Page 1: Table Of Contents
August 2017 Document 23348-M12-00 Copyright © 2006 by 3D Systems Corporation. All rights reserved. 3D Systems, the 3D logo, Sinterstation, sPro, SLS, and DuraForm are registered trademarks of 3D Systems, Inc. Other trademarks are the property of their respective owners.
Page 2 DuraForm® PA plastic sPro SLS® system powder laser sintering (LS) material using 3D Systems’ SLS equipment. What’s Inside?......3 Instruction Formats .
Page 3: About This Guide
To verify that your facility was properly Build Parts – how to run builds on the SLS prepared for SLS system installation, see the system, and how to monitor, control, and modify sPro Process Facility Guide and SLS Process a build in progress.
Page 4 SLS p r o c e s s A B O U T T H I S G U I D E u s e r ’ s g u i d e w h a t ’ s i n s i d e ? Breakout Parts –...
Page 5: Hazard Warnings
SLS p r o c e s s A B O U T T H I S G U I D E u s e r ’ s g u i d e h a z a r d w a r n i n g s Ha za rd Warnings You will find nine different types of warnings in See the...
Page 6: Instruction Formats
SLS p r o c e s s A B O U T T H I S G U I D E u s e r ’ s g u i d e i n s t r u c t i o n f o r m a t s I n s t r u c t i o n Fo r m at s Instructions in this guide use special text formats Operator Panel Buttons...
Page 7: Other Useful Documents
To order extra printed copies of these MSDS’s, SLS Process Facility Guide – details SLS contact 3D Systems Customer Support. process requirements for facility electrical power, room construction and atmosphere, Build Setup Help – provides detailed...
Page 8 SLS process. Each Material Guide describes SLS processing characteristics for one family of 3D Systems’ DuraForm powder materials, such as DuraForm PA. They also include safety and regulatory guidelines for DuraForm material handling.
Page 9: Safety
Label and point out hazardous equipment, Provide information about the hazards of materials, and procedures. equipment and materials in the form of Material Safety Data Sheets. These are ✓ Explain what to do in an emergency provided with all materials supplied by situation. 3D Systems.
Page 10: General Safety Guidelines
• Certified service personnel are those To prevent crush injuries to the body, use who have completed the 3D Systems extra caution when rolling the into and service training package and are certified out of the SLS system and BOS, and when to perform service tasks.
Page 11 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e g e n e r a l s a f e t y g u i d e l i n e s Alarms and Warnings Dress electrical cables, powder transport tubing, and coolant hoses to prevent...
Page 12: 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.
Page 13 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e S L S e q u i p m e n t s a f e t y f e a t u r e s SLS SYSTEM RESPONSE IF AN INTERLOCK FAILS Safety interlock devices mounted on the SLS system sense the hazardous operating conditions...
Page 14 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e S L S e q u i p m e n t s a f e t y f e a t u r e s Other Active Safety Features Laser beam optics and scanning areas,...
Page 15: Safety Labels
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e s a f e t y l a b e l s S afe t y L ab el s Safety labels are posted on all SLS process machines.
Page 16 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e s a f e t y l a b e l s SAFETY LABEL WHAT IT MEANS CRUSH HAZARD Mechanical motion of machine components presents a crush hazard in the vicinity of this sign.
Page 17: Electrical Safety
✓ Only 3D Systems certified service personnel are closed. should operate SLS equipment with access Hazardous voltage exists inside the panels or service doors open.
Page 18: Issues
The SLS system uses nitrogen, which SLS system(s) and RCM(s). must be passively vented to the outside. Use the sPro SLS system, RCM-140, and Do not install a fan in the nitrogen vent. RCM-230 electrical power requirements below nitrogen-inert atmosphere in the SLS system...
Page 19: Environmental Issues
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e e n v i r o n m e n t a l i s s u e s Noise Levels The following table quantifies the noise levels for various components of the SLS system.
Page 20: Laser Safety
U. S. Department of Health and Human within a day of the accident. The information can Services, Public Health Service, Food and Drug be sent by regular mail to 3D Systems marked Administration, Center for Devices and “Attention: Laser Safety Officer” or by e-mail to...
Page 21 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e l a s e r s a f e t y Laser Safety Labels on the SLS system The SLS system has the two types of laser safety labels below.
Page 22 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e l a s e r s a f e t y LASER RADIATION HAZARD LABEL LOCATIONS Behind raised laser window access door Behind the process...
Page 23 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e l a s e r s a f e t y DEFEATABLY INTERLOCKED PROTECTIVE HOUSING LASER LABEL LOCATIONS CAUTION CLASS 4 INVISIBLE LASER RADIATION WHEN OPEN AND...
Page 24 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e l a s e r s a f e t y LASER CERTIFICATION (AND MACHINE IDENTIFICATION) LABEL LOCATION Laser certification on machine ID label Machine ID label at left rear of...
Page 25 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e l a s e r s a f e t y General Laser Safety Rules Do not operate the SLS system with a broken Use of controls or adjustments, or or missing window.
Page 26 3D Systems- SLS laser or beam delivery system. When this certified service technicians. occurs, certified service personnel at your site Attempts by non-3D Systems-...
Page 27 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e l a s e r s a f e t y Certified service personnel should notify and instruct everyone in the area to wear safety glasses (ANSI Z136.1-1993 section 4.6.2 and ANSI Z87.1;...
Page 28: Powder Safety
’ s g u i d e p o w d e r s a f e t y Powde r S afet y All powders certified by 3D Systems are safe Powder Ignition Information during normal operation. However, you should...
Page 29 Specific powdered Material Safety Data Sheets (MSDS) from ystems, Inc.: materials US/Canada: Europe 3D S Mfgr. Contact: 3D Systems Corporation ystems GmbH 333 Three D Systems Circle Guerickeweg 9 Rock Hill, SC 29730 USA D-64291 Darmstadt, Germany Information Phone: 803-326-4080 or...
Page 30 Powder Handling Precautions During normal operation of the SLS system using 3D Systems’ materials, you are not required to wear a dust mask or special personal protection equipment unless specifically designated. Check...
Page 31 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e p o w d e r s a f e t y Safe Powder Handling Guidelines (continued) CATEGORY PRECAUTION •...
Page 32: Nitrogen/Oxygen Safety
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e n i t r o g e n / o x y g e n s a f e t y N i t ro g e n / Ox yg e n S a fet y The SLS system uses nitrogen to create an inert The table of...
Page 33 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e n i t r o g e n / o x y g e n s a f e t y Oxygen Deprivation Effects and Symptoms OXYGEN CONTENT (% BY VOLUME)
Page 34: Mechanical Motion Hazard Locations
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e m e c h a n i c a l m o t i o n h a z a r d l o c a t i o n s M e c h a n i c a l M o t i o n H a z a rd Lo c at i o n s You should be aware of the following pinch, crush, and rotating blade hazard locations...
Page 35: Hot Surfaces And Powders
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e h o t s u r f a c e s a n d p o w d e r s H o t S u r f a ce s a n d Powde r s The SLS system process chamber and the RCM both contain heaters.
Page 36: Duraform Material Handling Safety
IPC to the sources. Integrated Recycling Station (IRS), and contact 3D Systems Customer Support Hotline. If no Never try to open an IPC. Material leakage or damage is observed, store the full IPCs must only be removed from the IPC...
Page 37: Ipc Handling Safety
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e I P C h a n d l i n g s a f e t y I P C H a n d l i n g S a fe t y DuraForm material ships in a recyclable, palletized container called an IPC.
Page 38 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e I P C h a n d l i n g s a f e t y Lifting and Moving the IPC The IPC is designed to always remain in its built- in crate.
Page 39: Shutdown
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e s h u t d o w n Shutdow n Unless there is an Depressurization Emergency emergency, always The SLS system, IRS, and BOS all connect to...
Page 40: Emergency Shutdown
SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e e m e r g e n c y s h u t d o w n E m e rg e n c y Sh u td ow n Every SLS process machine has at least one large red emergency stop button (“E-Stop”).
Page 41 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e e m e r g e n c y s h u t d o w n SLS Process Machine E-Stop Locations and Effects (continued) MACHINE E-STOP LOCATIONS...
Page 42 SLS p r o c e s s S A F E T Y u s e r ’ s g u i d e e m e r g e n c y s h u t d o w n SLS Process Machine E-Stop Locations and Effects (continued) MACHINE E-STOP LOCATIONS...
Page 43: Sls Process
SLS p r o c e s s u s e r ’ s g u i d e S L S P R O C E S S This section introduces you to ystems’ unique SLS process and the SLS equipment you use 3D S to go from powder to parts.
Page 44: What Is The "Sls Process
SLS is performed by machines called SLS systems; the most widely known model of which is the sPro® SLS system. SLS technology is in wide use around the world due to its ability to easily make very complex geometries directly from digital CAD data.
Page 45: Sls Process Overview
SLS p r o c e s s S L S P R O C E S S u s e r ’ s g u i d e S L S p r o c e s s o v e r v i e w SLS Pro cess O ver view ➊...
Page 46 SLS p r o c e s s S L S P R O C E S S u s e r ’ s g u i d e S L S p r o c e s s o v e r v i e w ➎...
Page 47 Inert and Pre-Heat steps can be If you’re using liquid nitrogen tanks (instead disregarded, as these functions occur of the 3D Systems Nitrogen Generator), open automatically upon starting the build. If the build set-up has not been performed, inerting the nitrogen supply valve at the tank.
Page 48 SLS p r o c e s s S L S P R O C E S S u s e r ’ s g u i d e S L S p r o c e s s s t e p s Once the Part Piston has been homed, When the build has completed, open the maximize the Sinter application and select...
Page 49: About Sls Equipment
23 cm (9 in) taller than the model 140. This enables the model 230 to build taller parts in a taller RCM. The “140” and “230” sPro model numbers indicate the maximum part cake build volume for the machines; i.e, 140 liters or 230...
Page 50 SLS p r o c e s s S L S P R O C E S S u s e r ’ s g u i d e a b o u t S L S e q u i p m e n t IRS &...
Page 51: About Installation And Facility Requirements
These addresses are used by the beam delivery system. If this presents a problem, contact the The pre-installation facility checklist must be 3D Systems Customer Support Hotline completed and returned to 3D Systems Customer technical assistance. Support before you can schedule installation.
Page 52: About The Powder Management System
SLS p r o c e s s S L S P R O C E S S u s e r ’ s g u i d e a b o u t t h e p o w d e r m a n a g e m e n t s y s t e m Ab o u t t h e Powde r M a n a g e m e nt Sys te m 3D System’s Powder Management System When does the IRS send data to APMU?
Page 53: Adding Sls Process Capacity
SLS p r o c e s s S L S P R O C E S S u s e r ’ s g u i d e a d d i n g S L S p r o c e s s c a p a c i t y Ad d i n g S L S Pro ce s s Cap a c i t y You can grow your capacity to produce SLS parts Use multiple RCM’s...
Page 54 SLS p r o c e s s S L S P R O C E S S u s e r ’ s g u i d e a d d i n g S L S p r o c e s s c a p a c i t y Use multiple SLS systems To increase capacity further, use one IRS to service up to three SLS systems, all building concurrently and continuously.
Page 55 SLS p r o c e s s u s e r ’ s g u i d e P R E P A R E T O B U I L D This section describes what you need to do before you can build parts in the SLS system. It steps you through the following procedures: Setting Up a Build Packet .
Page 56: Prepare To Build
SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e s e t t i n g u p a b u i l d p a c k e t S et t i n g U p a B u i l d Pac ke t The instructions in this section summarize the Reposition parts in build volume...
Page 57 SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e s e t t i n g u p a b u i l d p a c k e t Add tab in Build Setup Main view...
Page 58 SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e s e t t i n g u p a b u i l d p a c k e t Save and Verify Build Packet When all parts are arranged and parameters are set, the last step is to save and verify the build...
Page 59: Cleaning And Checking Equipment
SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e c l e a n i n g a n d c h e c k i n g e q u i p m e n t Cleaning and Check i ng Equipment Follow these procedures to clean the Clean the overflow screens...
Page 60: Starting The Equipment
SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e s t a r t i n g t h e e q u i p m e n t Star ting the Equipment You need to power-on and start all your IRS start-up...
Page 61 SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e s t a r t i n g t h e e q u i p m e n t To save time, connect the RCM now and begin POWER-ON SLS SYSTEM preheating it, then continue starting the other...
Page 62 SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e s t a r t i n g t h e e q u i p m e n t RUN SINTER APPLICATION SLS SYSTEM MACHINE START-UP SEQUENCE Login to Windows.
Page 63 RCM lift air pressure on the SLS system Check pressure and flow gauges. gauge panel. The air pressure gauge labels indicate their correct readings. These are: sPro 140 lowh air pressure 350 kPa (51 psi) 350 kPa (51 psi) highv air pressure...
Page 64 IRS will commence automatic operation; (...it GAUGE PRESS. FLOW may be blending or transporting powder to Laser Window N2 105 kPa 7 lpm the sPro on demand). N2 Makeup Flow 105 kPa 0 lpm BOS start-up IR Sensor Flow 200 ccm Laser Coolant...
Page 65: Unloading The Ipc
SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e u n l o a d i n g t h e I P C U n l o a d i n g t h e I P C When the green light is on steady and the BOS operator panel display says...
Page 66 SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e u n l o a d i n g t h e I P C Connecting an IPC to an IRS After the pressure sensor line, umbilical, and ground wire are connected to the IPC, put the IRS...
Page 67 SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e u n l o a d i n g t h e I P C Powder flow.
Page 68 ( e m p t y ) SLS p r o c e s s ( e m p t y ) u s e r ’ s g u i d e...
Page 69: Docking The Rcm In The Sls System
SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e d o c k i n g t h e R C M i n t h e S L S s y s t e m D o c k i n g t h e RCM i n t h e S L S Sys te m After you (optionally) Before you start your...
Page 70: Pre-Build Checklist
At least 50 MB of hard-disk space on the SLS system computer. ✓ Enough nitrogen available (if you’re not using the 3D Systems Nitrogen Generator). ✓ The SLS system uses as much as 2800 liters gaseous nitrogen during the initial purge for a build, then up to 7 lpm during the build.
Page 71: Verifying Sufficient Powder
SLS p r o c e s s P R E P A R E T O B U I L D u s e r ’ s g u i d e v e r i f y i n g s u f f i c i e n t p o w d e r Ver i f y i n g S u f f i c i e nt Powde r You need to make sure You can start a build if...
Page 72 Once the powder has been leveled, and if the Roll the RCM into the void under the next build has not yet been set-up, minimize sPro. Be sure that the RCM is fully seated in the Sinter application and all of the sub- the void.
Page 73 SLS p r o c e s s u s e r ’ s g u i d e B U I L D P A R T S This section covers the tasks involved in building parts. Many of the procedures in this section are summaries of more detailed instructions in your Sinter application online Help.
Page 74: Build Parts
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e r u n n i n g S i n t e r Running Sinter You must start the SLS equipment before After about one minute, the DSPIF...
Page 75: Loading The Rcm
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e l o a d i n g t h e R C M Lo ading the RCM Before you load the RCM, verify that: Click the Man Ops button on the main Sinter...
Page 76: Homing The Part Piston And Roller
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e h o m i n g t h e p a r t p i s t o n a n d r o l l e r H o m i n g t h e Par t Pi s to n a n d R o l l e r After you load the RCM, After piston home, click Start Position...
Page 77: Messages In The Sinter Application
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e m e s s a g e s i n t h e S i n t e r a p p l i c a t i o n M e s s a g e s i n t h e S i nte r Ap p l i c at i o n When Sinter is running various types of messages appear in the Message List window (described below).
Page 78: Selecting The Display Language
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e s e l e c t i n g t h e d i s p l a y l a n g u a g e S el e c t i n g t h e D is p l ay L a n g u a g e You can select the language Sinter uses to display window titles, menu options, commands and...
Page 79: Adding & Leveling Powder
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e a d d i n g & l e v e l i n g p o w d e r Ad d i n g &...
Page 80 SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e a d d i n g & l e v e l i n g p o w d e r Add Powder Layer Parameters PARAMETER RANGE...
Page 81: Running A Build
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e r u n n i n g a b u i l d R u n n i n g a B u i l d Before you run a build, be sure you do everything When the file Open dialog appears, choose a...
Page 82: Restarting A Terminated Build
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e r e s t a r t i n g a t e r m i n a t e d b u i l d R e s t a r t i n g a Te r m i n ate d B u i l d If you terminate a build before completion, you may be able to restart it.
Page 83: Viewing A Build In Progress
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e v i e w i n g a b u i l d i n p r o g r e s s View ing a B ui l d I n Pro gres s During a build, the Build Viewer window Options on the Viewer Menu...
Page 84: Changing Heater Setpoints In-Build
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e c h a n g i n g h e a t e r s e t p o i n t s i n - b u i l d Ch a n g i n g H e ate r S e t p o i nt s I n - B u i l d During a build, you can change five critical heater setpoints in the Build Parts window.
Page 85: Sensor
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e c a l i b r a t i n g t h e I R s e n s o r Ca l i b rat i n g t h e I R S e n s o r This is a summary.
Page 86: Pausing A Build
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e p a u s i n g a b u i l d Paus i ng a B uil d When the Pause Build button is active, click on it to stop the build and display options.
Page 87: Modifying A Build In Progress
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e m o d i f y i n g a b u i l d i n p r o g r e s s M o d i f y i n g a B u i l d i n Pro g res s Make changes during a build with the Build Settings for Z levels below the current are...
Page 88 SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e m o d i f y i n g a b u i l d i n p r o g r e s s Adding and Deleting Parts and Other Changes Click the Add/Delete Parts button in the Build...
Page 89: When A Build Ends
SLS p r o c e s s B U I L D P A R T S u s e r ’ s g u i d e w h e n a b u i l d e n d s Wh e n a B u i l d E n d s At the end of a build, the Sinter application displays a summary of the actual build times such...
Page 90 SLS p r o c e s s u s e r ’ s g u i d e B R E A K O U T P A R T S When a build completes, you need to remove the sintered parts from the RCM part cake and clean them.
Page 91: Break Out Parts
SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e b r e a k o u t o v e r v i e w B re a ko u t O ve r v i ew When a build is complete, you need to remove Before breakout, you must:...
Page 92: Part Cake
SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e b r e a k o u t o v e r v i e w The table below summarizes your part cake PART CAKE PART CAKE COOLDOWN METHOD...
Page 93 SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e u n l o a d i n g r c m ( r e m o v i n g t h e p a r t c a k e ) ✓...
Page 94 SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e p o w e r - o n t h e B O S a n d d u s t c o l l e c t o r Power - o n t h e B O S a n d D u s t Co l l e c to r Before you turn on the BOS, make sure RCM cable is NOT connected to...
Page 95: Bos Start-Up
SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e B O S s t a r t - u p B O S Sta r t - u p After you power up the BOS as described above, start-up the BOS as follows:...
Page 96: Load & Raise Part Cake
SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e l o a d & r a i s e p a r t c a k e Lo a d &...
Page 97: Breakout Parts From Part Cake
SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e b r e a k o u t p a r t s f r o m p a r t c a k e B rea ko ut Par t s f ro m Par t Cake The part cake can remain extremely hot for hours after a build.
Page 98 SLS p r o c e s s B R E A K O U T P A R T S u s e r ’ s g u i d e d i s p o s e o f w a s t e p o w d e r D i s p o s e o f Was t e Powde r Connect BOS Disposing Powder...
Page 99: Part Finishing After Breakout
3D Systems recommends you also purchase a glass bead blaster (pneumatic blast cabinet). A bead blaster makes fine cleaning much easier and faster.
Page 100: Shutdown Bos
SLS p r o c e s s 1 0 0 B R E A K O U T P A R T S u s e r ’ s g u i d e s h u t d o w n b o s Shutdow n BO S Shutting down the BOS stops the following To shut down the BOS properly...
Page 101 SLS p r o c e s s u s e r ’ s g u i d e R C M This section describes the RCM (Rapid part cake Change Module), and its role in the SLS process. It includes operating instructions for the RCM as well as maintenance and troubleshooting recommendations.
Page 102: Rcm
SLS p r o c e s s 1 0 2 R C M & O T S u s e r ’ s g u i d e R C M & O T S o v e r v i e w RCM Over view You dock and load the preheated RCM in the SLS system and run a build.
Page 103: Rcm Features
SLS p r o c e s s 1 0 3 R C M & O T S u s e r ’ s g u i d e R C M f e a t u r e s RCM Fe atu res ➊...
Page 104 SLS p r o c e s s 1 0 4 R C M & O T S u s e r ’ s g u i d e R C M f e a t u r e s ➎...
Page 105: Rcm Specifications
SLS p r o c e s s 1 0 5 R C M & O T S u s e r ’ s g u i d e R C M s p e c i f i c a t i o n s RCM Sp e cific at ions Models RCM 140 - standard model...
Page 106 SLS p r o c e s s 1 0 6 u s e r ’ s g u i d e...
Page 107 SLS p r o c e s s 1 0 7 u s e r ’ s g u i d e...
Page 108: Rcm Description
SLS p r o c e s s 1 0 8 R C M & O T S u s e r ’ s g u i d e R C M d e s c r i p t i o n RCM D escrip ti o n This section describes the functions of each of The setpoints for these heaters depend on the...
Page 109 SLS p r o c e s s 1 0 9 R C M & O T S u s e r ’ s g u i d e R C M d e s c r i p t i o n RCM part piston and part cylinder When the RCM is loaded in the SLS system, the Be sure to clean the RCM seal after every build.
Page 110 SLS p r o c e s s 1 1 0 u s e r ’ s g u i d e...
Page 111 SLS p r o c e s s 1 1 1 u s e r ’ s g u i d e...
Page 112: Rcm Safety
• Certified service personnel are those they only occur during service procedures. who have completed the 3D Systems service training package and are certified to perform service tasks. Certification may occur at various levels, and servicers should only perform tasks they are authorized and certified to complete.
Page 113 SLS p r o c e s s 1 1 3 R C M & O T S u s e r ’ s g u i d e R C M & O T S s a f e t y If you hear an alarm, or if you see an error, To prevent injury and equipment damage, be alarm, or warning message on any...
Page 114 SLS p r o c e s s 1 1 4 u s e r ’ s g u i d e...
Page 115 SLS p r o c e s s 1 1 5 u s e r ’ s g u i d e...
Page 116 SLS p r o c e s s 1 1 6 u s e r ’ s g u i d e...
Page 117 SLS p r o c e s s 1 1 7 u s e r ’ s g u i d e...
Page 118 SLS p r o c e s s 1 1 8 u s e r ’ s g u i d e...
Page 119 SLS p r o c e s s 1 1 9 u s e r ’ s g u i d e...
Page 120 SLS p r o c e s s 1 2 0 u s e r ’ s g u i d e...
Page 121 SLS p r o c e s s 1 2 1 u s e r ’ s g u i d e...
Page 122 SLS p r o c e s s 1 2 2 u s e r ’ s g u i d e...
Page 123 SLS p r o c e s s 1 2 3 u s e r ’ s g u i d e...
Page 124 SLS p r o c e s s 1 2 4 u s e r ’ s g u i d e...
Page 125 SLS p r o c e s s 1 2 5 u s e r ’ s g u i d e...
Page 126 SLS p r o c e s s 1 2 6 u s e r ’ s g u i d e...
Page 127 SLS p r o c e s s 1 2 7 u s e r ’ s g u i d e...
Page 128 SLS p r o c e s s 1 2 8 u s e r ’ s g u i d e...
Page 129: Cleaning The Rcm
SLS p r o c e s s 1 2 9 R C M u s e r ’ s g u i d e l o a d i n g a n d u n l o a d i n g t h e R C M Lo a d i n g a n d U n l o a d i n g t h e R C M Follow the instructions in this section to load and Clean the part bed seal in the SLS system.
Page 130 SLS p r o c e s s 1 3 0 R C M u s e r ’ s g u i d e l o a d i n g a n d u n l o a d i n g t h e R C M BEFORE YOU LOAD THE RCM Connect the SLS system’s RCM cable to the RCM connector...
Page 131: Troubleshooting
SLS p r o c e s s 1 3 1 R C M u s e r ’ s g u i d e t r o u b l e s h o o t i n g UnLoad the RCM from the SLS System Tro u b l e s h o o t i n g after a build...
Page 132 SLS p r o c e s s 1 3 2 u s e r ’ s g u i d e...
Page 133 SLS p r o c e s s u s e r ’ s g u i d e I R S & I P C Follow the instructions in this section to use the IRS and IPC safely. They tell you how to connect an IPC to the IRS and load the virgin (new) powder, setup the IRS to send powder to the SLS system and receive powder from the BOS, and what actions to take in response to IRS warnings and alarms.
Page 134: Irs & Ipc
SLS p r o c e s s 1 3 4 I R S & I P C u s e r ’ s g u i d e a b o u t t h e I R S & I P C Ab o u t t h e I R S &...
Page 135: Irs Features
SLS p r o c e s s 1 3 5 I R S & I P C u s e r ’ s g u i d e I R S f e a t u r e s I R S Fe atu re s ➋...
Page 136: Irs Specifications
SLS p r o c e s s 1 3 6 I R S & I P C u s e r ’ s g u i d e I R S s p e c i f i c a t i o n s I R S S p e ci f i c at i o n s Input power 208/240 VAC, 50/60 Hz, 3 A...
Page 137: Ipc Features
SLS p r o c e s s 1 3 7 I R S & I P C u s e r ’ s g u i d e I P C f e a t u r e s I P C Featu re s ➏...
Page 138: Ipc Specifications
Access to the transmitter for service technicians is available through common enclosure access methods including use of common tools and removal of covers. Note: Changes or modifications to this equipment not specifically approved by 3D Systems may void the user's authority to operate this equipment.
Page 139: How The Irs & Ipc Work
SLS p r o c e s s 1 3 9 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k How th e IRS &...
Page 140 SLS p r o c e s s 1 4 0 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k Used (part cake) powder bin Virgin powder storage bin The Used bin in the left rear corner of the IRS...
Page 141 SLS p r o c e s s 1 4 1 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k Blender bin percent, it transfers a load of used powder.
Page 142 SLS p r o c e s s 1 4 2 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k Once blending is complete, the IRS resumes When the IRS blends a partial batch, it flashes the processing other transfer requests for loading...
Page 143 SLS p r o c e s s 1 4 3 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k Transporter Systems TRANSPORTER A conical stopper valve, operated by an air...
Page 144: Sls System
SLS p r o c e s s 1 4 4 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k The following table shows the destinations for Turn off L-Valve: When the level sensor LVL-R...
Page 145 SLS p r o c e s s 1 4 5 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k Shutdown.
Page 146 SLS p r o c e s s 1 4 6 I R S & I P C u s e r ’ s g u i d e h o w t h e I R S & I P C w o r k BOS powder transfers The IRS is a server responding to requests from the BOS meaning that all powder transfer...
Page 147: Ipc Description
SLS p r o c e s s 1 4 7 I R S & I P C u s e r ’ s g u i d e I P C d e s c r i p t i o n I P C D e s c r i p t i o n The Intelligent Powder Cartridge (IPC) is a When your are ready to use the IPC, move it next...
Page 148 SLS p r o c e s s 1 4 8 I R S & I P C u s e r ’ s g u i d e I P C d e s c r i p t i o n IPC batch unload sequence IPC ground connection Connect the ground wire...
Page 149 SLS p r o c e s s 1 4 9 I R S & I P C u s e r ’ s g u i d e I P C d e s c r i p t i o n IPC overpressure safety shutdown Powder flow.
Page 150: Irs & Ipc Safety
There is also a remote chance that the by trained and certified 3D Systems airborne dust cloud will explode in Customer Support personnel. the presence of an ignition source.
Page 151 SLS p r o c e s s 1 5 1 I R S & I P C u s e r ’ s g u i d e I R S & I P C s a f e t y IPC moving and storage safety Before you unload powder from the IPC, verify that the safety overpressure air line is...
Page 152: Irs Operator Panel And Stacklight
SLS p r o c e s s 1 5 2 I R S & I P C u s e r ’ s g u i d e I R S o p e r a t o r p a n e l a n d s t a c k l i g h t IRS Operator Panel and Stack l ight Use the IRS operator panel and stacklight run the IRS and determine its operating status.
Page 153 SLS p r o c e s s 1 5 3 I R S & I P C u s e r ’ s g u i d e I R S o p e r a t o r p a n e l a n d s t a c k l i g h t IRS Stacklight When status changes, Occasionally the status message overwrites a warning or error message.
Page 154: Irs Start-Up
SLS p r o c e s s 1 5 4 I R S & I P C u s e r ’ s g u i d e I R S s t a r t - u p IRS Star t-up Before you turn on the IRS, make sure the IRS umbilical is connected to IPC base fittings with ground cable is connected to the IPC band clamp.
Page 155: Irs Standby And Ready Modes
SLS p r o c e s s 1 5 5 I R S & I P C u s e r ’ s g u i d e I R S s t a n d b y a n d r e a d y m o d e s Default displays in Standby and Ready If one of the bins or the IPC is low, the IRS display prompts you to add more powder...
Page 156: Using Irs Main Menu
SLS p r o c e s s 1 5 6 I R S & I P C u s e r ’ s g u i d e u s i n g I R S m a i n m e n u Us i n g I R S M a i n M e n u Use the IRS main menu To select main menu options...
Page 157 SLS p r o c e s s 1 5 7 I R S & I P C u s e r ’ s g u i d e u s i n g I R S m a i n m e n u To access IRS Setup or Diagnostics menus From the Main...
Page 158: Using The Irs Setup Menu
SLS p r o c e s s 1 5 8 I R S & I P C u s e r ’ s g u i d e u s i n g t h e I R S s e t u p m e n u Us i n g t h e I R S S et u p M e n u You can access the Setup menu in Ready mode or Setup Menu Options...
Page 159: Using The Irs Diagnostics Menu
SLS p r o c e s s 1 5 9 I R S & I P C u s e r ’ s g u i d e u s i n g t h e I R S d i a g n o s t i c s m e n u Us i n g t h e I R S D i a g n o s t i c s M e n u You can access the Diagnostics menu in Ready Diagnostics Menu Options...
Page 160: Using The Irs Utilities Menu
SLS p r o c e s s 1 6 0 I R S & I P C u s e r ’ s g u i d e u s i n g t h e I R S u t i l i t i e s m e n u Us ing the IRS Utilitie s M e nu You can only access the Utilities menu in Standby From Standy mode display:...
Page 161 SLS p r o c e s s 1 6 1 I R S & I P C u s e r ’ s g u i d e u s i n g t h e I R S u t i l i t i e s m e n u To empty powder bins OPTION DESCRIPTION...
Page 162 SLS p r o c e s s 1 6 2 I R S & I P C u s e r ’ s g u i d e u s i n g t h e I R S u t i l i t i e s m e n u The container should be large enough to hold all the powder in the bin you’re emptying.
Page 163: Loading Virgin Powder In The Irs
SLS p r o c e s s 1 6 3 I R S & I P C u s e r ’ s g u i d e l o a d i n g v i r g i n p o w d e r i n t h e I R S Lo ading Vi rg in Powd er in the IRS To load virgin powder into the IRS Virgin...
Page 164 SLS p r o c e s s 1 6 4 I R S & I P C u s e r ’ s g u i d e l o a d i n g v i r g i n p o w d e r i n t h e I R S Step 2: Put the IRS in Ready mode Connect the bulkhead connector on the umbilical...
Page 165: Transporting Powder - From Irs To Sls System
SLS p r o c e s s 1 6 5 I R S & I P C u s e r ’ s g u i d e t r a n s p o r t i n g p o w d e r – f r o m I R S t o S L S s y s t e m Tra n s p o r t i n g Powd e r –...
Page 166: Blending
SLS p r o c e s s 1 6 6 I R S & I P C u s e r ’ s g u i d e b l e n d i n g B l e n d i n g When the Blender drops below approx.
Page 167: Loading Virgin Powder
SLS p r o c e s s 1 6 7 I R S & I P C u s e r ’ s g u i d e l o a d i n g v i r g i n p o w d e r Lo a din g Vi rg i n Powd e r When the IRS is low on Virgin powder, it will light up the When your are ready to use the IPC, move...
Page 168 SLS p r o c e s s 1 6 8 I R S & I P C u s e r ’ s g u i d e l o a d i n g v i r g i n p o w d e r IPC batch unload sequence IPC ground connection Connect the ground wire...
Page 169 SLS p r o c e s s 1 6 9 I R S & I P C u s e r ’ s g u i d e l o a d i n g v i r g i n p o w d e r Powder flow.
Page 170: Loading Used Powder
SLS p r o c e s s 1 7 0 I R S & I P C u s e r ’ s g u i d e l o a d i n g u s e d p o w d e r Lo a din g Us ed Powd e r To transfer used powder from the BOS sifter to IRS Stacklight...
Page 171: Maintenance
SLS p r o c e s s 1 7 1 I R S & I P C u s e r ’ s g u i d e m a i n t e n a n c e M a inten a n ce Moving the IRS If you need to move the IRS after you fill the bins...
Page 172: Irs & Ipc Troubleshooting
SLS p r o c e s s 1 7 2 I R S & I P C u s e r ’ s g u i d e I R S & I P C t r o u b l e s h o o t i n g I R S &...
Page 173 SLS p r o c e s s 1 7 3 I R S & I P C u s e r ’ s g u i d e I R S & I P C t r o u b l e s h o o t i n g IRS Error Messages (continued) MESSAGE DESCRIPTION...
Page 174 SLS p r o c e s s 1 7 4 I R S & I P C u s e r ’ s g u i d e I R S & I P C t r o u b l e s h o o t i n g IRS Error Messages (continued) MESSAGE DESCRIPTION...
Page 175 SLS p r o c e s s 1 7 5 I R S & I P C u s e r ’ s g u i d e I R S & I P C t r o u b l e s h o o t i n g IRS Error Messages (continued) MESSAGE DESCRIPTION...
Page 176 Customer Support Representative for Display Bin Weight Error...<deactivation assistance. code> along with the 3D Systems’ Customer After bin weight errors are reset, the IRS will Support phone number. resume powder transfers when you put it in Send a message to the...
Page 177 If you do not see the Convey Line Clean Press OK to change option on the IPC Transporter menu, call 3D Systems’ Customer Support Hotline assistance. IPC status Do Not Unload display As soon as the convey line clears, switch the...
Page 178 SLS p r o c e s s 1 7 8 I R S & I P C u s e r ’ s g u i d e I R S & I P C t r o u b l e s h o o t i n g Unplug the IRS umbilical’s pulse air Carefully vacuum powder in the IRS umbilical connector at the IPC.
Page 179 SLS p r o c e s s 1 7 9 I R S & I P C u s e r ’ s g u i d e I R S & I P C t r o u b l e s h o o t i n g Reconnect the IPC pulse air and powder connections.
Page 180 SLS p r o c e s s u s e r ’ s g u i d e S L S S Y S T E M This section describes the SLS system and provides operating, maintenance, and troubleshooting instructions. It frequently refers you to the Sinter Help because Sinter is the application you run on the SLS system when you build parts.
Page 181: Sls System Overview
SLS p r o c e s s 1 8 1 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m o v e r v i e w SLS System O ver view The SLS system builds parts in the removable A laser mounted on top of the SLS system scans...
Page 182: Sls System Features
SLS p r o c e s s 1 8 2 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m f e a t u r e s S L S Sys te m Fe at u re s ➊...
Page 183: Sls System Specifications
S L S s y s t e m s p e c i f i c a t i o n s S L S Sys te m S p e c i f i c at i o n s sPro 140 - standard model sPro 230 - 23 cm (9 in) taller than Models model 140...
Page 184: Sls System Description
Blackbody and IR sensor on swing-out panel Chamber viewing window RCM Description on page 108 for more about RCM models. Oxygen sensor The major sPro model 140 and 230 SLS system Nitrogen heater subassemblies are described below. Process Chamber Module Upper and lower chambers Part Bed...
Page 185 SLS p r o c e s s 1 8 5 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m d e s c r i p t i o n Lower Process Chamber (LPC) The LPC, or lower portion of the process chamber, Flexible thermal curtains on the inner side of...
Page 186 SLS p r o c e s s 1 8 6 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m d e s c r i p t i o n Image Processing Module The IPM is mounted on top of the SLS system.
Page 187 ’ s g u i d e S L S s y s t e m d e s c r i p t i o n Gauge panel Gauge Panel sPro SLS system TOP VIEW FRONT Regulated N2 Pressure N2 inlet pressure gauge;...
Page 188 SLS p r o c e s s 1 8 8 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m d e s c r i p t i o n RCM bay Machine Services Module (MSM) Separate frame for loading and unloading RCM;...
Page 189 66 for more information. days, and then must be purchased. The 60-day Manually control the SLS system. See the evaluation period is activated by the 3D Systems “Manual Operations” topic in Sinter Help representative who installs your system. If you do...
Page 190: Sls System Safety
SLS p r o c e s s 1 9 0 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m s a f e t y If your company purchased the password at the same time that it purchased the SLS system, the software will be fully activated by the field service...
Page 191: Starting The Sls System (Only)
SLS p r o c e s s 1 9 1 S L S S Y S T E M u s e r ’ s g u i d e s t a r t i n g t h e S L S s y s t e m ( o n l y ) Star ting the SLS System (only) These instructions Perform the procedures below to start up the SLS...
Page 192 SLS p r o c e s s 1 9 2 S L S S Y S T E M u s e r ’ s g u i d e s t a r t i n g t h e S L S s y s t e m ( o n l y ) Run Sinter application Login to Windows.
Page 193 Module are both on. RCM lift air pressure on the SLS system gauge panel. The air pressure gauge labels indicate their correct readings. These are: sPro 140 lowh air pressure 350 kPa (51 psi) 350 kPa (51 psi) highv air pressure...
Page 194 SLS p r o c e s s 1 9 4 S L S S Y S T E M u s e r ’ s g u i d e s t a r t i n g t h e S L S s y s t e m ( o n l y ) Check pressure and flow gauges.
Page 195: Bos
SLS p r o c e s s 1 9 5 S L S S Y S T E M u s e r ’ s g u i d e s h u t t i n g d o w n t h e S L S s y s t e m S h u t t i n g D ow n t h e S L S Sys te m Follow the procedures below to shut down the Depressurize.
Page 196: Sls System Service & Maintenance
SLS system service and maintenance WARNING! SLS system laser service procedures must only be performed and maintenance procedures must by 3D Systems-certified service only be performed by 3D Systems- technicians unless this guide certified service technicians. explicitly states otherwise. Attempts by non-3D Systems-...
Page 197 CLEAN THE LASER WINDOW cleaning the SLS equipment and preparing the At the SLS system, raise the laser window process chamber for another build on the sPro door (top front of machine). Close the laser 140 or 230. window shutter by pushing the shutter handle up and to the right.
Page 198 SLS p r o c e s s 1 9 8 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m s e r v i c e & m a i n t e n a n c e Carefully enter the RCM bay and wipe down Reinstall both windows and tighten frame the exposed area with ethanol and a clean...
Page 199 SLS p r o c e s s 1 9 9 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m s e r v i c e & m a i n t e n a n c e Replace the right side heater panel.
Page 200 SLS p r o c e s s 2 0 0 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m s e r v i c e & m a i n t e n a n c e Entering the machine through the bottom Exit Sinter, then wait for the SLS system to one can access the IR sensor window.
Page 201 Nitrogen Generator. During scheduled Before removing a the RCM. preventive maintenance, your certified Go to Man Ops and select the Roller button 3D Systems service representative will: on the tool bar. ✓ Replace the nitrogen generator filters as Using the arrows, move the roller to the needed.
Page 202: Sls System Troubleshooting
An alarm is active. Any correction labeled 3D CSE Only Normal in the table below must only be Steady A warning is active performed by a 3D Systems Customer Yellow Support Engineer (3D CSE) or Safety override during Flashing Authorized Service Representative.
Page 203 SLS p r o c e s s 2 0 3 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m t r o u b l e s h o o t i n g SLS System Failure Modes FAILURE MODE OR ERROR...
Page 204 SLS p r o c e s s 2 0 4 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m t r o u b l e s h o o t i n g SLS System Failure Modes (continued) FAILURE MODE OR ERROR...
Page 205 SLS p r o c e s s 2 0 5 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m t r o u b l e s h o o t i n g SLS System Failure Modes (continued) FAILURE MODE OR ERROR...
Page 206 SLS p r o c e s s 2 0 6 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m t r o u b l e s h o o t i n g SLS System Failure Modes (continued) FAILURE MODE OR ERROR...
Page 207 SLS p r o c e s s 2 0 7 S L S S Y S T E M u s e r ’ s g u i d e S L S s y s t e m t r o u b l e s h o o t i n g SLS System Failure Modes (continued) FAILURE MODE OR ERROR...
Page 208 SLS p r o c e s s u s e r ’ s g u i d e B O S This section describes the BOS (Breakout Station) and its role in the SLS process. It includes operating instructions, as well as maintenance and troubleshooting recommendations. Features.
Page 209: Bos Features
SLS p r o c e s s 2 0 9 B O S u s e r ’ s g u i d e B O S f e a t u r e s B O S Feat u re s ➊...
Page 210: Bos Overview
SLS p r o c e s s 2 1 0 B O S u s e r ’ s g u i d e B O S o v e r v i e w B O S O ve r v i ew When a build is complete, you need to remove the sintered parts from the RCM part cake and clean them.
Page 211: Bos Operator Controls And Indicators
SLS p r o c e s s 2 1 1 B O S u s e r ’ s g u i d e B O S o p e r a t o r c o n t r o l s a n d i n d i c a t o r s B O S O p e rato r Co n t ro l s a n d I n d i c at o r s Use the BOS operator controls and indicators BOS Operator Panel...
Page 212 SLS p r o c e s s 2 1 2 B O S u s e r ’ s g u i d e B O S o p e r a t o r c o n t r o l s a n d i n d i c a t o r s BOS Stacklight The colored lights on the BOS stacklight and COLOR...
Page 213 SLS p r o c e s s 2 1 3 B O S u s e r ’ s g u i d e B O S o p e r a t o r c o n t r o l s a n d i n d i c a t o r s Before you can move the part piston: After breakout, before you remove the RCM from the BOS, use the part piston jog switch to home...
Page 214: Bos Components
SLS p r o c e s s 2 1 4 B O S u s e r ’ s g u i d e b o s c o m p o n e n t s B O S Co m p o n e nt s BOS Door A motorized auger is at the bottom of the powder transport hopper.
Page 215 SLS p r o c e s s 2 1 5 B O S u s e r ’ s g u i d e b o s c o m p o n e n t s Work Platform (for BOS Pro 230) Enter BOS work platform functional description.
Page 216 SLS p r o c e s s 2 1 6 B O S u s e r ’ s g u i d e b o s c o m p o n e n t s Dust Collector The Donaldson-Torit VS-1200 3-phase Dust The flexible vacuum duct arm enables you to Collector removes airborne dust from the BOS...
Page 217: Bos Safety
SLS p r o c e s s 2 1 7 B O S u s e r ’ s g u i d e B O S s a f e t y B O S S afet y When you use any SLS equipment, follow all Using the BOS work platform general safety guidelines in...
Page 218 SLS p r o c e s s 2 1 8 B O S u s e r ’ s g u i d e B O S s a f e t y BOS RCM safety The rapid change module (RCM) is usually a hot module.
Page 219: Bos Power-Up Sequence
SLS p r o c e s s 2 1 9 B O S u s e r ’ s g u i d e B O S p o w e r - u p s e q u e n c e B O S Power - U p S eq u e n ce Before you turn on the BOS, make sure RCM cable is NOT connected to...
Page 220: Bos Start-Up
SLS p r o c e s s 2 2 0 B O S u s e r ’ s g u i d e B O S s t a r t - u p B O S Sta r t - u p After you power up the BOS as described above, start-up the BOS as follows: Turn the BOS POWDER TRANSPORT switch...
Page 221: Breakout Station Mode Operations
SLS p r o c e s s 2 2 1 B O S u s e r ’ s g u i d e b r e a k o u t s t a t i o n m o d e o p e r a t i o n s B re a ko u t S t at i o n m o d e o p e rat i o n s The BOS must be in “Breakout Station”...
Page 222 SLS p r o c e s s 2 2 2 B O S u s e r ’ s g u i d e b r e a k o u t s t a t i o n m o d e o p e r a t i o n s BOS Operation Tips The sifter level sensor can be seen from the RCM bay.
Page 223: States
SLS p r o c e s s 2 2 3 B O S u s e r ’ s g u i d e B O S o p e r a t i n g s t a t e s B OS O p erati n g States When the BOS is on, the display indicates the Powder Xfer Off...
Page 224 SLS p r o c e s s 2 2 4 B O S u s e r ’ s g u i d e B O S o p e r a t i n g s t a t e s If the sifter does fill in less than 2 minutes, the If the POWDER TRANSPORT switch is OFF, the BOS enters either the...
Page 225 SLS p r o c e s s 2 2 5 B O S u s e r ’ s g u i d e B O S o p e r a t i n g s t a t e s Waiting for IRS ✓...
Page 226 Pressing turns on the auger and sifter BOS. Rather, disconnect power from motors at the bottom of the hopper. When the the BOS and contact 3D Systems BOS enters the Stopping state, it stops both Customer Support Hotline for these motors.
Page 227 SLS p r o c e s s 2 2 7 B O S u s e r ’ s g u i d e B O S o p e r a t i n g s t a t e s Only use E-stop to shut down the BOS in an emergency.
Page 228: Using The Bos Main Menu
SLS p r o c e s s 2 2 8 B O S u s e r ’ s g u i d e u s i n g t h e B O S m a i n m e n u Us i n g t h e B O S M a i n M e n u Use the BOS main menu to view the BOS software Press...
Page 229: Using The Bos Setup Menu
BOS engineering parameters on the Process Params Eng Params menu should only be >RCM Com Mode changed by 3D Systems certified RCM Type service personnel. Process Params menu display To select Setup menu options From the BOS Main menu, select Setup.
Page 230 SLS p r o c e s s 2 3 0 B O S u s e r ’ s g u i d e u s i n g t h e B O S s e t u p m e n u SET RCM COM MODE SET RCM TYPE Use the...
Page 231 From the Eng Params menu, choose a MaxTime[operation_name] parameter, then BOS engineering parameters should press only be changed by 3D Systems certified service personnel. The current value of the MaxTime[operation_name] parameter From the Setup menu, choose Params, then appears;...
Page 232: Using The Bos Diagnostics Menu
Diagnostics menu, choose Input Status, menu should only be changed by then press . The Input Status menu appears. 3D Systems certified service personnel. Input Status >Move RCM Up Move RCM Down RCM Present Input Status menu display Press to choose the input you want to view...
Page 233 SLS p r o c e s s 2 3 3 B O S u s e r ’ s g u i d e u s i n g t h e B O S d i a g n o s t i c s m e n u The inputs on the Input Status menu perform the BOS operations below.
Page 234 BOS Keep hands and loose clothing outputs. Press to return to the Setup menu clear of RCM before part piston and contact 3D Systems Customer Support motion is enabled. assistance. Press to choose the output you want to Press...
Page 235 SLS p r o c e s s 2 3 5 B O S u s e r ’ s g u i d e u s i n g t h e B O S d i a g n o s t i c s m e n u VIEW OR CHANGE VALVE OUTPUTS The outputs on the Valves...
Page 236 SLS p r o c e s s 2 3 6 B O S u s e r ’ s g u i d e u s i n g t h e B O S d i a g n o s t i c s m e n u to switch the Air Cyl Valve ON VIEW OR CHANGE RCM POWER RELAY AND...
Page 237 SLS p r o c e s s 2 3 7 B O S u s e r ’ s g u i d e u s i n g t h e B O S d i a g n o s t i c s m e n u To view or change valve outputs on the General If you saved a...
Page 238: Using The Bos Work Platform
SLS p r o c e s s 2 3 8 B O S u s e r ’ s g u i d e u s i n g t h e B O S w o r k p l a t f o r m Us i n g the B O S Wo rk P l atfor m BOS Pro 230 Work Platform Use the BOS work platform to make breakout...
Page 239: Shutting Down The Bos
SLS p r o c e s s 2 3 9 B O S u s e r ’ s g u i d e s h u t t i n g d o w n t h e B O S Sh u t t i n g D ow n t h e B O S Shutting down the BOS stops the following To shut down the BOS properly...
Page 240: Bos Maintenance
SLS p r o c e s s 2 4 0 B O S u s e r ’ s g u i d e B O S m a i n t e n a n c e B O S M a i n ten a n ce Cleaning the BOS powder transfer hopper After servicing the machine, replace the grate and make sure the grate is flush with the...
Page 241: Bos Troubleshooting
SLS p r o c e s s 2 4 1 B O S u s e r ’ s g u i d e B O S t r o u b l e s h o o t i n g B O S Tro u b l e s h o o t i n g BOS error messages MESSAGE...
Page 242: Contacting 3D Systems
C O N T A C T I N G 3 D S Y S T E M S If you have questions about your SLS equipment, auxiliary machines, or DuraForm materials— or to request service—please contact 3D Systems at the appropriate number or address below.
Page 244 REPRESENTATIONS, GUARANTEES OR wishing to be bound should return this material WARRANTIES OF ANY KIND ARE MADE AS TO ITS to 3D Systems. Nothing contained herein is to be ACCURACY, FITNESS FOR A PARTICULAR USE OR considered as permission, recommendation, nor THE RESULTS TO BE OBTAINED THEREFROM.
Page 245: Glossary
SLS p r o c e s s u s e r ’ s g u i d e G L O S S A R Y advisory A type of Sinter See also message, application message AC box Electrical AC power cabinet on the lower warning, alarm, (color code yellow).
Page 246 SLS p r o c e s s 2 4 6 G L O S S A R Y u s e r ’ s g u i d e alarm A type of Sinter See also message, application message batch One unit of blended warning, advisory,...
Page 247 The can be infrared sensor on the right wall of the set to recycle or dispose of used powder after in sPro process chamber SLS® systems. breakout. When set to RECYCLE, the sifts The IR sensor measures the blackbody...
Page 248 SLS p r o c e s s 2 4 8 G L O S S A R Y u s e r ’ s g u i d e build The three stage part fabrication on an build packet archive See also import SLS®...
Page 249 SLS p r o c e s s 2 4 9 G L O S S A R Y u s e r ’ s g u i d e Build Setup The 3D Systems application that creates build files you can run on an CC box Chamber Controller electrical/ SLS®...
Page 250 SLS p r o c e s s 2 5 0 G L O S S A R Y u s e r ’ s g u i d e Cooldown stage The third See also of three SLS® system damper The hinged metal plate below the laser...
Page 251 SLS p r o c e s s 2 5 1 G L O S S A R Y u s e r ’ s g u i d e dialog box A subordinate window that opens in software. It either presents E-stop button (EMERGENCY STOP button) Any information or asks you to provide...
Page 252 Powder storage dispenser gauge panel Cluster of gauges, hose fittings, mounted on the left side of the SLS® system and valves at the right rear of the sPro SLS® process chamber. The feed hopper receives system for controlling...
Page 253 SLS p r o c e s s 2 5 3 G L O S S A R Y u s e r ’ s g u i d e homing Moving the part piston roller to its inerting Lowering the oxygen level and raising home limit to reestablish the SLS®...
Page 254 SLS p r o c e s s 2 5 4 G L O S S A R Y u s e r ’ s g u i d e Image Projection Module. Contains the IRS umbilical Flexible 5-meter harness of laser, laser focusing and...
Page 255 LS software to setup and build sets of 3-D travels in a scan line across the part bed. Scan parts on 3D Systems’ equipment. Some speed is measured in inches per second or LS software features and utilities are licensed.
Page 256 SLS p r o c e s s 2 5 6 G L O S S A R Y u s e r ’ s g u i d e Manual Operations mode message A brief color- Messages and Sinter application coded text notification the Message List...
Page 257 Detects the percentage of unhoused condition, which occurs only oxygen inside the process chamber. during service procedures. operator A person trained by 3D Systems to operate the SLS® system and all other equipment, and to perform all tasks associated with build preparation, building parts, and breakout.
Page 258 SLS p r o c e s s 2 5 8 G L O S S A R Y u s e r ’ s g u i d e partial batch A proportionally smaller batch virgin powder used powder with the parameter (SLS system)
Page 259 SLS p r o c e s s 2 5 9 G L O S S A R Y u s e r ’ s g u i d e part cylinder The rectangular steel vessel part piston Heated See also homing mounted in the that holds the...
Page 260 The powder spread across the contamination of the SLS® system powder bottom of the process chamber by the roller. supply. powder dispenser PowderNet 3D Systems’ Mechanism at the See also APMU proprietary network See also powder bottom of the Powder feed amount that interconnects SLS®...
Page 261 SLS p r o c e s s 2 6 1 G L O S S A R Y u s e r ’ s g u i d e powder transport tube Flexible pipe through profile The set of values Using the which powder flows between assigned to a...
Page 262 SLS p r o c e s s 2 6 2 G L O S S A R Y u s e r ’ s g u i d e RCM Com Mode (Service use only.) process roller The device in the process chamber that parameter that defines how the...
Page 263 The parameters that that creates a set of 3-D control the laser beam. parts starting with a build packet file created in 3D Systems’ Build scanner timeout The length of time the Setup application. LS software gives the...
Page 264 SLS process that creates volume of 140 liters; solid parts from 3-D CAD files. It makes parts (550 x 550 x 460) mm. sPro 230 has a by rolling a thin layer of powdered material maximum part cake volume of...
Page 265 Cooldown stage steps: build preparation, build, and breakout. build profile. The following 3D Systems SLS equipment Standby mode The mode play major roles in the SLS process: IRS, IPC, See also Ready (in both the RCM, SLS®...
Page 266 SLS p r o c e s s 2 6 6 G L O S S A R Y u s e r ’ s g u i d e SYSTEM ENABLE light When this green Used bin top left See also Virgin bin console light is on, you can load an RCM, then...
Page 267 SLS p r o c e s s 2 6 7 G L O S S A R Y u s e r ’ s g u i d e warning A type of Sinter application message (color code yellow). You must acknowledge a Virgin bin top right warning.
Page 268: Index
I N D E X SYMBOLS service & maintenance laser ✓ button (operator panel) SLS system X button (operator panel) SLS equipment 3D Systems SLS system about this User’s Guide Customer Support About menu option contacting (Hotline) view software version for...
Page 269 SLS p r o c e s s 2 6 9 I N D E X u s e r ’ s g u i d e overflows (SLS system) RCM Com Mode Used powder RCM Type status safety Virgin powder Setup menu status...
Page 270 SLS p r o c e s s 2 7 0 I N D E X u s e r ’ s g u i d e setting up a build packet in contacting 3D Systems standalone Customer Support Sales and Service to run from Sinter application...
Page 271 SLS p r o c e s s 2 7 1 I N D E X u s e r ’ s g u i d e DuraForm exhaust, SLS system handling safety HEPA, on waste powder drum Material Guide Nitrogen Generator Material Safety Data Sheet.
Page 272 SLS p r o c e s s 2 7 2 I N D E X u s e r ’ s g u i d e ground Intelligent Powder Cartridge. See IPC cable, IRS umbilical to IPC electrical safety connecting to IRS guidelines, safety description...
Page 273 SLS p r o c e s s 2 7 3 I N D E X u s e r ’ s g u i d e powder manifold language, display (selecting) about laser left/right certification label powder transport systems classifications powder transport to SLS system radiation safety...
Page 274 SLS p r o c e s s 2 7 4 I N D E X u s e r ’ s g u i d e MSDS, DuraForm Nitrogen Generator maintenance cables and filters maintenance service nitrogen/oxygen safety laser noise level SLS system Dust Collector...
Page 275 SLS p r o c e s s 2 7 5 I N D E X u s e r ’ s g u i d e overflow chutes, SLS system cleaning screens modules, SLS system powder transport parameters Build Profile, editing Part Profile, editing part cake cooldown...
Page 276 SLS p r o c e s s 2 7 6 I N D E X u s e r ’ s g u i d e from BOS to IRS from IRS to SLS system radiation safety, laser in BOS in IRS build heights IRS to SLS system...
Page 277 Class IV unload, from SLS system nitrogen/oxygen RCM heaters powder temperatures setpoints warning symbols targets service 3D Systems test manually Authorized Service Provider recycle used powder Certified Service Personnel restarting a terminated build contacting roller areas homing facility electrical...
Page 278 SLS p r o c e s s 2 7 8 I N D E X u s e r ’ s g u i d e safety override (flashing yellow lamp) after dspif initializes to load RCM shutdown SLS system for running SLS system running Build Setup from...
Page 279 SLS system software STL file activation storage guidelines BOS version, display support IRS version, display contacting 3D Systems SLS system Sinter utilities third-party software Sinter.exe transporter, powder third-party sorted facet file status, IPC SPI, RCM COM mode. See also...
Page 280 SLS p r o c e s s 2 8 0 I N D E X u s e r ’ s g u i d e view build in progress Virgin bin (IRS) capacity status virgin powder loading...

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