3D Systems ProJet 4500 User Manual
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3D Systems ProJet 4500 User Manual

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Summary of Contents for 3D Systems ProJet 4500

  • Page 1 ProJet® 4500 3D Professional Printer User Guide...

  • Page 2: Table Of Contents

    What’s It For? .................................... 20      File Formats ....................................20      Computer System Requirements .............................. 20      Install Print Platform .................................. 20     Install 3DPrint ..................................21-23     Locate the 3DPrint Icon ................................23     The 3DPrint Main Window ................................24     The 3DPrint Tool Bars ................................ 26-27     Opening and Selecting Files ................................28     Part Orientation ....................................29 14. PRINTER SET-UP and OPERATION ...........................33-34     Prepare the Build Area .................................35     Print the Build .................................... 35     Curing the Part .....................................35 Clean the Part ....................................36        Coarse Cleaning ..................................36        Fine Cleaning ....................................37     Additional Operations ...................................38     The Printer Status Report ................................  38 3D Systems, Inc.
  • Page 3 15. MAINTENANCE ...................................39   Cleaning the Printer ................................39   Routine Cleaning ..................................39   Vacuum Excess Core ................................39   Clean the Debris Separator ..............................40-41   Replacing the Wiper................................41 16. SERVICE and SUPPORT..............................42 3D Systems, Inc.

  • Page 4: Introduction

    (203 x 254 x 203 mm) ABOUT THIS GUIDE To order material cartridges or parts, please contact your Authorized reseller or contact 3D Systems Customer Support to locate your  nearest Authorized Reseller.  Safety Guidelines: Read and understand all safety guidelines before attempting to operate your printer. These guidelines provide impor- tant details on how to handle the VisiJet  material cartridge properly and also describe how to avoid personal injury and/or damage to the  ® printer. For more detailed information on material safety, see VisiJet  Material Guidelines. ® System Requirements: This section provides all the necessary facility requirements for electrical, hardware, dimensional and environ- mental data. Familiarization: An overview of the ColorJet Printing process of the ProJet 4500. ® Operations: Describes functionality and the build process when starting a new or existing design.  Maintenance: Provides detailed information when performing software/hardware/preventative maintenance to the printer.  Other Documents: The Warranty and Maintenance Agreements information, along with the Material Safety Data Sheet (MSDS/SDS).  Support: 3D Systems Customer Support will provide you information on how to obtain software updates; how to order parts and return  parts through 3D Systems’ Return Material Agreement (RMA). Information on how to get system upgrades and updates.  Help: Quick access to answers to Frequently Asked Questions (FAQ).  3D Systems, Inc.

  • Page 5: Copyright And Trademarks

    JPEG Group.  PNG library libpng version 1.2.2 Copyright © 1998-2002 Glenn Randers-Pehrson, (Version 0.96 Copyright © 1996, 1997 Andreas Dil- ger), (Version 0.88 Copyright © 1995, 1996 Guy Eric Schalnat, Group 42, Inc.) ZLIB general purpose compression library version 1.1.4, Copyright © 1995-2002 Jean-loup Gailly and Mark Adler. Microsoft Windows is a registered trademark of Microsoft Corporation.  3D Systems acknowledges the trademarks of other organizations for their respective products or services mentioned in this documenta- tion. FULL WARRANTY STATEMENT The full warranty statement for 3D Systems products is found on our 3DS Central web site: 3dscentral.3dsystems.com. FCC Notice This equipment has been tested and found to comply with the limits for a class A digital device, pursuant to Part 15 of the FCC Rules.  These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial  environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with  the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely  to cause harmful interference in which case the user will be required to correct the interference at his own expense.  NOTE: Changes or modifications not expressly approved by 3D Systems could void your authority to operate this equipment.  Limitations of Warranty and Liability This information is provided by 3D Systems for the convenience of its customers. It is believed to be reliable, but NO REPRESENTA- TIONS, GUARANTEES, OR WARRANTIES OF ANY KIND ARE MADE AS TO ITS ACCURACY, FITNESS FOR A PARTICULAR USE,  OR THE RESULTS TO BE OBTAINED THEREFROM. The information is based in whole or in large part on laboratory work and does not  necessarily indicate performance in all conditions. Notwithstanding any information provided by 3D Systems or its affiliates, the customer  remains fully responsible for determining which federal, state, or local laws or regulations, or industry practices are relevant to activities in  which it engages, as well as assuring that those laws, regulations, or standards are complied with under actual operating conditions, and  3D Systems undertakes no responsibility in these areas.  IN NO EVENT WILL 3D SYSTEMS BE RESPONSIBLE FOR DAMAGES OF ANY NATURE, INCLUDING SPECIAL OR CONSEQUEN- TIAL DAMAGES, RESULTING FROM THE USE OF OR RELIANCE UPON THIS INFORMATION. THE CUSTOMER ASSUMES ALL  RISK RESULTING FROM THE USE OF THIS INFORMATION. Customers use of the materials that follow is an acknowledgment of its  agreement to the foregoing. Any customer not wishing to be bound should return this material to 3D Systems. Nothing contained herein  is to be considered as permission, recommendation, nor as an inducement to practice any patented invention without permission of the  patent owner.  3D Systems, Inc.

  • Page 6: Useful Documents

    Software User Manual: A User Manual for the 3DPrint Software is supplied on the Installation media (a USB memory stick) with the  software. Additional copies are available on our Web Site at: 3dscentral.3dsystems.com. FEATURES and BENEFITS ProJet 4500 is our most convenient, easy-to-use, automated full-color 3D Printer to date.  We’ve built in the features that custom- ers most asked for: • Built-in heat curing – no infiltration required • 600 x 600 DPI Resolution yielding excellent surface finish (X-Y) • 0.102 mm (0.004 in) layer thickness (Z) • Integrated core recycling • Quick-loading binder cartridges • Fewer consumables to stock and replace • Office-friendly: Active dust and odor control, zero-liquid waste • Recyclable material cartridges and containers • Mobile Monitoring with iOS or Android mobile devices • Intuitive software and machine controls 3D Systems, Inc.

  • Page 7: Descriptions And Definitions

    Service Station – The Service Station is the small fixture in the back right of the Build Chamber used to clean the print heads during the  printing process.  The binder which enters the service station is drained into the waste tray below the build chamber.  Keeping this station  clean is critical for successful builds.  The wiper within the service stationshould be cleaned before each build. Waste Tray – This consumable item is used to collect and cure binder waste that is deposited into the service station during the printing  process. This feature is a replaceable unit. Debris Separator – The removable windowed pocket in the top-right of the build chamber is located just above the vacuum hose.  This  pocket is used to catch any small or broken parts from entering the feeder.  Feeder – The location in the printer which contains the core material used for printing.  Core is deposited from this feeder for each layer  of the building process. Vacuum Hose – The hose on the right-hand side of the build chamber which is used to transfer core to the feeder from newly -opened  containers, the build bed, overflows, and the cleaning station areas of the printer. Overflows – The trough in the front and rear of the build bed which collects excess core during the printing process.  The collected core  in these chambers is emptied periodically during the printing process and returned to the feeder for re-use. The front overflow needs to  be cleaned before each build. Fast-Axis – This assembly is the printer component which houses the carriage and fast axis rails on which the carriage moves.  The fast  axis moves on the slow axis rails which are housed beneath the build deck.  The fast axis moves in the left-right direction in the printer.  This assembly is a replaceable unit. Carriage – This assembly houses the print heads used for jetting binder selectively onto the core in the build bed.  This carriage is a  replaceable unit. Print Heads – The piezo-electric inkjet units in the carriage which are used to selectively jet binders onto layers of core through hundreds  of individual nozzles.  The print heads are cleaned in the service station periodically throughout the printing process to ensure proper  printing. Slow-Axis – The back-to-front axis of motion in the printer.  The slow-axis contains both the roller and fast-axis assembly. Roller – The rotating cylindrical tube on the slow-axis which is used to evenly spread thin layers of core across the build bed. Build Deck – The metal area surrounding the build bed which protects critical printer components from binder and core.  The service  station is located on the build deck. 3D Systems, Inc.

  • Page 8: Packaging

    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 Surface Hazard: A hot surface is accessible in the vicinity of this sign or behind the access panel. Avoid contact.  Hot surfaces can cause severe burns. Access panels are for servicing only and should be opened only by certified  service personnel or trained maintenance personnel.  Caution: Indicates something may happen that could cause loss of data, damage to equipment, or personal injury.  Wear gloves for any interaction with consumables. Wear sleeves whenever handling powder. Wear eye protection for any interaction with consumables. [NOTE: Wear respiratory protection if you decide to sand any parts.] SAFETY GUIDELINES Before using the printer, your company should have a safety program in place. The safety program should: • Label and point out hazardous equipment, materials, and procedures.  • Explain what to do in case of an emergency.  • Provide information about hazards of equipment and materials in the form of Material Safety Data Sheets  (MSDSs). The MSDSs are provided with all materials supplied by 3D Systems. The Visijet C4 Spectrum  MSDS is also available on 3DSYSTEMS.COM 3D Systems, Inc.

  • Page 9: General

    Do not ignore warning signs posted during printer service operations.  • To prevent potential skin-irritation and sensitization due to contact with material, follow all guidelines within Build Material Safety.  • To prevent pinch and crush injuries to the hand, use caution when replacing platform inside the build chamber.  • Use caution when touching the top of the printer as the curing lamp can cause the top of the printer to become hot. • Read and follow all printer instructions.  • Follow all safety rules and heed all cautions and warnings in this guide.  • Do not attempt to open chamber door while build in progress.   • Do not use any material without reviewing the Material Safety Data Sheets/Safety Data Sheets (MSDS/SDS).  • Dress power and communication cables behind printer to prevent tripping.  • Do not attempt to access, service, or adjust printer components. Do not attempt to perform any maintenance procedures unless  specifically trained to do so.  • Operators should be trained to operate system and perform all necessary tasks to create a part.  • Certified service personnel are those who completed the 3D Systems service training package and certified to perform service  tasks. Certification may occur at different levels, and service providers should only perform tasks they are authorized and certified  to complete.  • Do not ignore warning signs posted during printer service operations.  • If an error message appears on the printer’s LCD refer to “Error Messages” within this guide before resuming operation.  ELECTRICAL GUIDELINES DANGER: Hazardous voltage exists inside the printer. Injury or death from electrical shock can result if you remove the  printer’s external panels. Panels should only be removed for service by trained and certified 3D Systems Technical Support  personnel or your certified service reseller. To prevent electrical shock, the printer will not operate unless external panels are installed. Check the facility’s electrical ser- vice rating before you connect power to the printer.  3D Systems, Inc.

  • Page 10: Part Material Safety

    ColorJet Printing (CJP) ColorJet Printing (CJP) involves two major components: core and binder. Core material is spread in thin layers over the build platform  with a roller. After each layer of core material is spread, color binder is selectively jetted from inkjet print heads over the core layer, caus- ing the core to solidify. The build platform lowers with each subsequent layer and the process is repeated until the build is complete. Users of the printer should be informed of potential hazards of part material prior to working with a printer, or performing duties which may  result in exposure to uncured binder, such as removal of material waste pan and empty material cartridges. The VisiJet  C4 Spectrum  contains two components: ® ™ • granular core component (safe to handle with proper protection) • binder liquid (In the event of a spill, use gloves, protective eye wear, and sleeves and follow standard procedure as indicated in the  VisiJet® C4 Spectrum Post Processing User Guide). DISPOSAL • Disposal of fully-cured parts produced are not subject to regulations of any known agency worldwide.  • Waste Trays contain components which cause the binder to solidify. At this point, cured waste can then be disposed of as any cured  part. Always check with local regulations before disposing of any trash. • To find out facility disposal requirements, contact a local waste disposal provider. (Local environmental regulatory agency should  have a list of qualified providers.) You will need to give your disposal service provider a copy of the part material MSDS / SDS, possibly other forms included in the Appendix of your VisiJet  Material Handling Guide, such as Waste Profile Worksheet and SNUR ® (Significant New Use Regulation - U.S. only). A report will be provided, indicating disposal requirements, as well as a quotation for  regularly scheduled pickups. 3D Systems, Inc.

  • Page 11: Health Hazards / Irritant

    • Uncured material is a sensitizer, and can cause allergic reactions if it comes into contact with skin without protective gloves and pro- tective sleeves. Refer to personal protection equipment for more information. To avoid sensitization, do not allow uncured material to  contact skin. Consult the MSDS for specific information about the sensitization potential.  INHALATION • Under normal operation, inhalation of materials is not an expected route of entry. Wear a particulate dusk mask if concerned about  inhalation. • Ingestion  • Uncured VisiJet  C4 Spectrum Binder is toxic if ingested.   ® • Uncured material is toxic if ingested. Uncured material must not be present where food and drink are stored, prepared, or consumed  and not ingested. After handling materials, wash hands with soap and water before consuming or preparing food.  HANDLING FINISHED PARTS • Finished (cured) parts can be handled or disposed of the same as standard household plastic products. VisiJet  parts are not recy- ® clable. VisiJet  materials are not intended for and cannot be used for medical implantation, or food or drink handling applications.  ® • Uncured parts must be handled with gloves and eye protection. HYGIENIC PRACTICES • Appropriate hygienic practices should be followed, including washing with soap and water before meals, breaks, smoking, applying  cosmetics, using toilet facilities, and after work. • Employees should be alerted to the need to clean and rinse off any contacted surface promptly in order to prevent further contamina- tion. Ensure a convenient washroom location is provided with access to soap, water, and disposable paper towels. 3D Systems, Inc.

  • Page 12: Material Handling

     binder cartridge are pa ckaged in shipping cartons. Upon receipt of material shipments, inspect cardboard carton exterior  ® for signs of damage and leakage. If leakage is observed, DO NOT open carton, and contact 3D Systems’s Technical Support Hotline. If  no leakage is observed, keep the material cartridge in their cartons and store until material is used. Part Building • If uncured binder is observed on the part or platform after build, this is an abnormal condition, and is an indication that the printer  requires servicing by 3D Systems or a certified servicing reseller. Assume any liquid or paste-like material is part material. Do not  directly touch uncured part material without protective gloves. Discontinue use of the printer pending service by a 3D Systems Tech- nical Support Representative.  • Flammability and Combustibility • Do not expose materials to heat at or above 230°F (110°C), flames, sparks, or any source of ignition. (Though the U.S. Department  of Transportation does not consider VisiJet materials a “flammability hazard,” they do classify them “combustible” based on flash  points.) For more information on VisiJet material flash points and combustibility, see VisiJet C4 Spectrum Post-Processing Guide. ® Personal Protection Equipment • Exposure to uncured binder may occur when removing and disposing of the waste pan. To prevent   con- tact, wear chemically resistant protective gloves - nitrile or neoprene gloves are recommended.   Do not  use Latex gloves. Wear gloves at all stages of handling consumables. • In the event of a leak or spill of uncured part material, wear safety glasses with side shields to provide eye  protection. Wear eye protection at all stages of handling consumables. • Because of the printer’s built-in engineering controls, respiratory protection is not necessary during normal  operation. A NIOSH-approved (or equivalent) dust mask is recommended during depowdering. • Sleeve protectors are required during depowdering. 3D Systems, Inc.

  • Page 13: Regulatory Information

    (uncured)  is  the  spilled material. Use of heat above 65°C (149°F) may prove helpful in removing spilled part material from carpet.  • Tools contaminated with part material should be cleaned prior to reuse. Solvents such as denatured alcohol or Isopropyl  Alcohol (IPA), are normally required to clean equipment and tools. Wash with soap and water to remove any traces of ex- cess part material or solvent. Contact solvent suppliers for information on proper handling of solvents if used for clean-up. Waste Removal CAUTION: Uncured binder material is a sensitizer. Skin or eye irritation could occur when exposed to the chemical composition of the material • If there is spilled material around the cover of the waste tray, wipe with a paper towel before dispensing in trash. 3D Systems, Inc.

  • Page 14: Material Storage

    ® ™ ENVIRONMENTAL CONDITIONS • No direct sunlight, heat, flames, or UV energy CORE SHELF LIFE • 1 year from date of manufacture CLIMATE •  A cool, dry area with adequate ventilation TEMPERATURE RANGE • 40°F (4°C) to 80°F (27°C) MAXIMUM TEMPERATURE RANGE • 95°F (35°C) VisiJet  C4 Spectrum Core ® ™ ENVIRONMENTAL CONDITIONS • Avoid direct sunlight, heat, flames, or UV energy 3D Systems, Inc.

  • Page 15: Specifications And Requirements

    SPECIFICATIONS and REQUIREMENTS FOR YOUR PROJET 4500 OPERATING ENVIRONMENT WEIGHT • Maximum Temp. Range: 50-85° F (10-29.4° C) • Crated - 750 lbs (340 kg) • Recommended Temp. Range: 55-75° F (13-24° C) • Uncrated - 600 lbs (272 kg) DIMENSIONS (WxDxH) OPERATING HUMIDITY RANGE • 20-55% - non-cond. • Crated 75 x 68 x 48 in. (190 x 172 x 122 cm) • Uncrated 64 x 60 x 31.5 in. (162 x 152 x 80 cm) BUILD VOLUME • 8” x 10” x 8” (203 x 254 x 203 mm)        640  cubic inches  NETWORK CONNECTIVITY • TCP/IP 100/10 Base T LAYER THICKNESS •...

  • Page 16: System Components

    YOUR PROJET 4500 AT A GLANCE ® Printer Components Color Binder Pockets (C/M/Y) Clear Binder Pocket Feeder Debris Separator Housing Fast Axis Vacuum Hose Print Head Cartridge Fine Cleaning Wand Waste Tray Control Panel 3D Systems, Inc.
  • Page 17 Internal Components Color Binder Cartridges (C/M/Y) Clear Binder Cartridge IGUS Chain Debris Separator Fast Axis Assembly Vacuum Hose Fast Axis Assembly Service Station Build Chamber Carriage (contains print heads) 3D Systems, Inc.
  • Page 18 External Components Front Left Door Side Panel Printer Door Cleaning Station Control Panel Upper Real Panel Lower Rear Panel  (Power Supply) 3D Systems, Inc.

  • Page 19: Familiarization

    Once  clean,  the  part  is  complete.   There  is  NO  need  for  an  infiltration  step  as  with  previous  generations  of  CJP  printers  to  increase  strength. Support Material Part Material Additional steps may be taken to improve the color of the models. Please refer to the VisiJet C4 Spectrum Post-Processing Guide. 3D Systems, Inc.

  • Page 20: Using 3Dprint

    3DPrint  is a Windows-based software program designed to easily and quickly manipulate, annotate, and preview 3D modeling data  ® before printing it in a 3D Systems 3D printer. File Formats You Can Import and Print with 3DPrint ® Current file types supported are listed below: NOTE: The quality of data read through each of these file types is highly variable due to the way the source programs treat their data. • .zbd files are build files created by the 3DPrint  Software (can open but not import) ® • .zpr files are part files created by a number of software packages from other companies. 3DPrint  supports versions 1, 2, & 3. ® • .stl files are monochrome 3D model files exported by several 3D CAD packages. • .wrl (also known as VRML) files are color files that are exported by many 3D CAD packages. • .ply files are 3D color model files exported by several 3D CAD packages. Computer System Requirements Computer operating systems and hardware change frequently. Please check out the latest recommendations on our 3DS Central Web  site, in the Products section under your printer model, under Software: 3dscentral.3dsystems.com. 3D Systems, Inc.

  • Page 21: Install 3Dprint

    NOTE: You must have Administrator rights to install 3DPrint correctly. ® If you encounter any problems during 3DPrint  installation, please contact your local Reseller, or visit the support section of our Web  ® site: 3dscentral.3dsystems.com. Close all running applications and insert the 3DPrint  Installation  ® media (a USB thumb drive) into your computer. If  the  installer  does  not  automatically  start,  double-click  on  your  drive  icon.  Double-click  on  the  Setup.exe  icon.  This  starts  the  3DPrint  installation. ® 3D Systems, Inc.
  • Page 22 After Setup.exe is launched, you have the option to install the 3DPrint  application. ® Read the licensing agreement carefully. Select the destination directory. The Setup program prompts you for a selection and will suggest C:\Program Files\3DPrint  Software as the default directory:  C:// PROGRAM FILES (X86) 3D PRINT SOFTWARE 1.04 3D Systems, Inc.

  • Page 23: Locate The 3Dprint Icon

    It takes several minutes for 3DPrint  to install and then you are returned to the desktop. ® LOCATE THE 3DPRINT ICON ® Once installed, locate the 3DPrint  icon on your desktop. Double-click on it to open the splash screen. ® Locate the 3DPrint  icon on your desktop and double-click to OPEN. ® When a file is opened: 3D Systems, Inc.

  • Page 24: The 3Dprint Main Window

    THE 3DPRINT MAIN WINDOW ® The 3DPrint  Main Window has two (2) viewing modes - 3D (Cross-Sectional). Explore the features of the Main Window in the  ® sections below. Tabs Toolbar Top View Side View Build Box 3D View 3D Systems, Inc.
  • Page 25 Build  Bed  in  the  Z-X  plane.  It  also provides the Layer Slider, which  you  can  click-and-drag  to  move  up  and down the layers of the part. 3D  View  is  an  interactive  representa- tion  of  the  Build  Bed  where  you  can  quick- ly  change  the  angle  from  which  the  part  is  viewed using the mouse. 3D Systems, Inc.

  • Page 26: The 3Dprint Tool Bars

    THE 3DPRINT TOOL BARS ® 3DPrint  is designed to make the most-commonly used functions easy to find and use. The screen has tabs across the top, with a tool  ® bar below that. The toolbar changes depending on which tab is selected. Home Tab Home tab provides access to the most frequently used tools, such as File Save Save As, as well as Import and Export to bring  files into 3DPrint  or export them into another application. ® Transform Tab The Transform tab provides tools to move, scale, rotate and mirror your part, as well as copy and paste (to make copies of your part). Tools The Tools tab gives you access to the Print Time Estimator (how long the job will take to print) as well as Create a Fixture (Fixture to sup- port parts while printing), These functions will be described in more detail in later sections of this manual. 3D Systems, Inc.
  • Page 27 Ribbon Button The Ribbon button provides access to file functions such as OPEN, SAVE, PRINT 2D. 3D Systems, Inc.

  • Page 28: Opening And Selecting Files

    OPENING AND SELECTING FILES Open Files In 3DPrint ® When you launch 3DPrint, the Open dialog displays for you select a  file to print. Use the Open dialog to load a single Build file (.zbd, .bld),  or one or more Part files, (.wrl, .stl, .ply, .zpr, etc.), into 3DPrint ® By default, when a file is opened or imported, 3DPrint  will: ® • Warn you if any piece of the part falls out of bounds of the                    Build Bed bounds.  • Orient imported parts for the fastest print times. Choose Dimensions: • Once the file is open, it is necessary that you select your  preferred unit of dimensions. • Material type: Visijet C4 Spectrum Opening and Inserting Files: This function opens a new window to print a separate print job. It will not insert a .zbd file. It will however insert zpr, wrl, stl files  into an existing build volume. 3D Systems, Inc.

  • Page 29: Part Orientation

    If  a  part  has  a  particularly  delicate  feature,  especially  one  shaped  like  a  thin  rod,  align  that  feature  in  the  X-Y  plane  for  the  greatest  strength. If a part has particularly delicate features that are supported only by unprinted powder, build a Fixture for the part to reduce the  chances of breaking the feature during powder removal. Collision Detection: Though the bounding box may overlap, it will not detect a colli- sion unless the model geometry itself is touching. A dialogue will pop up if no collision is detected. Quick Place: Quick Place: The Quick Place function poisitions parts for fastest printing in  The Quick Place function positions parts for fastest printing in  the build volume by using bounding boxes. Bounding boxes posi- the build volume by using bounding boxes. Bounding boxes posi- tion parts for optimal spacing between parts.  tion parts for optimal spacing between parts.  3D Systems, Inc.
  • Page 30 Moving manually/translating the part: Parts can be manually moved if the default position is not ideal for your needs. • Mouse option – drag and place in top and side views.     You cannot  move a part in the isometric view.  • Translate – move based on position • Justify – front/back, left right, bottom • Rotate – x,y,z are axes of rotation. NOTE: Bounding boxes can intersect as long the actual 3D model  does not touch. Rotating a Part: Parts being prepared for a build can be rotated and scaled to suit your needs. Primarily, a part will be opened and  prepared in a default setting. • To rotate a part, select the part and choose Transform > Rotate. In the Rotate dialog, specify the plane and    degree of rotation, and click OK. • To keep a group of parts in the same relative orientation,     rotate the parts as a group. Select each part and then  choose Transform > Rotate. 3D Systems, Inc.
  • Page 31 • A part can also be rotated 90 degrees around Z-axis (top  view). A red box indicates that the part is outside the build  volume. Scaling the Part: Select the part and choose Transform. If you scale a part and it does not fit into the Build Bed, 3DPrint prompts  you with a warning telling you an object is extending beyond the  Build Bed boundaries and draws a red wire frame around the part. In the Scale dialog boxes, you have several options: • Scale the part as an absolute percentage of its size when it was         first brought into the build volume by entering a percentage. • Scale a part to a specific size by entering dimension values  directly in the X, Y, and Z fields. • In order to shrink it in this orientation, it is necessary to scale  it by changing the Y-direction to eight (8) inches. • Part is no longer at the bottom and scales around center of  bounding box. Justify part(s) to bottom (or drag to bottom)  for ideal printing. 3D Systems, Inc.
  • Page 32 • Two parts can now fit in this orientation now (but they  will be smaller than original design). Mirror: The Mirror feature will inverse the orientation of a  part in the X, Y, or Z Axis. The software does this by placing  a plane in the center of the part. Select a part and select Transform > Mirror. The • software will not create a separate part. It will take the  selected part and invert its orientation. • Mirror a group of parts by selecting the parts and then        choosing Transform > Mirror. 3D Systems, Inc.

  • Page 33: Printer Set-Up And Operation

    NOTE: Power up the printer This section will briefly introduce you to using 3DPrint  to prepare your part for building. It will then show you how to get your ProJet 4500 ® ®  ready and actually print your part. For all the details on using 3DPrint , refer to the 3DPrint User Manual. ® ® PREPARE THE BUILD AREA Go to your printer and check each item listed below to ensure the printer is ready to print. It is important to check each of these items  before every build. 1. Check that the Deck,  Fast  Axis,  and  Build  Bed      are clean of any loose core material. Vacuum any ex-      cess core powder from the surface. 2. Check that the Debris Separator is empty and cleaned      of excess powder.  3D Systems, Inc.
  • Page 34 3. Pull out the Debris Separator window to expose the     mesh filter. Using a small brush, brush any core par-     ticles from the mesh filter. Using an external vacuum,       remove any remaining debris/powder. 4. a. Wipe down Fast Axis Rails with a dry paper towel and         re-zero stops.  NOTE: Do not use water or any solvents to wipe the printer. b. Wipe the bottom of the print head (only in one (1) direction) with a      clean lint-free wipe before each build. Use the kit mirror to inspect      the print head for any excess residual fluid. 5. Remove wiper from Service Station (while wearing      safety gloves) and place in acetone. 3D Systems, Inc.

  • Page 35: Print The Build

    CURING THE PART When your part is finished printing, the printer runs a heat cure cycle. Heating will begin during the build and continue after the build is  complete. A timer on the LCD menu will count down the time remaining to cure the part. Curing the part is required for strength development and to  fulfill health and safety requirements.  If parts are uncured, they will make it through the Debris Separator. Do not vacuum uncured parts with the user hose. [NOTE: Do not open the door during the printer’s “drying” cycle. The overhead lamp will be cycling during this time and can pose a danger due to excessive heat.] 3D Systems, Inc.

  • Page 36: Clean The Part

    CLEAN THE PART Once your part has dried, you will need to clean it to remove any remaining loose Core material. Cleaning is done in two stages: “coarse”  cleaning, which removes the Core material around the part in the Build Bed; and “fine” cleaning, which removes any Core still clinging to  the part itself. Do not vacuum uncured parts. Run a cure cycle from the Utilities menu before vacuuming. Coarse Cleaning Your part prints and dries in the Build Bed surrounded by unused, loose core. You will need to remove unused core from the Build Bed  after the drying cycle is finished. Important: Use caution when removing and cleaning. T 1. Before you begin vacuuming, check the part orientation in 3DPrint to     avoid damage to your part. 2. On the LCD display, select VACUUM. 3. Open the printer top cover. The vacuum starts. Use the Control Knob move the Build Platform up as you vacuum. Unused Core that is vacuumed from the Build Bed is recycled back into the printer feeder so it can be used      for future builds. NOTE: Gloves, eye protection and sleeve protectors are required dur- ing depowdering. 3D Systems, Inc.

  • Page 37: Fine Cleaning

    Fine Cleaning After the bulk of the core is removed from the Build Bed, remove the part and transfer to the cleaning station where you can clean the  part of any remaining Core with the Air Wand. 1. Gently lift the part and place it into the cleaning station and begin to      depowder core material from the outside of your part. Be sure      to blow excess core material from inside of the part. 2. Use a brush to remove core from sections of your part that may be     fragile. 3D Systems, Inc.

  • Page 38: Additional Operations

    ADDITIONAL OPERATIONS When you start a print job, 3DPrint  checks the printer to ensure that there are enough materials to complete the job and that the printer  ® is properly prepared before starting the job. If the printer does not have enough core, binder, or print head life to complete the job, a mes- sage appears in the Printer Status dialog indicating what you need to do to prepare the printer for printing. IMPORTANT: Do not add core or binder to the printer, or change a print head, unless a message in the Printer Status dialog informs  otherwise. THE PRINTER STATUS REPORT The printer has an onboard Status Report you can use to check Core levels, head life remaining, etc. This is especially useful if the printer  is located some distance from the computer used to control it. To access the onboard Status Report, select STATUS REPORT on the LCD. The Report will look similar to the example below: BINDER LEVEL OK REMAINING 25% FEEDER LEVEL 4.6” BUILD PLATFORM 3.4”  WASTE OK THE PRINTER STATUS DIALOG The Printer Status dialog in 3DPrint  keeps you apprised of everything your ProJet 4500 needs to start your print job. . ® 3D Systems, Inc.

  • Page 39: Maintenance

    CLEANING THE PRINTER After cleaning the part take a few minutes and clean the printer. Regular cleaning and maintenance is the simplest, best way to ensure  your parts look their best, and to keep your printer running trouble-free. ROUTINE CLEANING Cleaning after every build will prepare the printer for the next build and keep the printer running smoothly. These tasks take only a few  minutes to perform but make a huge difference in how well your printer runs. VACUUM EXCESS CORE After every build, vacuum up all loose Core material in the Build Chamber, including the Build Bed, Deck, and Fast Axis including the Rails  and Carriage. To vacuum. [NOTE: Use gloves and sleeve protectors when handling consumables.] 1. Close the printer top cover and select VACUUM on the LCD menu. 2. Open the printer top cover. The vacuum starts. Remove      the vacuum hose from its stand. 3. Vacuum any excess Core in the Build Bed with the User Hose. Any other core      is unfit to recycle and must be cleaned with  3D Systems recommended exter-     nal vacuum and contaminate the powder inside the feeder. Important: Never vacuum up water or other fluids - it will clog the vacuum system. 3D Systems, Inc.

  • Page 40: Clean The Debris Separator

    KEEP VACCUM ON NOTE - When the feeder is full, it has enough Core to complete a build that uses the entire vertical capacity of the Build Bed. Adding  further core provides no benefit, and risks overfilling the feeder. Do not continue running the vacuum after the FEEDER IS FULL message  appears. If you continue to vacuum Core into the feeder, the LCD will display FEEDER LIMIT and the vacuum will be disabled. 5. When finished, return the hose to its holder. [NOTE: In the event of a powder spill, sweep the powder up and dispose of in a waste recep- tacle. Use only a non-ignition vacuum to vacuum spilled powder.] 3D Systems, Inc.

  • Page 41: Replacing The Wiper

    REPLACING THE WIPER The wiper in the Service Station should be cleaned before each build to ensure that there is a secure vacuum for each build. 1. In the Service Station, gently push down wiper and allow it      to rise for removal and cleaning. Lift the wiper and separate  from the base. 2. Using a metal pick (included in accessories kit), scrape residual      out of each vacuum hole to ensure a  strong vacuum. 3. Replace the wiper in the service station once each vacuum hole      is cleared of any obstruction. 3D Systems, Inc.

  • Page 42: Service And Support

    • .INI File (Obtainable through the 3DPrint Software Service Menu) • SPREAD.CSV File (Obtainable through the 3DPrint Software > Service Menu, Receive File option) Then type C:/SPREADLOG. • Head Report Information (Obtainable through the 3DPrint Software > Service Menu) • Binder/Core Types • Binder/Core Expiration Dates • EXACT Error Code/ Description of Problem CONTACT 3D SYSTEMS If you have any questions about your 3D ProJet or the 3DPrint Software, please contact your local Reseller/Service Provider. If they are  unable to help, contact us directly United States Technical Support - Europe/Middle East/Africa Corporate Headquarters: Phone: +44 20 8144 3907  333 Three D Systems Circle E-mail: support-emea@3dsystems.com  Rock Hill, SC 29730  Tel: +1.803.326.3900 Technical Support – North and South America Technical Support – Asia Pacific Phone: +1 781 852 5050...
  • Page 43 ADDITIONAL INFORMATION Materials Visit the Materials section of our Web site to get the latest information on:    Materials that are compatible with your printer.   Best Practices to help you create the very best parts. 3dscentral.3dsystems.com Service Visit the Support section of our Web site for tips on maintaining your printer, troubleshooting problems, or to contact our Service staff: 3dscentral.3dsystems.com 3D Systems, Inc.
  • Page 44 3D Systems, Inc. 333 Three D Systems Circle | Rock Hill, SC | 29730 www.3dsystems.com ©2014 3D Systems, Inc. All rights reserved. 22-95060 Rev. A...

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