3D Systems ProX 500 User Manual
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3D Systems ProX 500 User Manual

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ProX™ 500
3D Production Printer
User Guide
Original Instructions

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  • Page 1 ProX™ 500 3D Production Printer User Guide Original Instructions...

  • Page 2: Table Of Contents

    Laser Certification (And Machine Identification) Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3D Systems, Inc.
  • Page 3 To Use the Add Powder Layer Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Change the settings for each parameter in the Add Powder Layer dialog box to the settings you want, then click the Add 3D Systems, Inc.
  • Page 4 Cleaning the Laser Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 3D Systems, Inc.
  • Page 5 Drain Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 3D Systems, Inc.

  • Page 6: Introduction

    . ABOUT THIS GUIDE This guide describes how to operate and maintain your ProX 500 3D Printer, ProX Material Quality Control (MQC) System, and auxiliary equipment used for the SLS process . For part printing instructions, refer to the for your specific material.

  • Page 7: Introduction To The Prox™

    . Designed for smooth integration with your manufacturing workflow, the ProX 500 produces parts for a variety of end-use and functional prototyping applications in aerospace, medical, industrial design and more . Use the ProX 500 and DuraForm plastic materials to produce ®...
  • Page 8 ProX MATERIAL QUALITY CONTROL (MQC) SYSTEM The MQC System is designed to be used as the material handling unit for the ProX 500 SLS line of printers . It is responsible for delivering material to the printer, storing and mixing fresh and used material, and breaking out the SLS parts from the print cake which is produced by the printer .
  • Page 9 . The tag must be scanned to unlock the Fresh Material Input doors and add the material to the system . MQC System Operator Controls: User interface for operation of the MQC System . 3D Systems, Inc.
  • Page 10 Printer B . (for service personnel only) . AC Inlet: Power connection for MQC System . 3D Systems Nitrogen Generator Connection: If you have purchased a Nitrogen Generator from 3D Dust Collector Port: Connection for the dust Systems, it is connected here .

  • Page 11: Auxiliary Sls Equipment

    AUXILIARY SLS EQUIPMENT There are several auxiliary components which can accompany the ProX 500 system . The Nitrogen Generator and Bead Blaster (optional) are shown below . Nitrogen Generator Bead Blaster (Optional) 3D Systems manufactures a High-Performance Nitrogen Generator If you plan to use DuraForm SLS material, 3D Systems —...

  • Page 12: Prox 500 System Components

    ProX 500 SYSTEM COMPONENTS ProX 500 User Interface The User Interface, located on the front panel of the printer, consists of a touchscreen and the system status LED indicators . An E-Stop is located above the touchscreen . This switch, located above the touchscreen, immediately disables all hazardous machine functions or Emergency Stop: renders them safe .
  • Page 13 System Enable: This button re-enables the system following an emergency stop, which occurs after the emergency stop switch returns to the open state . USB: A standard auxiliary USB port connected to the control PC is located under the LED Indicators . 3D Systems, Inc.
  • Page 14 . It is part of a wider system of electronic ProX 500 Computer components (Field-Programmable Gate Arrays, Digital Signal Processors, etc .) which control the hardware of the system . ProX 500 Rear View 3D Systems, Inc.

  • Page 15: Part Transfer Cart Assembly

    Cylinder, Part Transfer Tray Part Cart, are used to remove the print cake from the ProX 500 print Transfer chamber and transport it to the MQC System . The system ships with the cylinder and tray . The transfer cart is optional .

  • Page 16: Mqc System Components

    System warning active and/or E-Stop condition or Yellow System is in service mode message present on user interface normal System is active . Printer System is active . Printer transports E-Stop condition or Green transports are enabled are disabled normal 3D Systems, Inc.

  • Page 17: Sifter Switch

    The material input hatch takes fresh material from the user and feeds it to the MQC System. To unlock the hatch, the user must first swipe the tag of the material container across the tag reader . Material Hatch Tag Reader 3D Systems, Inc.

  • Page 18: Safety Guidelines And Instructions

    Certified service personnel • are those who have completed the 3D Systems service training package and are certified to perform service tasks. Certification may occur at various levels, and servicers should only perform tasks they are authorized and certified to complete.

  • Page 19: Safety Symbols And Definitions

    CAUTION: Indicates something may happen that could cause loss of data, damage to equipment, or personal injury . CRUSH HAZARD: Injury or death from crushing weight . NOTCHED BELT ENTANGLEMENT: Injury or death from entanglement in notched pulley drive belt . 3D Systems, Inc.

  • Page 20: 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 SLS system contains equipment energized at 208 volts, 3-phase delta . Do not attempt to remove protective panels . There are no user serviceable parts inside .

  • Page 21: Sls Equipment Safety Features

    . If you suspect a safety interlock device is not working properly, do not operate your SLS equipment . Rather, disconnect power from the equipment and contact 3D Systems Customer Support for assistance . SLS System Response if an Interlock Fails Safety interlock devices mounted on the SLS system sense the hazardous operating conditions below .

  • Page 22: Other Active Safety Features

    The SLS system emits no toxic substances when using materials approved by 3D Systems . Emissions Material heating – Analytical testing on 3D Systems materials indicates no detectable emissions outside acceptable limits from the SLS system . (See the materials’ SDS .) Nitrogen –...

  • Page 23: Laser Safety

    (panel or door), you can be exposed to hazardous direct and scattered Class 4 invisible laser radiation which can cause severe burns and eye injury, or start a fire. LASER CERTIFICATION/IDENTIFICATION Identifies laser system Class and shows CDRH Statement of Compliance. 3D Systems, Inc.

  • Page 24: Laser Radiation Hazard Label Locations

    Laser Radiation Hazard Label Locations Print Chamber Enclosure Interlocked Protective Housing Laser Label Locations Laser Panels Blackbody Sensor Print Chamber Door 3D Systems, Inc.

  • Page 25: Laser Certification (And Machine Identification) Label Location

    Air Processing Module Laser Certification (And Machine Identification) Label Location 3D Systems, Inc.

  • Page 26: 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 27: Material Safety Information

    Material Handling Precautions During normal operation of the SLS system using 3D Systems’ materials, you are not required to wear a dust mask or special personal protection equipment unless specifically designated. Check the SDS of the material used for the specific precautions you should observe .

  • Page 28: Nitrogen/Oxygen Safety

    Recovery with treatment within 4 to 5 minutes . 4 – 6 % Coma within 40 seconds; convulsions, respiration ceases, death occurs . a . From Safety Bulletin SB-2 - 1983—”1983 by the Compressed Gas Association, Inc . 1235 Jefferson Davis Highway, Arlington, VA 22202 3D Systems, Inc.

  • Page 29: Mechanical Motion, Electrical Hazards, And Hot Surfaces

    MECHANICAL MOTION, ELECTRICAL HAZARDS, AND HOT SURFACES You should be aware of the following pinch, crush, rotating blade, heat, and electrical hazard locations on the SLS equipment: Print Chamber Enclosure Hopper Feed Module Disconnect Switch Blackbody Sensor Inner Print Chamber Door 3D Systems, Inc.

  • Page 30: Hot Surfaces In The Print Chamber

    Use appropriate gloves when removing the print cake from the print chamber, or let the print cake cool for several hours before you touch it . Inside of Print Chamber IR Sensor Feed Hopper Allow system to cool with door open after printing Heaters Print Chamber floor will be extremely hot after printing 3D Systems, Inc.

  • Page 31: Printing Parts With The Prox 500

    2 . Clean laser window (See the section, “Cleaning the Laser Window” on page 3 . Check the overflow screen which is located at the lower-left side of the ProX 500 and clean, if necessary. (See the section, “Cleaning and Replacing Filters” on page 4 .

  • Page 32: Set The Mqc System To Full Cycle Mode

    7 .5kg has been added from the container . The MQC System must be in Full cycle mode for material to be sent from the blended bin to the ProX 500 . Before selecting Full or Local cycle mode, the user should verify that the desired blend ratio is selected . (See Material Guide for recommended ratio .) 11 .

  • Page 33: Prox 500 Start-Up Sequence

    ProX 500 START-UP SEQUENCE If you’re starting the printer from it’s powered-off state, you must first perform the following machine start-up sequence before you start a print: • Start the chiller • Verify the system’s compressed air • Verify the system’s nitrogen supply •...

  • Page 34: Setting Up A Build Packet

    . The Build Setup application contains extensive online help with further details pertaining to the operation of the software . Build Setup can be launched and run on the computer connected to the ProX 500 or on a standalone computer . If you are using Build Setup with an offline (standalone) computer, you must export the .bpf file which creates a .bpz file, a compressed zip file that contains...

  • Page 35: Reposition Parts In The Workspace (Build Volume)

    NOTE: If you are using Build Setup with an offline (standalone) computer, you must export the .bpf file which creates a .bpz file, a compressed zip file. You must then copy this file to the ProX 500 computer. The .bpz file must be...

  • Page 36: Run Sinter Application

    For instructions on breaking out the parts from the print cake at the MQC System, refer to the section, “Breaking Out Parts” on page 47 . For post-processing parts, refer to the Material Guide for your specific material. 3D Systems, Inc.

  • Page 37: Prox 500 System Operations

    PROX 500 SYSTEM OPERATIONS Many of the basic operations and components of the ProX 500 have been covered in the previous sections of this manual . These will be referenced under the appropriate headings below . Remaining details will be described here .

  • Page 38: Restarting A Terminated Build

    . You can toggle this option on or off by selecting it . When checked, the system displays a dark Dark background background in the Build Viewer window . 3D Systems, Inc.

  • Page 39: Pausing A Build

    If you make changes near the current Z, the system may not be able to apply them . If you do not get the message The parameter change has been applied after clicking Apply, try again at a higher Z . (There is no message when the attempt fails .) 3D Systems, Inc.

  • Page 40: Adding And Deleting Parts And Other Changes

    . When a Build Ends At the end of a build, the Sinter application displays a summary of the actual build times such as the example below: 3D Systems, Inc.

  • Page 41: Manual Operations

    Before you can do either, these dependencies must be met: • SLS system start-up is complete and Sinter is running . Refer to the section, “ProX 500 Start-Up Sequence” on page 33 . • The Add Powder Layer window is closed .

  • Page 42: The Following Parameters Are Available To Set In The Add Powder Layer Dialog

    . NOTE: If the IR sensor core temperature is below 77 °C, the offline IR Calibration will wait until 77 °C has been reached, and then an additional 5 minutes for the core to stabilize . 3D Systems, Inc.

  • Page 43: Mqc System Operations

    The MQC System regulates the material usage for the ProX 500 . It stores and mixes fresh, blended, and recycled powder and can supply material for one or two ProX 500 printers. Each printer sends a separate refill request to the MQC System when its feed hopper is low .

  • Page 44: Shutting Down The Mqc System Completely

    Cleaning the MQC System Before Breakout Follow these procedures to clean the system before you print parts with your ProX 500 printer . 1 . Debris and loose powder from the MQC System can be cleaned up using a non-ignition vacuum cleaner .

  • Page 45: Unloading The Print Cake After A Print

    6 . With the handle facing towards you, fully insert the print cake cylinder into the print chamber, placing it over the print bed . Full insert print cake cylinder into chamber Make sure the outer tabs of the cylinder catch on the rim of the print chamber door . 3D Systems, Inc.
  • Page 46 14 . Slide the cylinder and tray out of the chamber and onto the cart . Align cart with print chamber Slide tray and cylinder onto cart 15 . Move the transfer cart to the MQC System . 3D Systems, Inc.

  • Page 47: Breaking Out Parts

    . 3D Systems recommends you also purchase a glass bead blaster (pneumatic blast cabinet). A bead blaster makes fine cleaning much easier and faster . See your Facility Guide for recommended third party suppliers .

  • Page 48: Mqc System User Interface Settings

    Navigate to the System Setup and Service screen . (Only the Setup screen is available to general users . The Service screen is only for use by 3D Systems Certified Technicians) The Activate Svc mode and Deactivate Svc mode options are only available to service personnel .

  • Page 49: Mqc System User Interface Settings

    Shows amount of powder in MQC bins (Kg and Liters) and the amount of powder re- quired to begin a powder blend . • F - Fresh powder bin • R - Recycled powder bin • B - Blended powder bin • Sifter status • Cooling lid status 3D Systems, Inc.

  • Page 50: Mqc Main Control Screen

    Change Sifter Mode • – Navigate to submenu . (only the Setup screen is available to general users . Service and Diag screens are Setup/Service/Diag only for use by 3D Systems Certified Technicians) • – Service RFID tag required Activate Service •...

  • Page 51: Operational Mode Screen

    Change replenish percentage for blending • Change sifter timeout To Load Fresh Powder 1 . After is selected, quickly press and release knob to display the following screen . Stop Cycle 2 . Rotate knob to select Load Fresh Powder . 3D Systems, Inc.

  • Page 52: Quickly Press And Release Knob To Display The Following Screen

    1 . Quickly press and release knob to display the following screen: 2 . Rotate control knob to select and quickly press and release knob . Service/Service/Diag 3 . Rotate control knob to select and quickly press and release knob to display the following screen: Setup 3D Systems, Inc.
  • Page 53 Select Change 7 . Push knob again to go back to mode . Select 8 . Continue to rotate until the selection is adjacent to the OK and push knob again (this will save your changes) . 3D Systems, Inc.

  • Page 54: Diagnostics Screen

    Minimum Fresh Blend Percentage: The minimum percentage of fresh material that is available for blending . • Maximum Fresh Blend Percentage: The maximum percentage of fresh material that is available for blending . • Max Recirculation Period: The maximum time (in seconds) that recirculation will take place . • 3D Systems, Inc.

  • Page 55: Used-Bin Diag Screen

    Transporter air on/off: Indicates whether or not the air responsible for transporting the • material out of the transporter is on or off . Weight: Gives the weight of the material in the blended bin . • Pressure: Gives the air pressure from the transporter . • 3D Systems, Inc.

  • Page 56: Sifter Diag Screen

    Part Cake 2 (thermocouple) temperature: Gives the temperature of the second thermocouple used to measure the temperature • in the part cake . Digital Output temperature: Gives the temperature of the digital output on the controller board of the MQC System . • 3D Systems, Inc.

  • Page 57: Maintenance Procedures

    PRINT CHAMBER MAINTENANCE Replacing Light Bulbs in the Process Chamber There are two light bulbs located on the heater assembly of the print chamber . If one or both of them burns out, contact 3D Systems Field Service . Cleaning the Print Chamber Before any new print job, clean the print chamber .

  • Page 58: To Clean The Print Chamber

    Use the Roller button to move the roller . Unlatch and open the print chamber doors . Brush material in the area that had been covered by the roller into the overflow, then clean the area with a non-ignition 3D Systems, Inc.

  • Page 59: Tools And Supplies

    . 2 . The laser window is enclosed in the baffle assembly. Remove the top cover of the assembly using a Laser window on clean cloth Cover when not in use 3D Systems, Inc.
  • Page 60 5 . Remove the O-ring and wipe it clean . 6 . Replace the O-ring into the laser window baffle assembly. O-Ring Side of lens that needs to be cleaned Remove and clean O-Ring Replace into baffle assembly 3D Systems, Inc.
  • Page 61 25 . Cover the lens using a lens tissue and weigh down with the tissue box . Replace top ring and fasten Replace lens Ensure O-Ring is visible and Cover when not in use with 2 .5mm allen wrench lens is flush with housing 3D Systems, Inc.

  • Page 62: Replacing The Laser Window

    4 . Use a dry swab to dry the black body . Repeat until clean . Cleaning the Exhaust Port To clean the exhaust port inside the print chamber, use a non-ignition vacuum cleaner to remove any debris that has accumulated . Print chamber showing exhaust port 3D Systems, Inc.

  • Page 63: Cleaning And Replacing Filters

    CLEANING AND REPLACING FILTERS There are several filters on the ProX 500 and MQC System that need to be cleaned or replaced periodically. It is suggested that each of them be checked weekly and replaced as necessary: ProX 500 Filters •...

  • Page 64: Electrical Enclosure Filter

    4 . Replace the filter cover. 5 . Close the printer door . “Sock” Filter 2-Stage Hepa Filter Thumb Screws Hepa Filter Electrical Enclosure Filters 2-Stage Hepa Filter (located on both sides of the enclosure) (Also located at rear of MQC System) 3D Systems, Inc.

  • Page 65: Chiller Maintenance

    When the chiller is free of fluids, open the drain filter housing at the rear of the chiller and uninstall/ reinstall a Pentek CW-F Polypropylene Wound Filter (Scott Equipment #155186-43) . Air vent filter replacement Drain filter replacement 3D Systems, Inc.
  • Page 66 EC Declaration of Conformity La Déclaration de CE de Conformité We, 3D SYSTEMS, INC. herewith declare that the following described machine in our delivered version complies with the basic safety and health requirements of the EC Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006, based on its design and type, as brought into circulation by us.
  • Page 67 3D Systems, Inc . 333 Three D Systems Circle | Rock Hill, SC | 29730 www .3dsystems .com ©2015 3D Systems, Inc . All rights reserved . pn 134012-00 Rev . C...

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