3D Systems ProX DMP 100 User Manual
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3D Systems ProX DMP 100 User Manual

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ProX
DMP 100
®
3D Production Printer
User Guide
Original Instructions

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  • Page 1 ProX DMP 100 ® 3D Production Printer User Guide Original Instructions...

  • Page 2: Table Of Contents

    Chemical Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 3D SYSTEMS, INC.
  • Page 3 Unloading a plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 3D SYSTEMS, INC.
  • Page 4 COPYRIGHT AND TRADEMARK NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 3D SYSTEMS, INC.

  • Page 5: Introduction

    . It will be then the responsibility of the user to qualify the manufactured dental elements in compliance with standards and regulatory requirements of each country . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 6: General Machine Operation

    During the manufacturing process, the roller must not disturb any of the previous sintered layers . This is why the correct conditions required for the manufacturing of layers is given in the following diagram . C : thickness of layers (c = c . . .) e ≥ 0 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 7: Safety Guidelines And Instructions

    Provide information about the hazards of the equipment and materials in the form of Safety Data Sheets (SDS) . The Safety Data Sheets are provided with all materials supplied by 3D Systems . All DMP equipment is designed with safety in mind . However, improper use, malfunctions, and excessive exposure could cause injury .

  • Page 8: Safety Symbols And Definitions

    When working in areas where reactive metal condensates are present, use fire retardant special fabric, rendered conductive, trousers without turn-ups and closed pockets . Before starting any operation or maintenance on the printer, consult the Technical User Guide . Antistatic shoes required . Safety shoes required . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 9: First Aid Section - What To Do

    • Any other pertinent information Please send this information to 3D Systems within a day of the accident . Electrocution The DMP system contains equipment energized at 400 volts . Do not attempt to remove protective panels . There are no user serviceable parts inside .

  • Page 10: Dmp Equipment Safety Features

    DAMAGE, INJURY, OR DEATH . IF YOU SUSPECT A SAFETY INTERLOCK DEVICE IS NOT WORKING PROPERLY, DO NOT OPERATE YOUR DMP EQUIPMENT . RATHER, DISCONNECT POWER FROM THE EQUIPMENT AND CONTACT 3D SYSTEMS CUSTOMER SUPPORT FOR ASSISTANCE . Safety interlock switch on the left door 3D SYSTEMS, INC.
  • Page 11 Safety interlock switch on the right door Safety interlock switch on the scanner head Safety interlock switch on the airlock door 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 12: Dmp System Response If An Interlock Fails

    The fully enclosed chamber blocks laser radiation from escaping to the outside . • The material of the chamber window, which conforms to CE EN207, also blocks laser radiation so you can safely observe the part during a print . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 13: Other Active Safety Features

    . ELECTRICAL SAFETY 3D Systems recommends explosion-proof wiring for the room where the DMP is operating and where the materials are stored . To prevent electrical shock, DMP equipment will not operate unless all external panels are installed and all electrical safety interlock circuits are closed .

  • Page 14: Personal Protective Equipment

    • Dedicated grounding points in each process room • Antistatic flooring • Antistatic floor mats In addition it is recommended to check the grounding itself on a regular basis . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 15: Vacuum Cleaners

    If available, use forced ventilation at your work station when handling powder . Set it to the correct strength to ensure maximal removal of air suspended powder, while preventing the ventilation itself from causing agitation of static powder . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 16: Material Safety

    MATERIAL SAFETY All materials certified by 3D Systems are safe during normal operation. However, you should be aware of the following issues: • Any material, material-like substance, or airborne cloud of material has a remote chance of rapid combustion .

  • Page 17: Potentially Hazardous Metal Powders

    You must make certain there is no automatic sprinkler system installed where aluminum, magnesium or magnesium alloys are stored . These materials will react with water to produce hydrogen which will create an explosion hazard . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 18: Material Handling Precautions

    Give operators access to the SDS’s that apply to materials they will be handling and ensure that they read them . If necessary, translate them . • File SDS’s in an easily accessible location for immediate reference. • Strictly follow all the conditions in each SDS . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 19: Gas Safety

    . 3D Systems recommends that you have an oxygen monitor installed in the room containing the DMP system . This monitor will alert you if the oxygen level drops below a designated point .

  • Page 20: Risk Relating To Gas Bottles

    Any machine-tool with digitally-controlled movements are likely to be susceptible to rapid changes in position . This results from inadvertent movements of the motorized axes: • Sintering axis, • Supplying axis, • Layering system . And from inadvertent movements of actuators: • Opening/closing of the airlock, • Scraper . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 21: Safety Labels On The Dmp System

    SAFETY LABELS ON THE DMP SYSTEM Laser certification / Identification with name plate Printer nameplate Laser certification Both are located at the right side of the printer . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 22: Warning Labels - Airlock Door

    Warning Labels - Airlock door Pinch Hazard Label - Front of the scanner head Burn Hazard Label - Oxygen sensor Behind the screen control panel Inside the manufacturing chamber Above the manufacturing chamber Adjacent to oxygen sensor 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 23 Warning labels - Exhaust filter Warning labels - Right side of the printer 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 24: Laser Safety Labels - Located On The Scanner Head Trap Door

    Laser Safety Labels - Located on the scanner head trap door Laser Safety Labels - Located on the scanner head Laser Safety Labels - Located on the scanner head/beam expander sides Laser Safety Labels - Located on the front doors 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 25: Laser Safety Label - Located Under The Airlock Door

    Laser Safety Label - Located under the airlock door Laser Safety Label - Located on the manufacturing chamber door 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 26: European Directives

    This section lists all of the equipment that is provided as a part of the ProX® DMP100 . For more detail on product specification, please refer to the ProX® DMP100 Facility Guide. • Main cabinet • Process filter with its transportation cart 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 27: Prox® Dmp100 At A Glance

    Airlock (see section "F . Airlock" on page 29) Pneumatic data management (see section "G . Pneumatic data management" on page 29) Process filter assembly (see section "H. Process filter assembly" on page 30) Process chamber window, part of the manufacturing chamber 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 28: Front Doors And Glove Doors

    VACUUM CLEANER HOSE (see section "4 . Vacuum cleaner hose" on page 26) OXYGEN ANALYSER SENSOR (see section "5 . Oxygen analyser sensor" on page 26) LENS CLEANER (see section "6 . Lens cleaner" on page 26) 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 29 The compacting element translates in order to clog the feeding piston, then, the piston rises to compact the powder . 2 . Collecting tank It recovers all non-sintered powders and residues of sintering that have to be treated within external recycling system . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 30: Laser Assembly

    A beam expander: optical device that expands the laser beam, • A scanner head, • A flat field F-Theta lens (420mm focus length). COLLIMATOR + BEAM EXPANDER ENCLOSURE OPTICAL RAIL SCANNER HEAD LENS (COULD NOT BE SEEN ON THE FIGURE) 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 31: Screen Control Panel And External Control Panel

    This device deactivates the locking system on the doors to access the airlock and the glove doors . USB PORT Allows to connect any USB device . START KEY This key activates/deactivates the machine start command using the “ON” button. 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 32: Connection Panel

    Compressed air supply : valve and automatic coupler with 6 mm splined adaptor Gas supply : valve and automatic coupler with 6 mm splined adaptor Electrical power supply 6mm exhaust gas Ethernet socket : RJ45 network cable Main cut-off switch: ON/OFF 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 33: Airlock

    • two solenoid valves that control operation of the chamber's gas feed and purge system according to the selected case (D), • A gas flow regulator to adjust flow rate in control mode (E). 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 34: Process Filter Assembly

    Caution : the lens filter must be replaced regularly. Consult the Maintenance section for the recommended maintenance interval and details on how to replace the filter. WARNING : DO NOT START THE LENS CLEANER BLOWER WHILE THE PROCESS FILTER IS NOT CONNECTED TO THE PRINTER . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 35: Lifting

    LIFTING Caution: moving the printer may affect settings (alignments, calibration . . .) . Contact your 3D Systems- certified Customer Support Engineer to check the operation of the printer after moving. When moving the ProX DMP100 system, follow the instructions outlined below : ®...

  • Page 36: System Use

    . PX Control To launch the application manually, double-click on the icon “PX_Control” from the desktop. PX Control 2 .X .X .1 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 37: User Interface

    • C .B . : the machine is on a cycling break, during manufacturing, • PREPA : the machine is on a preparation cycling, • MAINT : the machine is in maintenance mode . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 38: Preparation Menu

    Actions executed during the automatic cycle Button to launch the current cycle List of actions of the current step to be performed by the operator Available commands of the current step Button to navigate to the next step 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 39 (3) and the external control panel . Consult the section "Unloading a plate" on page 55 for details . When manual actions completed, click on Next to go to the next step . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 40 . Consult the section "Zero sintering search" on page 49 for details . This step is performed automatically: Click on the Start button (1): this will launch the automatic cycle . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 41 Consult the section "Creating the powder bed" on page 51 for details on how to control the well completion of the power bed . When cycle completed, click on Next (3) to go to the next step . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 42 60 days, the interface will at first prompt to change the lens cleaner filter. Perform the actions (1) . Consult the Maintenance section for details on how to replace the filter. 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 43 Then, perform the actions (2) : consult the section "Cleaning the laser optic system" on page 52 for details on how to clean the lens . Next Click on (3) to go to the next step . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 44 Click on the folder icon to launch the file browser (1). Select the manufacturing file and click on Load file (2) . Preparation Assistant will then return to the previous page . The inerting phase should then be initiated . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 45 (and the external vessel valves close) . It will trigger an oxygen error (4) . Click on Validate, then proceed again to the inerting phases process up to get the O2 level below the safety limit . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 46: Manufacturing Menu

    The delay start function offers the possibility to start the selected cycles at a specific time. If selected, the user can program the next start within the setting window: Click on Validate to confirm, or on Quit to cancel . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 47 The printer will finish the current layer sintering, will then proceed to the next layering cycle without sintering. The operator will have to: • Click on to continue the job or, • Click on to completely stop the manufacturing . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 48 (corresponding to the last zero sintering research cycle), Part height: the height of the sintered part in mm . • • LASER/OPTIC Defocus: defocusing value in mm, • Laser power: current Laser power, in % . • 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 49: Machine Status Menu

    Maintainer level: dedicated to special servicing procedures . Access to Adjuster level menus (with additional features and additional read/write access) + to the maintenance tool Expert level: total access to the settings and to the Expert tool Administrator level: reserved 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 50: Machine Preparation

    To close the glove door, make sure the Flat Bar is placed at first vertically. Then fully close the glove door, and place the Flat Bar horizontally (as shown on the left figure). Make sure to tighten securily the Palm Grip while the Flat Bar is placed horizontally . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 51 CLOSE = airlock facing the chamber side . • Tool required • A natural fiber brush for the cleaning process, • A 4mm hex key wrench, • 4 socket head screws (M5x12), to fix the sintering plate on the sintering piston. 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 52: Sintering Plate Preparation And Loading

    12 . Put on gloves (2) and open glove doors (3) (refer to section "Introduction" on page 46) . Glove door open Glove 13 . Remove the paper towel (used to protect the sintering plate) from the airlock . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 53: Zero Sintering Search

    Check the sintering plate is clean . Start the Zero sintering cycle on the control panel (see "Step 4 : Zero sintering" on page 36) . The zero sintering value will then be displayed . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 54: Loading The Feeding Piston

    . The amount of powder after filling the feeding piston must not exceed the height of the horizontal grooves from the feeding piston liner, to not prevent the implementation of the compacting unit . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 55: Creating The Powder Bed

    . If the powder bed is not properly completed, re-run the powder bed cycle . Proceed the next section only if the powder bed cycle is properly completed . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 56: Cleaning The Laser Optic System

    - Assay: ≥99.8% (based on denaturant-free substance) Holding the optical paper towel by both ends, wipe the towel over the lens from the top to the bottom . Use the clean air aerosol to blow away any dusts . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 57 15 . Close the head-lens assembly, making sure that the mechanical stop is in localized contact with the head-lens support (9) . Head-lens support Mechanical stop Tighten clamp 16 . Tighten the assembly (9) . Excessive tightening could damage the localized contact . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 58: Inerting The Manufacturing Chamber

    Continue step by step as described above, up to layer #5 . • If all five layers completed successfully on the first try, then start the full manufacturing in automatic mode. Make sure that during the first 10 layers, there is no short feed. 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 59: Unloading A Plate

    Put the natural fiber brush and the hex key wrench on the airlock, and close the airlock door. Only for powders oxidizable materials, purge the airlock for 5 minutes, then stop the purge . Rotate the airlock to CLOSE position . Put the gloves and open the glove doors . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 60 19 . Rotate the airlock in OPEN position . 20 . Open the airlock door . 21 . Remove the sintering plate . 22 . Close the airlock door . 23 . Proceed to the next section . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 61: Manufacturing Chamber Cleaning

    When left side cleaning complete, move back the carriage to the left (position 0) . Clean the whole chamber, in front and behind the pistons (5) . Brush the unsintered powder into the collecting cans . Make sure not to put powder behind the protection bellow (6) . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 62: Powder Collecting Cans Removal

    15 . Remove the collecting cans from the airlock . 16 . Close the airlock door . 17 . Close the front doors . 18 . Use a sieving system to sift the usable powder for the next job . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 63: Closing / Opening Px Control Application

    59) . Close the gas valve (1) and compressed air valve (2) located on right side of the printer . Switch the locking key to position "0" . Turn off the main switch (3) . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 64: Reasonably Foreseeable Misuse

    . Do not confirm the lens filter replacement warning message without actually replacing the filter. Maintenance The level of filter clogging impacts the quality of the sintering process. 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 65: User Maintenance

    WARNING: FINE METAL DUST IS HIGHLY FLAMMABLE . AVOID USING ANY IGNITION SOURCE NEAR THE MACHINE (OPEN FLAME, SPARKING, ELEVATED TEMPERATURE PARTS) . SERVICING: REPLACEMENT PROCESS FILTER PROCEDURE 1500 ITEM SPECIFICATION HOURS External Filter vessel Replace 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 66: Process Filter (External Filter)

    This procedure must be followed to ensure efficient sintering during the machine operation and also the operator’s safety during maintenance . 3D Systems recommends that you execute this procedure as written and have a Class D extinguisher available when performing this procedure .
  • Page 67 OR OPENED BY UNAUTHORIZED PEOPLE . WARNING: DO NOT START THE LENS CLEANER BLOWER WHILE THE PROCESS FILTER IS NOT CONNECTED TO THE PRINTER . Tools: • Permanent marker • 10mm wrench • 5mm Allen wrench 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 68 Step 2 is performed to disconnect filter from machine. When changing the filter, leave the pneumatic valves on the tubes. Only open the clamps on the filter vessel (as indicated below), and remove the valves from the vessel . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 69 Repeat the step 2 for the filter inlet port connection. When complete, proceed to step3. The filter is completely sealed off and safe to be handled and transported. Move filter cart to unloading area. 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 70 Reload a new clean filter on the transportation cart. Make sure the new filter is installed with the filter inlet and filter outlet ports oriented as shown . Attach the grounding wire to the filter removed previously. Remove the tape seals from the filter inlet and filter outlet ports. 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 71 Store the cover lid in a safe area. This cover lid will be needed to close the dirty filter on the next replacement (for example, in a closed bag attached to the cart) . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 72 12 . The machine has to do a purge cycle, in order to fill the filter with inert gas, because during connection of filter to machine, the argon in the filter may be lost. Refer to the section "Step 8 : Loading of the manufacturing file and inerting" on page 40 . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 73: Preventive Maintenance Schedule

    PREVENTIVE MAINTENANCE SCHEDULE Maintenance not listed on this section is only allowed to be performed by 3D Systems-certified Customer Support Engineer. ONCE A EVERY 3 EVERY 6 ITEM SPECIFICATION EVERY YEAR MONTH MONTHS MONTHS Air pressure Check : 5 .5 bar Pinch valve pressure Check : 3 .5<X<4 bar...

  • Page 74: Every 3 Months Maintenance

    Grasp the glove, • Stretch to seal close, • Roll up the glove by pressing against body, • Listen for leaks . If glove damaged, replace them with new one: • Glove reference : 1001619U00 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 75: Front And Back Casings Cleaning

    WARNING : STATIC HAZARD . METAL PARTICLE CONDENSATES INSIDE THE PRINTER ARE HIGHLY COMBUSTIBLE AND SHOULD BE KEPT AWAY FROM SOURCES OF POTENTIAL IGNITION . WEAR ANTI-STATIC CLOTHING, ANTI-STATIC SAFETY SHOES, STAND ON GROUNDED ANTI-STATIC FLOOR PAD . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 76 WARNING : STATIC HAZARD . METAL PARTICLE CONDENSATES INSIDE THE PRINTER ARE HIGHLY COMBUSTIBLE AND SHOULD BE KEPT AWAY FROM SOURCES OF POTENTIAL IGNITION . WEAR ANTI-STATIC CLOTHING, ANTI-STATIC SAFETY SHOES, STAND ON GROUNDED ANTI-STATIC FLOOR PAD . 3D SYSTEMS, INC. PN:80-D48 REV A...
  • Page 77 Caution: make sure not to damage the protection bellow during cleaning . 16 . Put back the cover panel and secure it by tightening the screws . 17 . Close the rear doors of the printer . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 78: Exhaust Filter Replacing

    Clean the filter guard with the use of damp cotton cloth, and install the new filter element. Replace the filter guard, and open the input valve. Close the left side door and the door located below the front doors of the machine . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 79: Every 6 Months Maintenance

    PLACE THE USED FILTER ELEMENT IN A CLOSED METALLIC CONTAINER IN A ROOM WITH FIRE DETECTION . Clean the filter guard with the use of a damp cotton cloth. Install the new filter element. Install the filter guard. Close the access door located below the main cabinet . 3D SYSTEMS, INC. PN:80-D48 REV A...

  • Page 80: Every 1 Year Maintenance

    The calibration must be controlled once a year . As explained on the procedure, the control of the calibration will require to draw a calibration plate and to retrieve the current printer correction file (xml format) that both must be sent to 3D Systems Customer Support for analysis.
  • Page 81 19 . Inspect visually the sintered lines are homogeneously well marked over the whole surface of the plate (1) . If the result is not correct (2), repeat the draw on a new calibration plate . If the result is still no correct, contact 3D Systems Customer Support .

  • Page 82: Copyright And Trademark Notice

    COPYRIGHT AND TRADEMARK NOTICE Copyright © 2017 3D Systems, Inc . All rights reserved . Subject to change without notice . This document is copyrighted and contains proprietary information that is the property of 3D Systems, Inc . 3D Systems, the 3D Systems logo, and ProX are trademarks of 3D Systems, Inc .
  • Page 83 3D Systems, Inc. 333 Three D Systems Circle | Rock Hill, SC 29730 | USA www.3dsystems.com ©2017 3D Systems, Inc. All rights reserved. PN: 80-D48 RevA...

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