1. Manuals
  2. Brands
  3. Z Corporation Manuals
  4. 3D Printers
  5. Z810
  6. System user manual

Z Corporation Z810 System User Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Z810 System User Manual
January 2004
®
Z
810 Color 3D Printer User Manual
Copyright © 2002-2004 Z Corporation
Rev. F, Part Number 09505

Advertisement

Table of Contents
loading

Related Manuals for Z Corporation Z810

Summary of Contents for Z Corporation Z810

  • Page 1 Z810 System User Manual January 2004 ® 810 Color 3D Printer User Manual Copyright © 2002-2004 Z Corporation Rev. F, Part Number 09505...

  • Page 2: Table Of Contents

    2.1.1 Z810 3D Printer......................11 2.1.1.1 Z810 Carriage Assembly..................14 2.1.1.2 Z810 Service Station .................... 15 2.1.1.3 Z810 Rear Connector Panel ................16 2.1.1.4 Z810 Printer Control Panel................... 17 2.1.2 ZF8 Powder Feeder ....................18 2.1.2.1 ZF8 Rear Connector Panel .................. 19 ZD8 D ....................
  • Page 3 ................... 95 SING OWDER 11.1.1 GENERAL INFORMATION ..................95 11.1.2 USING ZCAST ON YOUR Z810 3D PRINTER ............95 11.1.3 LOADING ZCAST INTO THE Z810 3D PRINTER ..........96 11.1.4 SETTING UP ZCAST BUILDS ................96 11.1.5 POST PROCESSING ZCAST PARTS ..............96...
  • Page 4 ..........113 LEAN OWDER CREEN ON THE OWDER EEDER 12.10 ZD8 D ......... 113 MPTY OWDER RAWER ON THE EPOWDERING Z810 SYSTEM DETAILS ....................115 13.1 ......................115 YMBOLS USED 13.2 ..................... 115 YSTEM PECIFICATIONS 13.3 ................116 ATERIAL TORAGE RECAUTIONS 13.4 E...
  • Page 5 EVER 14: ZD8 C ....................23 IGURE ONTROL ANEL 15: ZD8 P ................24 IGURE OWDER OLLECTION RAWER 16: ZD8 C ........................24 IGURE 17: P .................. 45 IGURE RINTING TATUS IALOGUE Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 6 You agree to indemnify, defend and hold Z Corporation and its officers, directors and employees harmless from and against any and all claims, losses, damages, costs and expenses resulting from any use of the Equipment other than for the production of early-stage appearance models and prototypes.

  • Page 7: Introduction

    3. Quick Start Guide. This section will give you a quick breakdown of steps needed to print your part. 4. Preparing the Z810 3D Printer. This section will guide you through the steps for preparing the Z810 3D Printer. It includes checking the powder, and fluid levels as well as maintenance procedures such as lubricating the axes and cleaning the service station.

  • Page 8: How It Works

    Inside the Z810 3D Printer there is a build piston, where the part is built (see Figure 1). Also represented in the diagrams are the roller, print heads, build area, and cleaning area. The roller moves horizontally across the build area.

  • Page 9: Figure 2: The Shelling Andi

    This is because the cross sections are printed in continuous strips along the y or the “fast” axis (the print heads direction of travel), bands across the x or the “slow” axis (the gantry direction of travel) and laminated layers along the z-axis. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 10: Figure 3: Illustration Ofz C

    Z Corporation Z810 System User Manual z-axis Less Strong x-axis Strongest Strong y-axis Figure 3: Illustration of Z Corp. System Print Orientations Accuracy. The accuracy of the printer depends on the materials you choose and the offset and scaling factors used. You can employ the anisotropic scaling feature in the software to adjust for expected shrinkage and bring your parts into true scale.

  • Page 11: System Components

    Z810 System User Manual Z Corporation 2 SYSTEM COMPONENTS Z810 PRINTER COMPONENTS The Z810 System consists of the following hardware components: 2.1.1 Z810 3D PRINTER Site Requirements: Power: 100-240 VAC, 50-60 Hz Compressed Air: Clean, dry air (dew point 40 C or below) Air Fitting: ¼...

  • Page 12: Figure 4: Z810 3D Printer

    Top Cover Power Switch Control Panel Top Cover Handle Overflow Chute Color Binder Container (Cyan, Pump Magenta, Yellow) zc3 Wash Fluid Enclosure Container Electronics Enclosure Overflow Vacuum Clear Binder Container Waste Container Receptacle Figure 4: Z810 3D Printer (Front View) www.zcorp-users.com...

  • Page 13: Figure 5: Z810 3D Printer

    Spread Roller Gantry - Print Moves along Head Spit the slow axis Area Print Heads Overflow Chute Printer Assembly - Top Deck Rests on the Gantry Figure 5: Z810 3D Printer (Top View) Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 14: Z810 Carriage Assembly

    Z810 System User Manual 2.1.1.1 Z810 Carriage Assembly Print Heads (Numbered from 0-5 from front to back) Carriage Cover Carriage Cover Latch Note: One is located in the back of the carriage (not shown) Figure 6: Z810 3D Printer Carriage Assembly www.zcorp-users.com...

  • Page 15: Z810 Service Station

    Z810 System User Manual Z Corporation 2.1.1.2 Z810 Service Station Wash Fluid Spray Nozzle Print Head Spit Area Print Head Parking Cap Squeegees Figure 7: Z810 3D Printer Service Station Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 16: Z810 Rear Connector Panel

    Powder Feeder Serial connector provided Cable - Connector Power Input provided - Connector provided Network Connection - Connector provided Diagnostic Video Serial Input Circuit Breaker Connector - No Connection - connector provided Connector provided Figure 8: Z810 3D Printer Connector Panel www.zcorp-users.com...

  • Page 17: Z810 Printer Control Panel

    Figure 9: Z810 3D Printer Control Panel Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 18: Zf8 Powder Feeder

    Z Corporation Z810 System User Manual 2.1.2 ZF8 POWDER FEEDER Site Requirements: Power: Voltage : 100VAC, 50/60Hz, 20A 115VAC, 50/60Hz, 17A 230VAC, 50/60Hz, 10A Compressed Air: Clean, dry air (dew point 40 C or below) Air Fitting: ¼ “Industrial” quick disconnect or other quick disconnect with ¼ inch NPTM pipe thread Dimensions: 31 inches (0.79 meters) deep x 32 inches (0.81 meters) wide x 78 inches (1.98 meters)

  • Page 19: Zf8 Rear Connector Panel

    ZF8 Rear Connector Panel Powder Feeder Serial Cable - Connector provided Air Connector - Connecting Hose provided Power Input - Connector provided Power Switch Figure 11: ZF8 Powder Feeder Rear Connector Panel Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 20: Zd8 Depowdering Unit

    Z Corporation Z810 System User Manual ZD8 DEPOWDERING UNIT Site Requirements: Power: Voltage: Receptacle For Plug Type : 190-200 VAC, 50Hz, 10.5A IEC 60309-2: RED-6h-32A-3p+N+E 208-230 VAC, 60Hz, 15A IEC NEMA L15-30 Plug 380-400 VAC, 50Hz, 5.3A IEC 60309-2 Plug, Red-6h-16A-3p+N+E Plug...

  • Page 21: Figure 12: Zd8 Depowdering

    Powder Drawer Powder Drawer. Handles. Allows C ollec ts loos e for easy pull out powder. and mobilization of powder drawer. Figure 12: ZD8 Depowdering Unit Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 22: Air Curtain

    Z Corporation Z810 System User Manual 2.2.1 AIR CURTAIN A fraction of the clean air exhausting from Selector Lever: the blower is focused into a curtain and The user can adjust the strength of the air curtain - that directed downward across the ZD8 window is, the fraction of the blower exhaust that is recycled into and front opening.

  • Page 23: Zd8 Control Panel

    Notice: Filter cleaning cycle has been initiated. Steady Cleaning is scheduled for next Stand-by mode, and will start shortly thereafter. Caution: Filter cleaning Flashing currently in progress. On/Off Please stand clear of machine. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 24: Powder Collection Drawer

    Z Corporation Z810 System User Manual 2.2.3 POWDER COLLECTION DRAWER All of the discarded powder from the depowdering process is deposited in the Powder Collection Drawer at the base of the ZD8 Depowdering Unit. During normal operation, the drawer is actively sealed to the underside of the machine.

  • Page 25: Despatch Lbb Forced Convection Oven (Option)

    A reference frequently used by U.S. firms to comply with OSHA regulations is the American Conference of Governmental Industrial Hygienists Industrial Ventilation Manual. Please review the Material Safety Data Sheet for ZCast powder. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 26: Quick Start Guide

    Z Corporation Z810 System User Manual 3 QUICK START GUIDE Here is a quick guide to printing a part in the Z810 3D Printer. 3.1 PRINTER PREPARATION 1. Clean the top deck. 2. Clean service station. www.zcorp-users.com...
  • Page 27 Z810 System User Manual Z Corporation 3. Spread powder over the build area. 4. Empty powder overflow chute. 5. Check fluid levels of binder, and wash fluid. Fill or replace if needed. Empty waste container. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 28: Setting Up The Build

    Z Corporation Z810 System User Manual 3.2 SETTING UP THE BUILD 1. Set up the build on the ZPrint Software. 2. Check 3D Print Setup for build settings and edit as needed. 3. Press 3D Print to begin printing process.

  • Page 29: Transferring The Part To The Depowdering Unit

    2. Transfer build pallet to cart using track system. 3. Transfer build pallet to depowdering unit. 4. Turn depowdering unit on and leave part in the depowderer to dry. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 30: Depowdering The Part

    Z Corporation Z810 System User Manual 3.4 DEPOWDERING THE PART 1. Turn air gun on and adjust air pressure. 2. Depowder part. Leave supporting powder underneath plaster parts. Depowder starch parts completely. 3. Remove part from depowdering unit. 4. Clean depowdering unit.

  • Page 31: Transfer To Oven

    As you increase the strength of the part in this manner you are also inceasing the amount of time to dry the part. Use of the removable build plate and oven drying the part are recommended. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 32: Gross And Fine Depowdering

    Z Corporation Z810 System User Manual 3.7.1.2 Gross and Fine Depowdering • Become familiar with where the parts are placed and how they are oriented in the build box so you do not accidentally bump or brush against a fragile part during the depowdering process.

  • Page 33: Preparing The Z810 3D Printer

    2. Using the wash bottle and nylon brush, clean off the parking cups and wipe any standing water off with a paper towel and replace the cover plate. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 34: Greasing The Fast Axis

    Z Corporation Z810 System User Manual 3. Wipe the cover plate and deck off when finished. Technical Tip – The cover plate may be removed and cleaned under running water remove any debris. Keeping the machine clean will ensure that it works optimally.

  • Page 35: Oil Slow Axis

    4.4.2 SLOW AXIS PATH. Place oil on a paper towel and wipe the slow axis path on the deck. Close top cover and repark by clicking ‘OK’ on the software. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 36: Fill Bed

    Z Corporation Z810 System User Manual FILL BED 1. Press the ‘Fill Bed’ button on the control panel. This will prompt the powder feeder and gantry to deposit and spread powder over the build pallet. It will continue spreading until the build pallet is covered.

  • Page 37: Checking Powder Levels

    This continues until the detector reads full after stirring. When the feeder detects that it is full, the vacuum switch will not turn on the vacuum until powder is dispensed from the feeder. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 38: Check Fluid Levels

    Z Corporation Z810 System User Manual CHECK FLUID LEVELS 4.8.1 BINDER CONTAINERS Check the fluid levels on the binder and waste containers. It is good practice to fill the binder bottles when they are half empty. The color binder containers can hold half a gallon (2 liters) of color binder.

  • Page 39: Check Waste Container

    1. Unscrew cap. 2. Place paper towel around the float sensor located at the bottom of the binder cap to prevent drips. 3. Remove bottle. 4. Empty out waste fluid. 5. Replace waste container. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 40: Zc3 Wash Fluid Container

    Z Corporation Z810 System User Manual 4.8.3 ZC3 WASH FLUID CONTAINER Over time, zc3 wash fluid will evaporate or become contaminated with powder and will need to be replaced. If the fluid level has reached 1/2 of the container, it will need to be replaced.

  • Page 41: Using Zprint Software

    Part with opening If the part has an opening or is hollow, place the opening or hollow side up. This will allow for the removal of powder during the gross depowdering process. Hollow Part Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 42: Part Containing Overhangs

    Z Corporation Z810 System User Manual 5.2.2 PART CONTAINING OVERHANGS Unsupported overhangs should be placed on the left hand-side and as close to the build plate as possible. The plaster powder, being extremely fine, is more fluid in the build.

  • Page 43: Powder Settings

    3. ZCast Material System The ZCast material system has been found to remain dimensionally accurate during printing and thus, the recommended anisotropic scaling values are one (1) in all axes. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 44: Saturation Values

    Z Corporation Z810 System User Manual 5.3.1.2 Saturation Values The saturation values determine how much binder is placed on the powder to print the part. The part is made up of two areas, the shell and the core, as described in Section 1.2, How It Works.

  • Page 45: Printing The Build

    Figure 17: Printing Status Dialogue Box 3. Press ‘OK’ to confirm that these have been checked to begin the build. Once the build has begun, a dialog box will appear reporting the status of the build. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 46: Removing The Part

    Z Corporation Z810 System User Manual 6 REMOVING THE PART SET TIMES Once the build has completed, let the part sit in the printer to set. This will allow the part to dry while being supported by surrounding powder. Recommended Set Times...

  • Page 47: Gross Depowdering

    3. Insert the vacuum hose into a vacuum receptacle in the powder feeder, and turn on the vacuum. 4. Lift the top cover of the printer to gain access to the build area. 5. Vacuum off the top deck. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 48 Z Corporation Z810 System User Manual 6. Vacuum powder around the edges of the build area and part. Technical Tips - • Place the vacuum nozzle at an angle to facilitate airflow into the powder feeder and improve suction control.

  • Page 49: Transfering The Parts To The Depowdering Station

    TRANSFERING THE PARTS TO THE DEPOWDERING STATION 1. Put printer offline. Press the ‘Load/Unload’ button on the control panel to raise the build pallet. Build Pallet Lifted Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 50 Z Corporation Z810 System User Manual 2. Vacuum off any surrounding powder. Vacuum Nozzle 3. Place the tracks on each side of build pallet. Tracks 4. Secure the tracks to the top deck by interlocking the “j-shaped” slots with the track pegs.
  • Page 51 Build Pallet Tracks Cart 6. Press ‘Online’ on the control panel to lower build pallet. 7. Push or pull pallet onto cart. Remove tracks and replace in storage position on cart. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 52 Z Corporation Z810 System User Manual 8. Lift ZD8 Window. 9. Move cart in front of ZD8 Depowdering Track on ZD8 Station. Depowdering Unit 10. Orient the ZD8 turntable so that the track pegs are towards the front of the depowdering unit.

  • Page 53: Post Processing Tools

    It is thinner than the Wide Blade Utility Scraper and can therefore reach smaller areas. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 54 Z Corporation Z810 System User Manual 3. Soft Horsehair Brush: This brush has very soft bristles and assists the user with the gross depowdering process. Brushing powder away from the part is a useful technique prior to the vacuuming step.

  • Page 55: Depowdering The Part

    4. Adjust airflow by using the control valve. Slide the red ring down to lock the settings. PLEASE NOTE: When depowdering thin walled or fine detailed areas, use lower air pressure. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 56 Z Corporation Z810 System User Manual 5. Depowder the part beginning from the top surface area and working downwards. Rotate turntable as needed. Remove as much powder from part as possible. For plaster parts remove supporting powder. For starch parts remove supporting powder.
  • Page 57 8. Remove part from oven and complete depowdering (for plaster and ZCast parts only) 9. Remove part from depowdering unit. 10. Clean depowdering unit by using the external vacuum to remove any debris. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 58: Infiltrants

    However, the true versatility of the Z810 System is derived from the spectrum of material properties that can be achieved by applying one of our infiltration materials to parts that will be exposed to a variety of product testing environments.
  • Page 59 The resin will cure at room temperature after 24 hours. For more information on the uses of Z-Max epoxy, please refer to the technical data sheet that can be found on the User Group Website at www.zcorp-users.com. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 60: Using Z-Bond Cyanoacrylate

    Z Corporation Z810 System User Manual 8.2 USING Z-BOND CYANOACRYLATE Z-Bond cyanoacrylate is an extremely fast setting, low viscosity, general-purpose infiltration resin. This resin is designed to rapidly strengthen parts. Z-Bond is a one part, user friendly, no-odor, non-blooming resin that may eliminate the need for special ventilation.

  • Page 61: Using Z-Snap Epoxy

    For more information on the uses of Z-Snap epoxy, please refer to the technical data sheet that can be found on the User Group Website at www.zcorp-users.com. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 62: Using Paraplast X-Tra Wax

    Z Corporation Z810 System User Manual 8.4 USING PARAPLAST X-TRA WAX Paraplast X-Tra is a low viscosity, general purpose, infiltration wax formulated to melt at very low temperatures (122°F or 50°C) and strengthen both starch and plaster powder parts. This material cures rapidly and enhances the vibrancy of color parts.

  • Page 63: Applications

    Z810 System User Manual Z Corporation 9 APPLICATIONS Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 64: Gluing Multi-Pieced Parts

    Z Corporation Z810 System User Manual In this section, you will learn various ways to maximize the versatility of your Z Corporation 3D Printer through the implementation of advanced part processing techniques. Please visit the User Group Website at www.zcorp-users.com for more information.

  • Page 65: Painting Parts

    6. Apply laquer primer by spraying. A hand-held, air sprayer will be necessary for the highest quality surface finish. 7. Apply colored lacquer gloss paint to achieve the shiny, plastic-like finish. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 66: Polyester Resin

    (HVAC) of the interior space. Prototype ducting produced on the Z Corporation 3D Printer can be used for form and fit testing, as well as air-flow testing across a range of temperatures and humidity. The parts...

  • Page 67: Electroplating

    If the surface is not leveling, it can be sanded in between baths to help get a shiny finish. Contacts If you would like to have a part plated, we recommend contacting Jason Channell at Associated Electroplaters, Inc. Phone Number (248) 547-5520. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 68: Water Transfer Printing

    Cubic Printing. Process Description Part preparation: Print the chosen part using any Z Corporation plaster series powder. The part should be infiltrated with cyanoacrylate or epoxy resin. Sand the part prior to dip printing. For an improved finish, the part can be sprayed with a spray-filler (such as Plasti-kote Sandable Primer or Spraila AutoK) and sanded again.
  • Page 69 Due to the exposure to water here, Z Corp. parts must be well infiltrated and finished completely with the primer, even if the image is to be partially applied. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 70 Z Corporation Z810 System User Manual Top Coating: The parts are clear coated or varnished to protect the printed surface. A varying degree of gloss can be achieved by using different top coats. Polishing completes the process. Presenting: The finished parts can now be used. The surface can be very durable and scratch resistant –...

  • Page 71: Investment Casting

    The parts burn out well and do not have any expansion problems that would lead to shell cracking. Investment casting of Z Corporation parts is a good way to get a final prototype, or a near-net shape part made of the specific alloy your application requires.
  • Page 72 Note: this process has been omitted by some users to their satisfaction. Patterns infiltrated with resin should skip the autoclave process and go directly to the burnout oven. 3. Z Corporation patterns should be burned out at 1750-1800 F (954-982 C) in an oxygen rich environment.

  • Page 73: Flexible Parts

    6. Let the parts sit on wax paper to cure. Make sure excess material is not dripping into a puddle on the wax paper. This will be difficult to remove after it cures. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 74: Thermoforming

    – PVC, polystyrenes, polyesters, acrylics etc. in this process. Making light gauge (plastic less than 0.060”) thermoforming molds for prototype parts is an ideal use for Z Corporation 3D Printers and plaster powder. For more information regarding the process and the industry, check out SPI’s website: www.plasticsindustry.org/index.htm...
  • Page 75 Z810 System User Manual Z Corporation The instructions below are specific to molds produced on Z Corporation Printers. It is assumed that the user currently owns a thermoforming system and is familiar with using molds created from other techniques for creating thermoformed parts.

  • Page 76: Rtv Molding

    Master patterns are classically sanded and polished regardless of the method of their production. This makes parts printed using Z Corporation technology a perfect fit due to the ease in which their surface finish can be enhanced.
  • Page 77 Note that it is only necessary to follow these steps to achieve the appearance of an injected molded part with an ultra-smooth finish. Instructions: 1. Remove, post-process and infiltrate the printed part from the Z Corporation 3D Printer. Infiltration with cyanoacrylate or epoxy is recommended. The use of wax is not recommended because the part will not accept a primer later in the finishing process and is not easily sanded.
  • Page 78 Z Corporation Z810 System User Manual 4. Sand the filler with 220-grit sand paper. The finish at this point should be completely smooth with no surface defects. 5. Prime the part with a sprayable / sandable primer. Z ® Corporation recommends Plasti-kote Sandable Primer for ®...
  • Page 79 5 Inhibition – The failure of silicone to cure within the recommended cure time. Surfaces of the mold will typically remain gummy, uncured or stick to the master pattern. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 80 Z Corporation Z810 System User Manual Preparing and Pouring the Silicone Mold Preparing the silicone is relatively easy but must be performed properly to ensure a good mold. Pay close attention to the mix ratio of the two components of the silicones. Be sure to prepare a large enough volume to completely encase the pattern.
  • Page 81 RTV molding is an extremely efficient method of generating multiple parts with thermoplastic properties. There is no faster method of generating the master pattern than with a Z Corporation 3D Printer, which will reduce the overall time it takes to get your final cast part. Whether a Z Corp.

  • Page 82: Changing And Aligning The Print Heads

    Z Corporation Z810 System User Manual 10 CHANGING AND ALIGNING THE PRINT HEADS 10.1 CHANGING THE PRINT HEADS WARNING: Do NOT touch or contaminate the gold contacts on either the print heads or the carriage with your fingers. Avoid spilling binder on the contacts. If you do get binder or anything else on the gold contacts, clean them with an alcohol swab.
  • Page 83 12. Insert the new print head and push down firmly on top to make sure the print head is seated securely in the carriage. Repeat for all print heads. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 84 Z Corporation Z810 System User Manual 13. Replace the carriage cover and tighten the clamps in the front and back of the carriage. Press the ‘Online’ button once to complete the process or click ‘Done’ in the software. The print heads will now need to be aligned.

  • Page 85: Aligning The Print Heads

    To print a sharp pattern, the pad should be at the height of the top deck. • PLEASE NOTE: If it is too high up, the roller will hit the pad and move it. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 86 Z Corporation Z810 System User Manual 3. Close the top cover and put the printer online. 4. Select the ‘Alignment’ option under the 810Service menu. 5. Click on ‘Print Test Pattern’ in the alignment dialog box. It will take a minute to initialize the printer, send the pattern, and print.
  • Page 87 Print head 0 is the reference, print heads 1 through 5 are aligned to print head 0. Each row is labeled at the left, F1 and S1 correspond to Fast1 and Slow1 on the dialog box and following. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 88 Z Corporation Z810 System User Manual See the examples below for properly and improperly aligned reticules. Normal reticule patterns: Fast axis to the left Good fast axis reticule Fast axis to the right The three short lines are interleaved with the long lines.
  • Page 89 S2 – Head 2, Slow F3 – Head 3, Fast S3 – Head 3, Slow F4 – Head 4, Fast S4 – Head 4, Slow F5 – Head 5, Fast S5 – Head 5, Slow Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 90 Z Corporation Z810 System User Manual 10. Click ‘OK’. The software will ask you to update the alignment. Click ‘OK’ to update the printer’s configurations. 11. Remove the paper off the plate carefully. If you would like to save the...
  • Page 91 HP ink. You may place a flat brick, such as the purge brick build (810purge.stl), under Sample files, under your part to purge all black ink before printing your part. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 92: Changing Material Systems

    Applications section of the User Group Website at www.zcorp-users.com. To change material systems on the Z810 3D Printer, use the following procedure: 1. Remove all powder from the top deck and under the build plate.
  • Page 93 IF USING STARCH OR PLASTER POWDER, make sure scraper assembly is attached. PLEASE NOTE: Failure to remove scraper assembly when using ZCast powder will result in damage to the scraper blade. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 94 Z Corporation Z810 System User Manual 8. Change ZF8 Powder Feeders with the desired powder system. 9. Fill ZF8 Feeder with desired powder if necessary. 10. Use the ‘Fill Bed’ option under the 810Service menu to spread powder. 11. Set up build in ZPrint Software and print.

  • Page 95: Using Zcast 500 Powder

    Applications Team for information about a free online training session at (781) 852-5005 or via email at applications@zcorp.com. 11.1.2 USING ZCAST ON YOUR Z810 3D PRINTER Before using ZCast on your Z810 3D Printer, you will need to upgrade to metal snowplows, remove the scraper blade, and change powder feeders. Metal Snowplows...

  • Page 96: Loading Zcast Into The Z810 3D Printer

    11.1.4 SETTING UP ZCAST BUILDS Follow best practices for setting up a build in Z Corporation 3D Printers found in the ZPrint Software User Manual. For more information, please refer to the ZCast Direct Metal Casting –...

  • Page 97: Material Ordering

    Dispose of ZCast powder according to local and state regulations. 11.1.10 QUESTIONS AND SUPPORT If you have any questions regarding this product, contact the Z Corporation Applications Team for technical support at (781) 852-5005 or via email at applications@zcorp.com.

  • Page 98: Using Zp250 Powder

    0.06” (1.5 mm). 11.2.1 MACHINE SETUP • Remove all of the powder currently in the Z810 3D Printer (build piston, overflow bin). Consult the Z Corporation Service Department for documented instructions on changing a ZF8 Feeder from zp102 to zp250 powder.
  • Page 99 • Go to the “3D Print Setup” window under the File Menu and select zp250 powder as the powder type. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 100: Part Removal And Post Processing

    Z Corporation Z810 System User Manual 11.2.3 PART REMOVAL AND POST PROCESSING 1. Remove the part and depowder. Dry the parts in in an oven at 150°F (66°C) for at least 2 hours or longer depending on the mass/volume of the part.
  • Page 101 Several thin coats are better than one thick coat. Use a paper towel or tissue paper to remove excess epoxy that may have pooled on the surface of the part. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 102: Infiltration Addendum

    Z Corporation Z810 System User Manual 7. Let the part sit for 30 minutes at room temperature to allow excess Z-Snap epoxy to drain or wick into the fixture. Z-Max parts should sit at ambient for 1 hour prior to the oven cure.

  • Page 103: Maintenance

    1/2 full. 1. Open right cabinet door, and disconnect zc3 wash fluid container. 2. Empty out zc3 wash fluid container. Fluid Disconnect - Push Silver Button to Release 3. Remove filter. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 104 Z Corporation Z810 System User Manual 4. Place paper towel around the filter to absorb any fluid when unscrewing the filter. Unscrew the filter. 5. Remove screen and clean under running water. PLEASE NOTE: The screen will feel slimy. Rinse off the screen with water until it no longer feels slimy.

  • Page 105: Flush System With Distilled Water

    3. Open cabinet door. Remove color binder containers and empty color binder into respective binder containers. 4. Fill containers with distilled water. 5. Return color binder containers reconnect float sensor fluid connection. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 106 Z Corporation Z810 System User Manual 6. Remove clear binder container through Fluid Disconnect the quick disconnect. Float Sensor Disconnect 7. Pull out clear binder container. PLEASE NOTE: When removing the clear binder container, tilt the binder container as shown to prevent damage to the fluid connections.
  • Page 107 Remove the distilled water. Replace the float sensor into the binder container and replace the clear binder container. Close cabinet door. 14. When ready to use the Z810 Printer, replace the distilled water with Z Corp. binder and flush fluid system for three minutes.

  • Page 108: Clean Under Gantry

    Z Corporation Z810 System User Manual 12.3 CLEAN UNDER GANTRY It is necessary to clean under the gantry when powder and binder have adhered to the bottom causing layers to be dragged when printing. It is also good practice to clean under the gantry to prevent powder and binder build-up once a month.

  • Page 109: Oil Slow Axis Rail

    12.4 OIL SLOW AXIS RAIL The slow axis rails are located on the front and back of the Z810 3D Printer. They can be found between the top deck and the cabinet. These rails need to be oiled once a week.

  • Page 110: Clean Spreader Roller

    Z Corporation Z810 System User Manual 12.6 CLEAN SPREADER ROLLER The spreader roller may become dirty with powder and binder debris after printing. Cleaning the spreader roller will prevent uneven spreading of powder over the build pallet. 1. Choose the ‘Toggle Roller on/off’ option under the Service menu or press F4.

  • Page 111: Cleaning The Squeegee Squirters

    4. Replace squirter cap. Jet Cleaning Tool 5. Realign squirters with the squeegees, if necessary, using pliers. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 112: Bleeding Air From The Fluid System

    Z Corporation Z810 System User Manual 12.8 BLEEDING AIR FROM THE FLUID SYSTEM Air may get into the fluid system through leaks or have run low on binder. If you need to remove air from your system, follow the procedure below: 1.

  • Page 113: Clean Powder Screen On The Zf8 Powder Feeder

    The powder drawer should be emptied weekly. If you are a heavy user or if your part geometry encapsulates large volumes of powder, the powder drawer may need to be emptied more frequently. 1. Release powder drawer by moving the control switch to the left. Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 114 Z Corporation Z810 System User Manual 2. Slide the powder drawer out. There are two handles available. One handle option extends out to allow you tow, push, and maneuver the powder drawer to and from an emptying location. The other handle option allows you to pull and push the powder drawer at the base.

  • Page 115: Z810 System Details

    •Operating Conditions: 68 to 85ºF, 20 to 60% Relative Humidity, non-condensing. Lithium Battery: Internal to the Z810 3D Printer is a lithium coin cell type battery. This may be any one of the following: Type: CR2032, either Maxell, Panasonic, Renata, Sanyo or Sony.

  • Page 116: Material Storage Precautions

    Z Corporation Z810 System User Manual 13.3 MATERIAL STORAGE PRECAUTIONS Carefully read the Material Safety Data Sheets (MSDS) before using any Z Corporation materials. Material Storage Usage Powder Store powder on pallets in a cool, dry, Use of powder in...
  • Page 117 LAYERS: zlib InflateInit error %d 1902, LAYERS: zlib Inflate error %d 1903, LAYERS: zlib InflateEnd error %d 1904, LAYERS: missing layer info packet 1905, LAYERS: layer is too big, %dK bytes 2000, STRIPES: spurious read event Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 118 Z Corporation Z810 System User Manual 2001, STRIPES: bad saturation 2002, STRIPES: too many lines per stripe 2003, STRIPES: line is too long 2004, STRIPES: bad print mode %d 2005, STRIPES: bad line offset 2100, UNRLE: bad layer number 2101,...
  • Page 119 TCP: can't create event 4001, TCP: can't launch thread 4002, TCP: thread refuses to die 4003, TCP: error %d creating socket 4004, TCP: error %d setting socket option 4005, TCP: error %d binding socket Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...
  • Page 120 BINDER: weak pressure from pump %d 4701, BINDER: can't write plumbing state 4702, BINDER: invalid plumbing type %d 4800, MATERIALS: unknown combination These are unique to Z810: 50000, CUSTOM: can't find CBDIO PCI card 50100, POWDER: feeder timeout 50101, POWDER: feeder not present,...
  • Page 121 Z810 System User Manual Z Corporation 50103, POWDER: overflow full, OVERFLOW FULL 50200, SERVICE: failed head check, BAD HEADS %02X 50300, PISTONS: build piston is tilted) Z Corporation Service (781) 852-5050 / (887) 88-ZCORP...

  • Page 122: Index

    Z Corporation Z810 System User Manual INDEX Collision Detection, 43 Contacts, 83 3D Print, 45 Depowderer. See ZD8 Depowdering Unit Depowdering, 55 Air Gun, 55 Disconnect Aligning the Print Heads. See Alignment Binder Containers, 105 Alignment, 85 Drying Time Edit Alignment, 89...
  • Page 123 Oil, 35 Painting, 65 Slow Axis Rail, 109 Part Snowplows, 35 Drying Time, 56 Software. See ZPrint Software Part Removal from the Z810 Printer. See Spreader Roller, 110 Part Removal Squeegee Squirters Part Orientation, 41 Cleaning, 111 Circular Features, 42...
  • Page 124 Z Corporation Z810 System User Manual Control Switch, 23 Depowdering, 55 Z810 3D Printer, 11 Emptying Powder Drawer, 113 Carriage Assembly, 14 Filter Cleaning, 23 Components, 11 Light Push Button, 23 Control Panel, 17 Powder Collection Drawer, 24 Error Codes, 116...
  • Page 125 Appendix I ® ZCast Direct Metal Casting DESIGN GUIDE February 2004 ® 09521 ZCast Design Guide Rev B...
  • Page 126 Appendix I Table of Contents Introduction ................. 4 Cautions & Warnings ..............5 CAUTION .......................... 5 WARNING ......................... 5 ZCast Advantages ..............6 The Materials ........................6 Design Freedom........................ 6 Locating a Foundry ..............7 Foundry Trial Parts......................7 Designing with ZCast – Mold Design.......... 8 Sources of Mold Design Information.................
  • Page 127 Appendix I Pour............................21 Pouring Metal................22 Metal Types........................22 Material Handling..............22 Storage..........................22 Disposal........................... 22 Powder Recycling ......................23 10 Finishing ................... 23 10.1 De-molding ........................23 10.2 Secondary Operations....................23 10.3 Ovens .......................... 23 11 Foundry Consumables.............. 24 11.1 Sand Casting Glossary....................

  • Page 128: Appendix I - Zcast Design Guide

    ZCast. But it also covers some of the basics of sand casting to help familiarize those with less casting experience. Z Corporation is dedicated to your successful application and usage of this product. Please contact Z Corporation directly to schedule a free online training session at (781)852-5005. Ask for the ZCast applications engineer.

  • Page 129: Cautions & Warnings

    Appendix I 2 Cautions & Warnings 2.1 CAUTION MOLD MUST BAKED DRY PRIOR TO POURING DO NOT INFILTRATE THIS MATERIAL WITH RESIN OR WAX!! ZCAST PARTS IN ITS UNTREATED (RAW) STATE CONTAINS ABOUT 10% MOISTURE UNIT WEIGHT. CASTING MOLTEN METAL AGAINST UNTREATED MATERIAL RELEASES LARGE AMOUNTS OF STEAM AND SMOKE, RISKING SERIOUS PERSONAL INJURY OR DEATH!!

  • Page 130: Zcast Advantages

    Either the sand mold can be created with machined patterns, or, to keep the time to casting to a minimum, the patterns can be ® printed on a Z Corporation 3D Printer using zp 100 series materials. ZCast Design Guide - 6...

  • Page 131: Locating A Foundry

    If you have trouble finding a foundry in your area, contact your Z Corporation sales manager to help you locate an experienced foundry.

  • Page 132: Designing With Zcast - Mold Design

    Appendix I 5 Designing with ZCast – Mold Design ZCast offers flexibility and simplicity in mold design. Because of its simplicity, the engineer or designer can spend more time focusing on the design of the part rather than on the design of the mold.

  • Page 133: Direct Pour

    Appendix I Direct Pour 5.2.1 A mold designed by this method incorporates the cavity of the casting and the entire gating system, including risers and vents. This keeps the mold setup simple by minimizing parts. It is most handy for small molds: up to 5 lbs in aluminum or 15 lbs in bronze. Larger castings can be feasible if the gating system is kept simple, for example, a short sprue leading to a single gate.

  • Page 134: Combination Method

    The pattern can be machined from a variety of materials or the pattern can be printed on a Z Corp. 3D Printer. If printed, the patterns would be made with one of the Z Corporation plaster based materials (zp100 series), infiltrated with an epoxy and mounted to a board. A zp100 series pattern can be used multiple times.

  • Page 135: Direct Pour

    Appendix I 5.3.1 Direct Pour Before addressing the mold design specifics, we will consider the basic steps of designing a mold using a standard CAD package. Most middle to high-end CAD packages such as Pro/E, SolidWorks, Catia, Unigraphics, and Autodesk Inventor, etc. as well as some tooling packages such as Magics Tooling will contain the tools you need to create a mold.

  • Page 136: Combination Method

    Appendix I 5.3.3 Combination Method The combination method is slightly more process oriented and is not represented in the context of this document. Users familiar with the conventional sand casting process that incorporates the use of a pattern will find this technique to be desirable using ZCast.

  • Page 137: Design Techniques With Zcast

    Appendix I 6 Design Techniques with ZCast 6.1 Direct Gating Conventional methods of runner design are based on having a flat pattern that must be drawn out of a sand mold. This forces the runners and gates out sideways resulting in a mold that covers a larger area.

  • Page 138: Venting

    Appendix I Arching is a phenomenon that occurs on the first few layers printed. It diminishes as the part continues to build. To minimize arching, print the non-critical faces of your mold facing downwards. Figure 8: Arching Figure 7: Addition of stiffening ribs printed in the shelled mold 6.5 Venting...

  • Page 139: Venting Cores

    Appendix I 6.5.1 Venting Cores Follow these guidelines to obtain best results when designing vents for your cores: • The cores should be shelled in by approximately .250” (7mm) wall thickness where possible. • Any single wall of the core should be no thicker than 0.500”...

  • Page 140: Parting Lines

    Appendix I 6.6 Parting Lines The process for creating a mold in CAD software typically involves taking an object (the casting) and subtracting it from a larger, encompassing object (the mold). The mold must then be split along a generated surface or a plane. Traditionally, the parting line is very carefully chosen to create a pair of patterns to form the cope and drag without undercuts, and minimize the number of cores necessary.

  • Page 141: Mating Surfaces

    Appendix I 6.8 Mating Surfaces The mating surfaces of the mold should be offset to accommodate for surface imperfections. A total gap of 0.020” (0.5mm) should be created, in the model, at all mating surfaces. The offset can be created on either side of the parting surface or split between them. Even with an intentional gap, there will likely be some portion of the mold or core that rubs against another part when the mold is assembled.

  • Page 142: Wall Thickness Guidelines

    Appendix I 6.10 Wall Thickness Guidelines As indicated in the section 6.3 ‘Shelling Your Mold’, thinner sections bake quicker and more efficiently. Maintain the following guidelines for modeling your mold with thin walls: • Any mold wall that is in contact with metal should be no less then 0.5” (12mm) thick, and no more then 1”...

  • Page 143: Machine Settings

    Appendix I • Using “Bleed Compensation” is recommended. This will improve the accuracy so parts will fit together better • Orient parts so that the most critical faces are facing up in the build. For example, when possible, put the outside of the mold components (non-molding surfaces) facing down in the build.
  • Page 144 Appendix I Figure 13: a,b,c: Horizontal filter orientation – Metal rises up through filters (maximum are achieved with horizontal placement. d,e,f: Vertical filter orientation ZCast Design Guide - 20...

  • Page 145: Mold Preparation

    Appendix I 7 Mold Preparation After the mold is designed and printed in a Z Corporation 3D Printer, there are only a few necessary steps before you are ready to pour metal: Mold Wash – Mold wash is used in traditional sand casting to improve the surface finish of the castings.

  • Page 146: Pouring Metal

    ZCast powder is a non-toxic substance. Please consult the Material Data Safety Sheet for product details. Dispose of ZCast powder according to local and state regulations. ASM metals handbook, 4 edition Heine & Rosenthal Foseco foundryman’s handbook Consult Z Corporation prior to pouring ZCast Design Guide - 22...

  • Page 147: Powder Recycling

    The surface may be bead blasted or sand blasted. Castings may be heat- treated. 10.3 Ovens You can bake your parts in one of the ovens offered through Z Corporation, or any other oven º that will reach temperatures up to 400 F.

  • Page 148: Foundry Consumables

    Appendix I 11 Foundry Consumables You can purchase foundry consumables through a wide offering of vendors. This includes items such as core wash, pouring sleeves, filters, core paste, etc. Prominent foundry consumables that are commonly used are: Ceramic filters – These disposable items are inserted into either the pouring sleeve, or they are often placed in the drag in a cavity in line with the runner channel.

  • Page 149: Sand Casting Glossary

    Appendix I 11.1 Sand Casting Glossary Cope 11.1.1 Cope and Drag Molds are typically made up of two halves encapsulating the outer surfaces of the casting. The two parts are called the cope and drag; the cope being the “top” section and the drag being the “bottom.”...

  • Page 150: Pouring Cup

    Appendix I Core prints (light areas) 11.1.4 Pouring Cup The pouring cup, as the name implies, is where the molten metal is poured into the mold. The pouring cup can take many different forms, each to better optimize the feeding of metal into the mold and minimize the amount of turbulence produced...

  • Page 151: Ingates

    Appendix I 11.1.8 Ingates The metal enters the mold cavity through the ingates. Ingates typically feed thicker sections of the casting, which subsequently, feed thinner Runners sections. Thick sections, where the metal will be slowest to cool, should be Ingates allowed to feed thin sections that cool more quickly and may freeze off before the entire casting is filled.

  • Page 152: Conclusion

    With the information in this document, the design and pouring of your prototype metal parts is only a step away. If you or your foundry has questions about any of the information contained herein, or need additional information, please contact us the Z Corporation Applications Team at applications@zcorp.com.

Table of Contents