐bit or higher LAN connection Internet connection

‐ Network connection between computer and machine (e.g. via router)

5.4.2 PC software

The following software must be installed on the computer intended for use.

‐ Operating system Windows 7 32‐bit / 64‐bit (optional) or higher ‐ TeamViewer 10 Host ‐ netfabb Rapid Shape Version (see Chapter 6.6)

For more information on the software used:

‐ http://www.microsoft.com

Here you can obtain information on the operating system used

‐ http://www.teamviewer.com

Here you can obtain information on trouble‐shooting or the latest updates for TeamViewer.

‐ http://www.microsoft.com

Here you can obtain all information required for the slicing software netfab.


5.4.3 IP address

The default setting for the system is DHCP (dynamic IP address). Should a static IP address be used, this can be set in the menu under "Settings" (see Chapter 7.6). Should you require details of your IP address please contact your administrator.

5.4.4 Internet access / TeamViewer port

‐ The computer to be used for netfabb requires internet access in order to obtain regular software updates and material libraries

‐ Moreover, this computer requires approval to use the TeamViewer program so that, if required, the service team can access the computer.

6 Getting started Before putting into operation it is essential to have read in full and understood the chapter Publication

details

Document Type: English version of the original German operating instructions

Product: Serie P20 Revised: RS_0001_B_en Status: 2018/01 Original

language : German

Copyright © Manufacturer

Address: Rapid Shape GmbH Generative Production Systems Römerstraße 21 71296 Heimsheim, Germany

Telephone: Fax:

+49 (0) 7033 309878 0 +49 (0) 7033 309878 40

Email: Internet:

[email protected] www.rapidshape.de

Distribution: Address: Institut Straumann AG Peter Merian‐Weg 12 4052 Basel, Switzerland

Telephone: Fax:

+41 (0) 61 965 11 11 +49 (0) 61 965 11 01

Email: Internet:

[email protected] www.straumann.com

Note: The product markings (P20, D20II) used in this operating instructions are equivalent to each other and identify the same product.


7 Safety information Should there be any queries or uncertainties, please immediately contact the Rapid Shape Service.

7.1 Unpacking the machine

Never carry the machine alone, at least two persons should be employed for this purpose.

(1) Grip the machine with both hands and carefully remove the machine out of the packaging

(2) Place the machine on a strong base

Ensure that no objects fall into the machine, as these could cause malfunctions.

7.2 Setting up the machine

(1) Position the machine in a room separated from other work (2) Position the machine in a temperature‐controlled room with a constant

temperature ±2°C (optimal) In this respect, always observe the stipulations of the respective material manufacturers

(3) Protect the machine as well as materials from direct exposure to sunlight (4) Only position the machine on a strong foundation

7.3 Connecting up the machine

(1) Connect the mains cable (rear side of the machine), making sure that nobody can trip over the cable. Please observe safety instructions!

(2) Optional: Connect the mains cable (rear side of the machine) Internet connection is required to obtain optimal support


7.4 Starting the machine


(1) Actuate the mains switch on the rear side of the machine

(2) Machine starts up ‐ Display indicates, "Starting machine" ‐ Z‐axis carries out reference pass upwards

(attention: risk of entrapment)

‐ Operating system starts up ‐ Operator panel starts

Figure 3 Start screen/main menu

7.5 Printing the first test job

Once the machine is up and running, the main menu will appear on the display.

Slide the reservoir containing the material into the machine and introduce the platform.

Now select

“Start Job” (right button) „More Functions“ (right button) press AUSWAHL (middle button) „Testjob“

(right button) „My first job“ (selection) „Start Job“ (selection)

in order to print the first job.

Caution: The detailed description of the machine operation is described in Chapter 7 of these instructions

Caution: While the job is being printed,

you can already carry on with the further

setting up of the digital workflow in

Chapter 6.6.

Once the print job has been completed,

please check the result. Should you find

that the print result deviates from the

desired result, please contact the service

team.


7.6 Installation and set up of software

You require the software netfabb to carry out your own print jobs for the 3D print system.

Caution: The following sections provide a brief overview of the netfabb software. However, we would like to

point out that this is just one small part of netfabb. Should you require a more detailed explanation, please

consult the netfabb operating manual.

All further information on operation can be found in the current version of the netfabb operating manual.

Where can the netfabb operating manual be found?

‐ After installing the netfabb program directory

‐ Link to the netfabb internet site

http://www.netfabb.com/manuals_download.php

7.6.1 Installation of netfabb

Install the netfabb version provided on the USB stick supplied.

Please pay attention to the installation instructions on the USB stick, these provide instructions and may also

include adjustments.

7.6.2 netfabb settings

Some adjustments are required in the settings to optimize both netfabb and the slicing process. The following

section gives step‐by‐step information on these setting options.

(1) Open netfabb.exe.

Click on the menu item Rapid Shape. (2) Click on Settings.

Figure 4

The following window provides the setting options: Platform ‐ Avoid platform borders: ‐ Slide control: 0mm ‐ 2.50mm set the value to:

0.25mm. ‐ Part orientation while import: ‐ Select the option: Keep part position. ‐ Keep parts on platform: ‐ Set the tick to Keep parts on platform.

Slicing parameters ‐ Subvoxelization:

‐ Select the option: Subvoxelization 2x2x2. *Recommended setting

Figure 5

Settings

Rapid Shape


Explanation of terms: Avoid platform borders: ‐ Enlarges or reduces the limits of the build

surface (red limit lines). Part orientation while import: ‐ Move to Origin: Sets the component

automatically to the zero point. ‐ Keep part position. Sets the components to

the point initially marked . Keep parts on platform: ‐ Tick: Always keeps the component on the

build platform. ‐ No tick: User can move the component in the

z direction. CAUTION: Components that do not sit directly on the build platform cannot be built unless they are given sufficient substructure to provide support.

Subvoxelization: ‐ Increases the calculating accuracy during

slicing. A higher value does not necessarily mean that the

build result is better. Too high settings, prolong the slicing process enormously. The setting 2x2x2 produces very good results.

Figure 6

7.6.3 Adding/ changing a machine in netfabb

If you are using netfabb for the first time or have received a new machine, you have to add your

machine in netfabb. The following section gives a step‐by‐step explanation of the process.

(1) Open netfabb.exe.

Click on the menu item Rapid Shape. (2) Now click the box after the machine

selection .

Figure 7

(3) In order to add a machine click . (4) In order to edit an already existing machine

click .

Figure 8

Rapid Shape


This window allows you to enter your machine data. ‐ Machine name: freely selectable name. ‐ Machine type: Select the type of machine ‐ Scaling X/Y: Enter the scaling values that you

have received from Rapid Shape (see USB stick).

‐ IP Address: Should your machine be connected with a network, enter the IP address of the machine here.

‐ Username/Password: Here you have to enter a username and a password in order to be able to send the build job directly to the machine (Standard: rapid/shape).

‐ Correction: (Only relevant if your machine is corrected optically). You receive the optical correction specially manufactured for your machine from Rapid Shape (see USB stick) The optical correction is added by clicking

and accessing the directory in which you have saved the file.

Figure 9

(5) When you have entered all the data concerning your machine or alternately have selected your data, save your changes by

clicking .

Figure 10

7.6.4 Adding a material in netfabb

If you are using netfabb for the first time or have received a new material or machine, you have to add a

new material in netfabb. The following section gives a step‐by‐step explanation of the process.

Caution: In the case of a corresponding maintenance contract, Rapid Shape updates the material parameters on a regular basis. This automatically makes available additional material parameters as well as updates existing ones. In the case of an update of existing materials, the existing "Parameter Set" is always left unchanged. Changers are added under a new "Parameter Set" with new data. This guarantees for the user that existing process parameters are not changed. (1) Click on the menu item Rapid Shape. (2) Now click the box after the parameter

selection.

Figure 11

Rapid Shape


(3) In order to add a new material click

. (4) In order to edit an already existing material

click .

Figure 12

This window allows you to enter material data. ‐ Name: freely selectable name. ‐ Machine type: Select the type of machine. ‐ Material: Select your material from a

predefined list. ‐ Parameter set: Here you can select different

parameter sets. (xx/xx Intensity: x.x W(DO) ) xx/xx: year/month of the parameter set

‐ Layer size: Select here a layer thickness from a predefined list. The smaller the layer thickness, the more precise the print result. The print time increases as the layer size decreases.

Figure 13

(5) You can set/alter the parameters of your materials in detail.

To do this click .

Figure 14

The material parameter settings allow you to adjust the following object values: Object properties ‐ Overcure: Prolongs/shortens the exposure

time. ‐ Support Width: Only for 2 dimensional

support files (*_s.stl). ‐ Offset: (X and Y enlargement/shrinkage)

Alters the size of the component in X and Y direction by the set absolute value.

‐ Shrinkage: (X and Y shrinkage) Alters the size of the component in X and Y direction by the set percentage value.

‐ Z‐Shrinkage: (Z shrinkage) Alters the size of the component in Z direction by the set percentage value.

‐ Z‐Compensation: (Z enlargement/shrinkage) Alters the size of the component in Z direction by the set absolute value.

Figure 15

(6) Click the process properties tab in order to adjust additional settings to the process values:

The material parameter settings allow you to adjust the following process settings:


Process properties ‐ Burn in factor: Burning in the first layers.

Figure 16

(7) When you have completed all the settings, save your material parameters by clicking

.

Figure 17


8 Operation After machine start you will be presented with the start screen or main menu.

Here you can use the controls (chapter 7.1) to navigate between the menu items. The menu items are

explained in the following chapters.

8.1 Controls overview

Operation is effected by means of three control buttons, as well as the installed monitor.

The function of each respective control buttons is shown on the respective display (Figure 18).


In principle the following applies: (1) Arrow facing left: go further to the left/up (2) Red dot: entry/confirmation. (3) Arrow facing right: go further to the

right/bottom.

Figure 18

Figure 19

8.2 Menu „Start Job“ (Process: Print components)

In order to be able to print 3D models the digital workflow stages already described in Chapter 2.3 are

required.

Digital workflow (schematic representation):

By putting the machine into operation in Chapter 0 you have already successfully prepared the machine. The

following will now explain the process from the preparation of the print data to the removal of the printed

component.

1) Generation of the 3D data

2) Processing of the 3D data (optional)

3) Preparation of the 3D data for the printer system

4) Print of the 3 dimensional component

5) Post‐processing6) Use of the component


Caution:

When your design / modeling software enables the automatic linkup of netfabb, chapters 7.2.1 through 7.2.4

can be dispensed with. In this case, jump directly to Chapter 7.2.5.

Caution:

The operating aids for your netfabb slicing software explained in this section are just a small part of the

overall functions of the slicing software.

For more information on operating netfabb, please consult http://www.netfabb.com

The operating manual of your current netfabb version contains a lot of helpful information on using and

operating the software. The operating manual can be found as follows:

‐ In the program directory of the netfabb installation (installation field on the USB stick supplied)

‐ Under the following internet address http://www.netfabb.com/manuals_download.php

8.2.1 Loading the stl file

In order to be able to print 3D models, so‐called *.stl files need to be loaded in netfabb.

Open netfabb.exe. (1) Click on the menu item Rapid Shape.

(2) Click Open file.

Figure 20

(3) Now enter the directory address of your *.stl files at the top in the address bar. Alternatively, you can also select the directory via the directory structure.

‐ All known files is the filter in place as the default setting. You can adjust the filter manually.

(4) Select *.stl and confirm the selection with Open.

Figure 21

(5) The *.stl file is now loaded. This can take some time and depends on the size and complexity of the file. Figure 22

TestJob.stl

TestJob.stl

Ordneradresse Ihrer *.stl Datei

Rapid Shape


(6) Once the 3D model has finished loading, the 3D model appears on you build surface.

Figure 23

8.2.2 Select machine

In order to prepare and to optimize the print data for your machine, a machine must first be selected.

(1) Click on the arrow under the option Machine. A list opens with the available machines.

(2) Select the desired machine. (3) Click on the desired machine to load the

data of the machine.

Figure 24

8.2.3 Select material

In order to prepare and optimize the print data for the material to be used, the desired material must first

be selected.

(1) Click on the arrow under the option

material. (2) A list opens with the available materials you

have added. (3) Select the desired material. (4) Click on the desired material to load the data

of the material. Make sure that the material is selected to match the material to be filled.

Figure 25


8.2.4 Slicing

The slicing process generates the print data for your printer system, cuts the 3D model in individual layers

with the set thickness.

Preconditions: ‐ Activate the menu item Rapid Shape ‐ Machine selected ‐ Material selected ‐ *.stl file loaded ‐ If necessary, supports loaded/generated

(1) Click . (2) The slicing process begins. The slicing process depends on the size and/or complexity, and can take some time. You can abort the slicing process by clicking Cancel.

Figure 26

(3) Once the slicing process has ended, a new window opens.

Here you can check the print data and individual layers and save the job data (e.g. for later transfer via USB stick) and/or send direct to the printer See following chapter.

Figure 27

8.2.5 Transfer of print data via network

Transfer of job data via the network is the simplest, fastest and safest method to use and is the one we

recommend.

In order to be able to transfer print data via a network ‐ the IP address of the machine must be saved in the machine settings in netfabb. ‐ and the netfabb PC must be able to contact the machine. This means: Port 20, 21 not blocked, test with ping successful. If need be, contact your system administrator.

(1) Once the slicing process is completed, you can select the option in the following menu ‐ Send to Printer (Sends the file to the

printer, but does not save this on the PC, however).

‐ Save as File and Send (Sends the file to the printer and also saves this on the PC).

Figure 28


(2) Send to Printer A new window opens in which the name of the build job must be entered. Name of the job any name ending .rshapebuild or .tgz (as suggested by netfabb). File ending must not deviate as the machine can otherwise not recognize the job.

Confirm your entry with OK. (3) The build job is now sent to your machine.

Figure 29

(4) Save as File and Send A new window opens in which you can enter the location on your PC as well as any desired name for your build job.

(5) Confirm your entry with Save. A new window opens in which the name of the build job must be entered. Name of the job any name ending .rshapebuild or .tgz (as suggested by netfabb). File ending must not deviate as the machine can otherwise not recognize the job.

Confirm your entry with OK. (6) The build job is now saved on your PC and

sent to your machine.

Figure 30

Figure 31

The print data are now available under "Start Job".

8.2.6 Transfer of print data via USB stick

Instead of via a network, the data can also be transferred via USB stick.

(1) Connect a USB stick to your PC. USB stick in the delivery scope of the machine.

(2) Save the build job with "save file" or "save as file and send" on the USB stick in the root directory (i.e. not in a subdirectory). Name of the job any name ending .rshapebuild or .tgz (as suggested by netfabb). File ending must not deviate as the machine cannot otherwise recognize the job. Tip: If you name the job “autostart.rshapebuild”, you can start the job with pressing just one button.

(3) Remove the USB stick securely (right click eject). (4) Insert the USB stick in the USB slot on the front panel of the machine. (5) The machine transfers all .tgz and .rshapebuild files to the machine. The print data are now available under "Start Job".


8.2.7 Preparing the material reservoir and build platform


Preparing the material reservoir

Ensure that the underside of the reservoir is clean (crystal clear) and the reservoir is undamaged.

If necessary, clean the underside of the material reservoir with isopropanol followed by glass cleaner.

Remove foreign bodies and, if need be, polymerized material inside the material bath (see Chapter 7.5.2).

Check whether there is sufficient material in the reservoir. If required, top up with fresh material and mix this carefully using a silicon spatula.

Minimum level: 5‐8mm Maximum level: 5mm below the top edge of the reservoir

Preparing an empty material reservoir:

Clean the underside of the material reservoir with isopropanol followed by glass cleaner.

Clean the inside of the material reservoir using isopropanol. Only use a finely woven cloth to do this. Never use hard and/or sharp objects.

Fill the material reservoir with the material selected in the slicing program.

Tips:

Changing material too often is very time consuming. Therefore, the preferred method

is to use a separate reservoir for each material.

Always keep a minimum reserve of 3 reservoirs in stock.

The material reservoir is a wearing part and must be replaced if the surface is damaged

by blisters, scratches, clouding etc.

Preparing the build platform:

Cleaning should take place before and after every print process.

Remove all residue of the material. Check that the holes in the platform are free of material residue.

Clean the platform using isopropanol.


Tips:

Clean the build platform once a day using acetone in order to remove all material residues

and, at the same time, to improve adherence of the build job to the platform.

8.2.8 Starting a job

Once print data has been transferred to the machine, a job can be selected and started.

(1) Select "Start Job" in the main menu and select a job in the next menu "Select Job".

(2) Acknowledge the job by pressing the middle confirmation button.

(3) The printing process begins.

Figure 32

8.2.9 Removing the build job


Precondition ‐ The build job was ended ‐ The reference pass was terminated ‐ Briefly allow the platform to drain

It is essential to wear suitable protective clothing

(Hand protection)

(1) Once the job is ended and the excess material has drained off, you can loosen the knurled screw above the build platform.

Figure 33


(2) Carefully remove the build platform by slowly pulling the platform out towards you. Caution: When removing, use the specially designed removal tool to prevent dirtying the machine and/or laboratory.

Figure 34

(3) Prevent the component thus removed from being affected by UV and clean it directly after removal.

Prolonged UV radiation can polymerize any excess material remaining on the component and thus impair the quality of the component.

8.2.10 Cleaning the component


General instructions:

It is essential to consult the material manufacturer's instruction when post‐

processing (cleaning, or drying and post‐exposure).

It is only by observing the instructions of the material manufacturer for the process

that bio‐compatibility can be reliably achieved.

When cleaning utilize the Rapid Shape Part Cleaner or high proof isopropanol. Under

no circumstances are additives such as acetone or similar to be used. This damages

the component immediately and leaves white marks.

Preparation ‐ Prepare ultrasound bath ‐ Have paper toweling ready ‐ Removal of the build platform from the

machine once the build job is completed 8.2.9 Removing the build job

It is essential to wear suitable protective clothing in accordance with the stipulations of the manufacturer (hand protection, protective goggles, respiratory protection, and protective coat).


(1) Place the build platform on a paper towel and remove the build job from the build platform carefully with a spatula. [Contained in starter kit] ‐ Hold the spatula carefully at a 45° angle at one of the corners of the build

job. ‐ Carefully chip away at the corner of the component to get under it. ‐ Carefully position the spatula under the loosened corner and chip away in

order to completely remove the build job from the build platform. (2) Fill the cleaning fluid in a suitable container and place it in the ultrasound bath. (3) Place the component carefully in the container filled with isopropanol. (4) Start the ultrasound bath and let it run for 3 minutes. (5) Remove the component from the ultrasound bath. (6) Remove the excess material as well as the excess isopropanol.

This is best accomplished by using gently metered compressed air. (7) Carefully place your component once again in a new container filled with clean

isopropanol. (8) Start the ultrasound bath and once again let it run for 3 minutes. (9) Remove the component from the ultrasound bath. (10) Remove the excess material as well as the excess isopropanol.

This is best accomplished by using gently metered compressed air. (11) Should the component still display signs of excess material, repeat step (3) and

(4). (12) The cleaning process is completed once all excess material has been removed.

8.2.11 Post‐processing


General instructions:

It is essential to consult the material manufacturer's instructions when post‐

processing (cleaning, or drying and post‐exposure).

There are different manufacturer stipulations for the different materials that can be used on Rapid Shape

machines. Read the safety data sheet and the material data sheet of the manufacturer!

Post‐processing with a flash device (example)

Preparation ‐ Flash device with a wavelength of approx. 280‐580nm

(1) Place your cleaned components in the exposure chamber of the flash device (2) Set the respective number of flashes and, if necessary, make additional settings

on your device and start the process (3) Remove your components following successful completion of the process.


8.3 Menu "Calibration“ (LED calibration)


Calibration of the LED is important for the quality of the print. A regular calibration is

therefore essential. The following section gives a step‐by‐step explanation of the

process.

Preparation ‐ Start the machine ‐ Remove the material reservoir and platform ‐ Insert the calibration plate ‐ Put on UV protective goggles ‐ Prepare calibration device

(1) Start the calibration program (main menu, left‐hand button ) "Calibration".

(2) Use selection button to acknowledge calibration (middle button).

(3) Wait 5 min until the LED has warmed up. (4) Switch the measuring device on. (5) Set the light intensity sensor in the middle of the

displayed calibration point. Alter the calibration value of the machine with the right/left buttons until the desired measurement is displayed. (See chapter 3.5)

Figure 35

(6) End calibration: Save and end after the calibration via the button Exit. The projection onto the build surface is ended. The menu is closed.

About the calibration device [1] Sensing input, connection 8‐pin DIN45326 [2] Battery symbol: Indicates the charge state of

the battery [3] Function display [4] Secondary image line


[5] Key DATA/ENTER Displays in standard mode the maximum (MAX), minimum (MIN) and average (AVG) value of the recorded measurements. Confirms the current selection in the menu.

[6] Key CLR/ESC Resets the maximum, minimum and average value of the recorded measurements. Resets the value stipulated via the arrow keys in the menu.

[7] Key HOLD Retains the measurement in normal mode. Increases the current value in the menu.

[8] Key UNIT/MENU Enables the unit of measure to be stipulated. Pressing this key and at the same time the key DATA takes the user to the menu.

[9] Key STD‐BY Switches the unit of measure of the cross‐section surface in the menu between m² and inch².

[10] Key REL Activates in standard mode the relative measuring mode (display of the difference between the current value and the value saved via the key press). Reduces the current value in the menu.

[11] Key ON‐OFF/AUTO‐OFF Switches the device on or off. Pressing this key and at the same time the key HOLD deactivates the automatic off function.

[12] Symbols MAX (maximum value), MIN (minimum value) and AVG (average)

[13] Main line [14] Symbol and commentary line (DeltaOhm, 2005)

Figure 36 (DeltaOhm, 2005)

8.4 Menu "Info"

Here you can find all the required information about the machine, e.g.

‐ Firmware states

‐ Version information

‐ IP address

‐ …

8.5 Menu "More Functions“

The menu "More Functions" provides a range of handy and easy‐to‐use menu items.


8.5.1 Verifying/setting parallelism


To prevent components from adhering to the build platform it is essential to ensure

that the build platform is set parallel to the projection surface. The following section

gives a step‐by‐step explanation of the process.

Preparation ‐ Machine started up ‐ Build platform fitted ‐ Calibration plate slided in ‐ Build platform in reference position (top)

Required tools: ‐ Allen key 2.0mm ‐ Allen key 3.0mm ‐ Playing cards from starter kit

(alternative: Small sheets of paper /business cards)

Figure 37

Preparing the machine (1) Remove, if necessary, [if still in the machine] the material reservoir and slide in the calibration plate. (2) Navigate to the menu “Setting parallelism“.

Main menu More Functions Setting parallelism.

Start the "Find Zero" process (3) Press the key "Find Zero". (4) The platform lowers until the zero point.

Wait until the platform has reached its zero point. (5) Take a piece of paper card and try to slide it under each corner of the platform. If the card slides

under none of the corners, the platform is sufficiently well adjusted.

Setting parallelism (6) If the card can be easily slid under a corner, parallelism must be set.

To do this loosen the retention screws (blue arrow in the next picture). To adjust the parallelism, turn the adjusting threaded bolts at the corner you wish to change in the desired direction.

(7) To re‐verify parallelism, repeat stages 3 through 5.

Threaded bolts for adjustment purposes Retention screws


Running the platform in the starting position (8) Press the right key in the menu „Setting parallelism“. (9) The platform rises up to the reference point in the basic setting position.

It is important to wait until the platform has reached its reference point.

Caution: Once the end switch has been reached the platform travels slightly back down again. This is intentional in order to be able to precisely determine the starting position.

8.5.2 Cleaning the reservoir of particles

During component printing a piece of polymerized material can become loose and be deposited in the

reservoir. This happens in particular if there is insufficient support.

This small piece must be removed so as to prevent it from damaging the reservoir.

One possibility is to empty and filter the reservoir. Although this is the best method due to being the safest

one, it is, at the same time, rather time consuming.

It is virtually impossible to separate a small piece of material from the remaining fluid material.

For this reason the menu item "Clean Reservoir" provides a process that thinly cures the lowest layer in the

reservoir and thus binds all the particles/pieces located there.

Removing the plate also removes the bound particles.

8.6 Menu „Show Image“

The menu item "Show Image" enables the projection of saved pictures for test and analysis purposes. Should

it be necessary, the service team can guide you through this menu.

Caution: Always remove the reservoir and build platform before you display a picture as otherwise the

material in the reservoir and on the platform will cure.

8.7 Menu „Settings"

The "Settings" menu is used to undertake more settings, such as, for example IP settings. Due to the many

setting adjustments possible, operation has been configured for mouse and keyboard use.


9 Cleaning and maintenance

9.1 Cleaning


Cleaning the machine

A brief cleaning of the machine must be undertaken after every printing operation and this must include:

Preparing the build platform:

Remove all material residue.

Check that the holes in the platform are free of material residue.

Clean the platform using Rapid Shape Machine Cleaner or isopropanol.

Moreover, the machine should be constantly checked to ascertain that the following components are

always clean:

‐ Protective glass

‐ Material reservoir bottom

‐ Material reservoir Remove foreign bodies and any polymerized material

‐ Housing in general

Cleaning the material reservoir

The material reservoir is one of the basic elements of this machine, and therefore every opportunity

should be taken to clean it.

Clean the inside of the material reservoir using isopropanol. Only use a finely woven cloth to do this.

Clean the underside of the material reservoir with isopropanol followed by glass cleaner. Caution: Isopropanol leaves streaks. It is absolutely essentially to clean afterwards with glass cleaner.

9.2 Regular maintenance by the customer



Maintenance and care is integral to a correctly functioning production machine.

Therefore, it is absolutely essential to follow the instructions on maintenance and care

very precisely.

Care before every print job

(A) Remove the cured material from the material reservoir by means of silicon spatula or filter the material using a fine filter or use the "Clean reservoir" function in the menu "More Functions". Caution: SENSITIVE ‐Never use sharp / metallic objects.

(B) Remove the cured material from the printing platform using a spatula. The printing platform must have a completely smooth surface before the print job can start.

Daily maintenance

(A) Check that the protective glass is absolutely clean (no dust, resin or streaking). o Should it be necessary, clean with isopropanol (ISO), followed by glass

cleaner.

(B) Clean the underside of the material reservoir with isopropanol followed by glass cleaner.

Weekly maintenance

(A) Carry out a parallelism check of the build platform. (B) Check the light intensity in the calibration menu.

9.1 Yearly maintenance

More extensive maintenance above and beyond that detailed above is only to be carried out

by your distributor. For information on maintenance agreements, maintenance intervals as

well as general information concerning maintenance, please contact your distributor.


10 Shutting down the machine

(1) Select in the main menu "Shutdown". (2) The shutdown dialog appears. Confirm that you wish to shutdown the machine.

Only after the machine has been completely shutdown is the main switch to be switched off!

11 Disposal Once all service fluids have been removed from the machine, it can be locally disposed off in accordance with

those regulations governing disposal of electronic devices in force locally.

Should you be unaware of where the machine can be disposed of locally, the machine can be sent to Rapid

Shape for disposal. All costs arising in this connection ‐ for example, for dismantling and transport ‐ are to be

borne by the customer/operation himself.

Materials:

Hoods: Aluminum, steel, plastic (ABS), glass

Housing: Aluminum, steel, plastic (POM), glass

Electronics: Circuit boards/PCBs, electronic components, aluminum (housing), steel (housing)

Other materials <10%: Various

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