Stratasys FDM 2000 Manual
  1. Manuals
  2. Brands
  3. Stratasys Manuals
  4. 3D Printers
  5. FDM 2000
  6. Manual

Stratasys FDM 2000 Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Introduction
FDM 2000 / 3000 / 8000
Release 2.0
Stratasys Document no. 105208-0001
Rev. B

Advertisement

Table of Contents
loading

Related Manuals for Stratasys FDM 2000

Summary of Contents for Stratasys FDM 2000

  • Page 1 Introduction FDM 2000 / 3000 / 8000 Release 2.0 Stratasys Document no. 105208-0001 Rev. B...

  • Page 2: Introduction

    The purpose of this manual is to provide you with the necessary information to operate and maintain the Stratasys FDM 2000/3000/8000. This manual comple- ments the procedures covered by the Stratasys training program. However, it does not serve as a substitute for hands-on learning. It also functions as an integral part of the complete documentation for your Stratasys system configuration.
  • Page 3 F2/3/8000-3 Procedures About This Manual—Organization All of the Stratasys product documentation uses letter designated page num- bers (appendices use lower case letters). You may find references within this manual to page numbers in other Stratasys documentation. The letter designa- tions are as follows:...
  • Page 4 F2/3/8000-4 About This Manual—How This Manual is Organized Procedures FDM 2000/3000/8000 Manual 10MAY01...
  • Page 5 • FDM 2000/3000/8000 Modeler • Modeling Materials FDM 2000/3000/8000 The FDM 2000, FDM 3000, and FDM8000 use Fused Deposition Modeling (FDM) to turn computer-aided design (CAD) geometry into models that can be used for design reviews, manufacturability stud- ies, investment casting patterns, and marketing.

  • Page 6: Materials

    Overall tolerance is ± 0.005" in the X, Y, and Z axes. Actual results depend on the model. Materials The FDM 2000/3000 is capable of using a variety of inert, nontoxic materials: ICW06 — Investment Casting Wax P400 ABS — ABS Plastic P500 ABSi —...
  • Page 7 FDM System documentation. Elastomer Stratasys E20 elastomer is a thermoplastic polyester based elastomer formu- lated to provide a tough, flexible material that offers a unique combination of mechanical and physical properties. Stratasys E20 elastomer was devel- oped for applications requiring flexible models such as window and door seals, straps, gaskets, toys and container designs.
  • Page 8 Procedures FDM 2000/3000/8000 Support Systems The FDM 2000/8000 uses the unique Break Away Support System (BASS). BASS uses a second nozzle to extrude the support material. The supports are designed to prop up the overhanging portions of the part during modeling. The supports detach easily, making the finished product look better with minimal post-model- ing finishing.

  • Page 9: Bass

    About The FDM Support System Support Groups For best use of the FDM 2000/3000/8000 system, the .sml file must be made correctly. The layer of support making direct contact with the model must be part of a group designated strictly for supports.
  • Page 10 (see Insight online help) Generating Toolpaths/Tip Path (see Insight online help) Creating an SML File (see Insight online help) Sending an SML File to the FDM machine (see Insight online help) Positioning the FDM Head (page F16-35) FDM 2000/3000/8000 Manual 10MAY01...

  • Page 11: Capabilities

    Contact Stratasys’ Training department for details. Space The FDM 2000/3000 uses 26 x 36 inches of bench-top space. If you are not purchasing a Stratasys table, make sure the table you use can support 500 lbs. Two to three feet of space behind the FDM 2000/3000/8000 (side) are needed for clearance when opening the back door to change the spools of material.
  • Page 12 Contents F2/3/8000-i FDM Manual 2000/3000/8000 Release 2.0 Stratasys Document No: 105207-0001 ® 10 MAY 01 Rev. B...
  • Page 13 Stratasys, Inc. Printed in the USA. FDM 1500, FDM 1600, FDM 1650, FDM 2000, FDM 3000, FDM 8000, 3D PLOTTER, FDM, Insight, Models in Minutes, ProtoSlice, and QuickSlice are trademarks of Stratasys, Inc.

  • Page 14: Table Of Contents

    Support Sets ______________________________ F2/3/8000-9 Finishing the Part _________________________ F2/3/8000-9 Capabilities ______________________________ F2/3/8000-11 Requirements ____________________________ F2/3/8000-11 Installation ______________________________ F2/3/8000-11 FDM 2000/3000/8000 Procedures Calibration ______________________________ F2/3/8000-13 Downloading Buttons_________________ F2/3/8000-13 Toolpath Width Calibration ___________ F2/3/8000-15 T12 and T16 Tip Offset Calibration _____ F2/3/8000-16...
  • Page 15 Replacing the Foam Foundation ____________ F2/3/8000-31 Removing the Foundation ____________ F2/3/8000-31 Attaching the Foundation _____________ F2/3/8000-31 Positioning the FDM Head ____________ F2/3/8000-33 FDM 2000/3000/8000 Maintenance Maintenance _____________________________ F2/3/8000-35 Equipment Required _________________ F2/3/8000-35 Cleaning the FDM Head __________________ F2/3/8000-36 Daily Cleaning ___________________________ F2/3/8000-38...
  • Page 16 Stratasys Customer Support. Call (952) 906-2283 or 1-800-801-6491 (U.S.A. Toll Free), (Customer Support, 7:00 a.m. to 6:00 p.m. C.T.) You can also reach us at our internet address: support@stratasys.com When calling in for service, always have your workstation’s serial number, software version, and hardware serial number ready.
  • Page 17 F2/3/8000-vi Contents 10 MAY 01 FDM 2000/3000/8000 Manual...

  • Page 18: Fdm 2000/3000/8000 Procedures

    F2/3/8000-12 Procedures FDM Procedures 2000/3000/8000 Release 2.0 Stratasys Document no. 105209-0001 Rev. B FDM 2000/3000/8000 Manual 10MAY01...
  • Page 19 F2/3/8000-13 Procedures Every time you receive a new version of software, you must download the “buttons” file. These are the FDM system build/move parameters. Go to the FDM Status window Click on the calibration icon Set up the Configure Modeler to what is currently in the FDM Click on the green check to go to the calibration page.

  • Page 20: Calibration

    FDM 2000/3000/8000 switches between the modeling tip for modeling material and support tip for release material. If the last position of the modeling tip before the FDM 2000/ 3000/8000 switches to release material is X=1.0, Y=1.3, Z=2.0, the head and Z- stage need to be calibrated so the modeling tip is moved out of the way, and the support tip is positioned at X=1.0, Y=1.3, Z=2.0.

  • Page 21: Toolpath Width Calibration

    F2/3/8000-15 Procedures About The FDM —Calibration Toolpath Width Calibration If your FDM modeler is not extruding the correct toolpath widths, follow these steps to check the toolpath widths and change them, if necessary. Start FDM Status application. Click the Calibration button (micrometer icon). Specify the properties of the modeler in the Configure Modeler window.

  • Page 22: T10 Tip Offset Calibration

    Model Material Support Material Correct Calibration Support Material Model Material Incorrect Calibration FDM 2000/3000/8000 Manual 10MAY01...
  • Page 23 F2/3/8000-17 Procedures About The FDM —Calibration Tip Offset Procedure 1. Check the tightness of the tip using the tip wrench. 2. Start FDM Status application. 3. Click the Calibration button (micrometer icon). 4. Specify the properties of the modeler in the Configure Modeler window. This is much like the configuration window in Insight.

  • Page 24: Creating A Calibration Box

    Example: ssys_T12P400_T12S100_r_z010 model tip slice height model material support material support tip 5. You can open this job in Insight and you can download the SML file using FDM Status. FDM 2000/3000/8000 Manual 10MAY01...

  • Page 25: Fdm 2000/3000/8000 Usage

    The front door to the FDM must be open when changing the FDM head, tip, or foam foundation. Press Pause or Stop to unlock the front door. (The FDM 2000/3000/8000 interlock feature prevents access through the front door until the Pause or Stop buttons are pressed.) This illustration shows the proper positions of the FDM head and front...

  • Page 26: Changing The Fdm Head

    Usage—Modeling Operations Changing the FDM Head Removing an FDM Head from the FDM 2000/3000/8000 If the FDM tip temperature is above 50° C (122° F), insulating gloves must be worn to avoid direct skin contact with the FDM head and tip.
  • Page 27 F2/3/8000-21 Procedures Usage—Modeling Operations Be very careful not to touch the hot FDM tips or the FDM head. Always wear heat resistant gloves. After both latches are detached, swing the FDM head to the right until the inside of the head is completely visible. Lift up the FDM head to detach its upper hinges from the back plate’s lower hinges.

  • Page 28: Attaching An Fdm Head

    F2/3/8000-22 Usage—Modeling Operations Procedures Attaching an FDM Head to the FDM 2000/3000/8000 Make sure both draw latches are hanging freely on the FDM head. With the FDM head positioned as indicated in the illustration on page F2/3000-20, line up and drop into place the FDM head’s upper hinges with the lower hinges of the back plate.

  • Page 29: Removing Backflow From The Head

    It might be helpful to lower the Z stage platform before removing backflow. Remove the motor block if necessary. The tweezers supplied by Stratasys can often be used to remove excess material without removing the motor block. It might be necessary to unclip the cable for easier access to the set screws.

  • Page 30: Setting Modeling Temperatures

    Before proceeding, make sure; 1) the Z stage platen is at least 6 inches below the FDM head. 2) the FDM head is mounted to the FDM . 3) the liquefier is heated to the correct temperature. FDM 2000/3000/8000 Manual 10MAY01...

  • Page 31: Attaching Fdm Tips To The Fdm Head _ F2/3/8000-25

    F2/3/8000-25 Procedures Usage—Modeling Operations Removing an FDM tip from the FDM head Unscrew the tip using the tip wrench. Avoid direct skin contact with the hot FDM head and tip. Always wear heat resistant gloves. Make sure the tips are at the recommended modeling temperature before removing them.
  • Page 32 Press the “Load” button once to toggle it off. Before Proceeding Each tip is designated for use with only one material. Never use a tip for a material other than the one you select for that tip. FDM 2000/3000/8000 Manual 10MAY01...

  • Page 33: Changing Spools Of Modeling Material

    F2/3/8000-27 Procedures Usage—Modeling Operations Changing Spools of Modeling Material Removing an Empty Spool of Material Press “UNLOAD” on the keypad for the modeling tip to begin the unloading process. Allow the machine to run for 10 seconds and then open the head. Pull the filament out from the front of the machine.
  • Page 34 Make sure the spool does not rest on its tension ball. If you are loading ABS, open the head and insert the filament seals using the tool supplied by Stratasys. Press the “LOAD” button. Feed the filament gently into the guide hole on the bottom of the sensor block (do not force it), while continuing to unspool filament, until you feel it being pulled into the FDM head.

  • Page 35: Enabling The Auto Shutoff

    F2/3/8000-29 Procedures Usage—Modeling Operations Enabling the Auto Shutoff The FDM is equipped with an Auto Shutoff feature. Turning this feature on causes the FDM to turn itself off after completing a model. The cooling fan will remain on for 30 minutes to prevent backflow. To enable the Auto Shutoff feature: Press the “AUTO SHUTOFF”...

  • Page 36: Dry Filament Measurement Procedure

    Set the vacuum dryer to 20 mm Hg. Preheat the material to 175 Place the material in the vacuum dryer for 2-3 hours. Spools can be sent to Stratasys for drying. Contact your sales representative or call Stratasys Customer Support. FDM 2000/3000/8000 Manual...

  • Page 37: Replacing The Foam Foundation

    Procedures Usage—Modeling Operations F2/3/8000-31 Replacing the Foam Foundation To perform the operations below, the front door of the FDM must be com- pletely open. Removing the Foundation Envelope temperature for modeling with ABS is 70 C (158 Always wear heat resistant gloves. Turn the locking latch on the Z stage platen clockwise so it is in a horizon- tal position.
  • Page 38 F2/3/8000-32 Usage— Modeling Operations Procedures ↔ ↔ ↔ ↔ ↔ FDM 2000/3000/8000 Manual 10MAY01...

  • Page 39: Positioning The Fdm Head

    Procedures Usage—Modeling Operations F2/3/8000-33 Top View Positioning the FDM Head The FDM does not home in X, Y, and Z when on “Pause.” If an SML file is sent to the FDM while it is on “Pause,” the operator must turn the “Pause”...
  • Page 40 FDM will pause. Mount and load a new spool of material and then press the Pause button to resume building the model. Aborting a Model To abort a model in process: Close the FDM status window. FDM 2000/3000/8000 Manual 10MAY01...

  • Page 41: Fdm 2000/3000/8000 Maintenance

    F2/3/8000-35 FDM 2000/3000/8000 Maintenance Equipment Required The following equipment is required for maintenance of the Stratasys FDM 2000/ 3000/8000. Some of these items are included in your start-up kit. • Phillips head screwdriver • small flat-head screwdriver • plastic putty knife •...

  • Page 42: Cleaning The Fdm Head

    On the liquefier temperature control, verify it is running in auto- matic mode (the red light on the “AUTO/MAN” button should be off). If the red light is on, press the “AUTO/MAN” button twice to turn it off. Call Stratasys technical support for further instructions. FDM 2000/3000/8000 Manual...
  • Page 43 Procedures Maintenance—Cleaning the Head F2/3/8000-37 The liquefier temperature control MUST operate in AUTOMATIC MODE. You could overheat the liquefier when the control is operating in manual mode (in manual mode, the lower display of the liquefier control indicates the percentage of output, NOT temperature.) The ma- chine is in Manual mode if there is a light showing next to the “M”...

  • Page 44: Daily Cleaning

    This will change the accuracy of the FDM and void the factory-set calibration of the X-Y table. Be sure to use only the computer cables supplied by Stratasys with the FDM 2000/3000/8000. They have been designed and tested to give optimum performance and to protect the system from electro- static discharge.

  • Page 45: Periodic Maintenance

    FDM. Wait for the FDM to pause (the light on the “Pause” button will flash.) If it does not pause, call the Stratasys service department. Press the “Enter” button on the control panel keypad.

  • Page 46: Cleaning And Lubricating The Lead Screws

    A high temperature Teflon lubricant must be used to lubricate the xy table cables. Stratasys recommends “Krytox” which is included in your “Start Up” kit. Do not use any other type of lubricant. The xy table cables should be lubricated monthly to ensure continued optimal performance and prevent drying and cracking of the coating which protects the wire.

  • Page 47: Fdm 2000/3000/8000 Troubleshooting

    Procedures Troubleshooting F2/3/8000-41 FDM 2000/3000/8000 Troubleshooting Symptom Cause Solution FDM head runs opposite Parameters not downloaded Reload parameters the direction it is supposed to after 201 is changed X-Y driver cables are Swap X-Y driver interchanged cables Z stage runs opposite the...

  • Page 48: Torque Limiting

    Troubleshooting—Torque Limiting Procedures Torque Limiting The torque limiting function has been integrated into the Stratasys firmware to protect against damage to the filament drive system during operation. This function constantly monitors the motor current draw to the filament drive motors. If the system detects an abnormality, the machine is put on pause so the model is not wasted.
  • Page 49 Reference Applications Manual Release 5.0 Stratasys Document No: 105211-0001 Rev. B Applications Manual 10MAY01...
  • Page 50 Reference Applications Revision Date July, 1995 April, 1996 December, 1996 October, 1997 May 2001 Applications Manual 10MAY01...
  • Page 51 CAD design to an investment casting, using the model as the master pattern. The mold can be liquefied at a temperature of only 150 degrees Fahrenheit or 50 degrees Celsius, and the Stratasys investment casting wax can be milled, drilled, carved, sawed, and tapped. Applications Manual...
  • Page 52 Reference Applications Conceptual Models Conceptual Models The speed and accuracy of the FDM hardware allows engineers to produce a new part each time the product undergoes a revision. In addition, a full-scale proto- type of a proposed part, handed out at the final presentation or included with the proposal package, has strong appeal for prospective clients.
  • Page 53 Finishing Touches Chemical Finishing and Polishing Finishing Touches Stratasys 3-D models which use casting wax, machinable wax, or ABS can be polished and finished either mechanically or chemically. Mechanical Finishing and Polishing In mechanical finishing, the surfaces of the model are smoothed and the seams are removed with an abrasive such as sandpaper, Scotch-Brite, or a flat file or a tool such as a hand-held razor knife.
  • Page 54 Each model design has unique geometry which determines the shape of the picks, knives, and sanding blocks best suited to that model. Tools for P400-ABS Plastic (ABS) Stratasys recommends the following tools for finishing parts made from ABS: A needle-nose pliers A good electric detail sander (e.g. Dremil Sander)
  • Page 55 — precautions must be taken to ensure the safety of the user. Stratasys and its customers have informally tried some solvents as model cleaning/polishing agents, however STRATASYS DOES NOT INTEND THIS INFORMATION AS A RECOMMENDATION OR GUIDELINE FOR USE.
  • Page 56 Reference Finishing Touches Chemical Finishing and Polishing The following is an example of a reported general procedure for ICW05: Remove any supports using a needle-nose pliers and dental picks. Remove any surface irregularities with an appropriate abrasive (sandpaper, a file, etc.) Apply heptane with a soft cloth or cotton swab, rubbing until the surface of the model takes on a creamy appearance.
  • Page 57 Reference Finishing Touches Chemical Finishing and Polishing Epoxy Epoxy is a two-part chemical which coats the model, giving it a smoother appear- ance and also acting as a structural reinforcement. The epoxy is a mixture of polyester resin and styrene monomer which creates a hard shell and provides reinforcement for the model.
  • Page 58 A-10 Reference Finishing Touches Chemical Finishing and Polishing ABS Finishing Tips and Techniques Tools Required Needle-nose pliers Various picks and files One or more small spatulas One or more small chisels 120 grit sandpaper 320 grit sandpaper Random-orbital sander Detail sander ABS glue Super glue Hot knife...
  • Page 59 Reference A-11 Finishing Touches Chemical Finishing and Polishing Sanding the Model Use sandpaper to remove small bits of material without changing the part's dimensional tolerances. Use 120 grit sandpaper for larger bits and 320 grit sand- paper to give the part a smooth surface. Use a Random-orbital sander to smooth large surface areas evenly.
  • Page 60 A-12 Reference Finishing Touches Chemical Finishing and Polishing ICW06 Finishing Tips and Techniques Tools Required Needle-nose pliers Various picks and files One or more small spatulas One or more small chisels 220 grit sandpaper Hot knife Removing Supports Use a small spatula or chisel to pry most of the support away from the part. This minimizes the risk of damage to the part.
  • Page 61 ® and Master Extra Soft Utility Red Wax Gaps in the wax model must be filled before the model can be shelled. Stratasys recommends using Patch-Eze red patch wax to fill small gaps. Patch-Eze is tacky and should not be used as a general filler. This is because casters rinse the model with a citrus based solvent.
  • Page 62 A-14 Reference Modeling with ABSi w/BASS or ABS w/BASS When switching from an SR2 head to a BASS head, there are several changes that must be made. Changing the Keypad Setting Press space 2 3 9 on the keypad on the FDM. Press 5 enter The screen will read ABS RB_SF Press 8 to change it, then press enter...
  • Page 63 Reference A-15 Modeling with ICW Preparing the FDM system for Modeling with the ICW Change the head assembly according to procedures found in the User guide in the FDM Hardware section. Install the model and support tips according to the procedures found in the user guide in the FDM Hardware section.
  • Page 64 A-16 Reference Reprogramming the Support Watlow If you are switching from soluble material to ICW, the support watlow must be reprogrammed. Currently the soluble material tells the watlow to lower to a safe temperature while not in use, but when running wax, that “lower” temperature is very high (wax runs at 75).
  • Page 65 Reference A-17 Modeling/Calibrating with Elastomer E20 elastomer is a thermoplastic polyester based elastomer formulated to provide a tough, flexible material that offers a unique combination of me- chanical and physical properties. E20 elastomer was developed for applica- tions requiring flexible models such as window or door seals, straps, gaskets, toys, or container designs.
  • Page 66 A-18 Reference Changing the Keypad Setting Press space 2 3 9 on the keypad on the FDM Press 5 enter The screen should read ABS RB_SF If the setting is 25, press 8 to change it then press enter Press enter again to exit the keypad After you are finished running elastomer and are switching back to soluble material, you must put the setting back to 25 Setting up FDM Status to run Elastomer...
  • Page 67 Reference A-19 X, Y, and Z offset calibration 1. Follow standard steps for Tip offset calibration. a. Start FDM Status. b. Click the Calibration button. · Specify the properties of the modeler in the Configure Modeler window. This is much like the configuration window in Insight. Specify the: model &...
  • Page 68 A-20 Reference 4. You will now download and build the special elastomer calibration file. Click Add a Job button to display the file open window. Find the file: e020_XYZ_CalBox.sml.gz for your modeler. The file is located in the Insight installation directory. For an FDM 3000 you will find the file at: c:\Insight\modelers\fdm3000\e020_XYZ_CalBox.sml.gz where Insight is installed at c:\Insight.
  • Page 69 Reference A-21 9. If the support material is not centered, return to the Calibration window to change the X and Y offset increments. a. In the Calibration window, click the +X, -X, +Y, -Y buttons to change the offset increment. b.
  • Page 70 A-22 Reference Material Handling for E20 Elastomer Do not open the sealed bag until you are ready to load the elastomer. Do not leave the spool in an open environment. Store unwrapped E20 and E20R material that is not in use in a dry box with desiccant.
  • Page 71 Insight™ 3.7 Installation Guide 14950 Martin Drive Eden Prairie, MN 55344 USA Telephone: (952) 937-3000 Fax: (952) 937-0070 www.stratasys.com November 21, 2003 PN# 104067-0013...
  • Page 72 The following information describes how to install Insight software on workstations running Microsoft Windows XP, Microsoft Windows NT 4.0 or Microsoft Windows 2000, for use with Stratasys FDM 1650, 2000, 3000, 8000, FDM Titan, FDM Vantage, FDM Maxum/Quantum, and Prodigy Plus modelers. This guide is divided into two sections: Section 1 - Installing Insight software Section 2 - Initial calibration of the FDM modeler.
  • Page 73 This utility allows you to install the Insight 3.7 software, review the Release Notes or other documentation, or access the Stratasys web site. If you select the Install button in the Insight Software Installer window, skip to step 6 below.
  • Page 74 Enter the name you want to use for your modeler. This can be any alphanumeric name. Use names to differentiate between modelers, if you have multiple modelers. Enter the COM port number that you will use to communicate with the FDM 2000, FDM 3000, or FDM 8000 modeler.
  • Page 75 Insight 3.7 Installation Guide page ____________________________________________________________________________________ 7. After successful installation of Insight, it is not necessary to logout. You can immediately use any of the Insight applications contained in the Insight Program Group. Section 2 - Initial calibration of the FDM 1650, 2000, 3000, or 8000 modeler.
  • Page 76 Insight 3.7 Installation Guide page ____________________________________________________________________________________ Tip Offset Procedure If you are installing a new FDM modeler or have recently changed the heads or tips, you will want to perform tip offset calibration. Refer to the FDM manual for a more complete description of the tip offset calibration procedure.
  • Page 77 Insight 3.7 Installation Guide page ____________________________________________________________________________________ 7. Choose Cal boxes and Tip offsets as the type of Download data. For tip-offset calibration, you will want to download the current offsets and a calibration box. 8. Click the Download button to build an initial calibration box using the current modeler configuration and offset values.
  • Page 78 Insight 3.7 Installation Guide page ____________________________________________________________________________________ 11. Repeat steps 8 through 10 as necessary, until the support material is centered on the model material. 12. After completing the X and Y offset calibration, peel away the support material layer from the final calibration box.
  • Page 79 P400/500 Soluble Release User Guide WaterWorks P400/500 Soluble Release User Guide Release 2.0 Stratasys Document no. 10263601E ® 02MAY01...
  • Page 80 Stratasys, Inc. Printed in the USA. FDM 1500, FDM 1600, FDM 1650, FDM 2000, FDM 3000, FDM 8000, FDM Quantum, 3D PLOTTER, FDM, Models in Minutes, ProtoSlice, QuickSlice, and Insight are trademarks of Stratasys, Inc.
  • Page 81 P400/500 Soluble Release User Guide Contents Introduction to WaterWorks P400/500 Soluble Release Preparing the FDM Changing the Watlow Temperatures Changing the FDM Tip Attaching FDM Tips to the FDM Head Removing an FDM Tip from the FDM Head Changing Spools of P400/500 Material Mounting a Spool of Material Removing an Empty Spool of Material Removing a Mounted Spool of Material...

  • Page 82: Introduction To Waterworks P400/500 Soluble Release

    If you have any questions regarding the procedures in this guide, please call Stratasys Customer Support at 952- 906-2283 or 1-800-801-6491 (U.S. Toll Free). This User Guide details the procedures necessary to set up and use the soluble release material on your FDM .
  • Page 83 P400/500 Soluble Release User Guide Hardware Settings Set the operating temperature for soluble support liquifier at 235°C. The • support liquifier Watlow temperature controller should automatically read 235° C when building a part. The Watlow has a secondary temperature setting of 210° C. Whenever the •...

  • Page 84: Preparing The Fdm

    P400/500 Soluble Release User Guide Preparing the FDM Changing the Watlow Temperatures The temperature control graphic does not necessarily contain the recommended temperatures for the modeling tip, support tip, and modeling envelope. Always check the white label on the side of the material spool and set the controls for the temperatures specified there.

  • Page 85: Changing The Fdm Tip

    P400/500 Soluble Release User Guide Close the front door to the modeling envelope when you are using materials that require envelope temperatures higher than ambient. Changing the FDM Tips P400/500 Soluble Release Material must be used with a T12 or T16 support tip. The T12 tip is recommended for a .007”–...

  • Page 86: Removing An Fdm Tip From The Fdm Head

    P400/500 Soluble Release User Guide Partially screw on the FDM tip and allow it to heat up to the liquefier temperature. Start the FDM tip by screwing it into the liquefier. Do not screw the tip all the way into the liquefier. Wait for the actual temperature reading on the liquefier temperature control (Watlow) to reach the set temperature.
  • Page 87 P400/500 Soluble Release User Guide Before Proceding Each tip is designated for use with only one material. Never use a tip for a material other than the one you select for that tip. ® 02MAY01...

  • Page 88: Changing Spools Of P400/500 Material

    P400/500 Soluble Release User Guide Changing Spools of P400/500 Material Mounting a Spool of Material Inspect the wheels, spools, tips, and head before starting each model. Tighten the tips to prevent ooze and seam defects. If you tighten the tips you must check calibration.

  • Page 89: Removing An Empty Spool Of Material

    P400/500 Soluble Release User Guide Press “UNLOAD” on the keypad to end the unloading process. Repeat steps 2-5 for the model tip, if necessary. Remember to set the temperature to 235° C before loading a spool, either by pressing Enter on the keypad or by manually increasing the temperature.

  • Page 90: Removing Soluble Supports With The Ultrasonic Cleaner

    P400/500 Soluble Release User Guide Removing Soluble Supports with the Ultrasonic Cleaner Soluble supports are removed using the Ultrasonic Cleaner. Use the following procedure to remove soluble supports. The Ultrasonic Cleaner Start-up kit includes: Ultrasonic tank • Tank lid • Basket •...
  • Page 91 P400/500 Soluble Release User Guide Plug the tank and generator into the extension cord. Step 2: Prepare the Tank Make sure that all cords connected to the tank are securely fastened and dry and that the tank is plugged in. Fill the ultrasonic tank (11 gallons/42 liters) with water to slightly above the fill line.
  • Page 92 P400/500 Soluble Release User Guide Carefully open one bottle of solution concentrate. Slowly add the concentrate to the tank spreading the powder over the entire surface of the water. Completely empty the bottle of concentrate and dispose of bottle when done.
  • Page 93 Stratasys cannot anticipate local, state or international regulatory statutes. Stratasys recommends that disposal procedures be verified by the proper authorities in your region. Stratasys cannot be held liable if the solution is not disposed of properly. ®...
  • Page 94 P400/500 Soluble Release User Guide MATERIAL SAFETY DATA SHEET – P400/500 SC Supplier: Stratasys, Inc. Emergency Telephone Number: +1.952.937.3000 14950 Martin Drive Contact Name: S. Scott Crump Eden Prairie, MN 55344 USA Date: September 7, 1999 Revision 1.1 Ingredients: Product Name:...
  • Page 95 P400/500 Soluble Release User Guide Health Hazard Data: Identification The concentrated product is a white, granular and beaded material. Causes eye and skin burns. Reacts with moisture to release heat and reacts with metals to release hydrogen. Threshold Limit Value: No established value.
  • Page 96 P400/500 Soluble Release User Guide VII. Handling and Storage: Handling: Avoid contact with the skin, eyes, and clothing. Use proper lab safety techniques (i.e. gloves, goggles, etc). Wash exposed areas immediately and thoroughly after skin contact from working with this product and before eating, drinking, using tobacco products or using the restroom.
  • Page 97 Stratasys shall not be held liable for any damage resulting from handling or from contact and use with the above product.
  • Page 98 Reference Utilities Manual Release 6.0 Stratasys Document No: 105212-0001 Rev. B Utilities Manual 10MAY01...
  • Page 99 Reference Utilities Manual Revision Number Date April, 1995 November, 1995 February, 1996 April, 1996 December, 1996 March, 1997 October, 1997 May, 2001 Utilities Manual 10MAY01...
  • Page 100 139-255 refer to rollback, and even numbers from 0-254 refer to the gain in RPMs/in/sec. Odd numbers from 129-137 are reserved for special functions and are to be used only by engineers at Stratasys. Below are detailed explanations of each part of the code.
  • Page 101 Reference Stratasys Modeling Language SML Code Format 100 is a gain number. All even numbers are known as “gain numbers.” Gain numbers are not specified in RPMs. They refer to RPMs per head speed in inches per second. This means the wheel speed is dependent upon the head speed.
  • Page 102 Reference Windows NT Shell Scripts ssrecov Model Recovery Description The ssrecov utility recovers or restarts a build in which the sending command was interrupted due to a power failure or surge, or inadvertent logoff from your system. You can run Model recovery on all FDM modelers including the FDM, 1650, 2000, 3000, or 8000, as long as you are using Insight.
  • Page 103 Reference Windows NT Shell Scripts ssrecov runacl.exe Description RUNACL.exe is a program used to communicate between the PC and the control- ler, similar to the Unix ssrun utility. Find Runacl.exe in the Insight install directory, for example C:Insight20/ Utility/Runacl.exe Double click on Runacl.exe to access the program and make sure the pause light is not flashing on the FDM hardware.
  • Page 104 Reference Technical Notes Release 5.0 Stratasys Document no. 105214-0001 Rev. B 10MAY01 Notes...
  • Page 105 Reference Release October, 1997 May, 2001 10MAY01 Notes ®...
  • Page 106 Part 1: Summary of Existing Techniques The following is a description of a set of postprocessing techniques collected from various Stratasys users. This is intended to help identify the state-of- the-art in postprocessing among users. The listed techniques are being experimented with at Biomet in order to establish their strengths and limita- tions.
  • Page 107 Moving the Z Stage While Modeling Stratasys recommends that you do not move the Z stage while building models. Moving the Z stage causes the model to be inaccurate because the FDM modeler does not keep its last Z stage position in its memory.
  • Page 108 Reference Warning Messages The Insight Messages window displays a variety of messages that help you know the progress of your work. Some of these messages require a specific action by the user. Warning “STL Model is oversized in X, Y, and/or Z” This message occurs when you open an STL file and any portion of the STL file is outside the modeling envelope.
  • Page 109 This is because when the head is closed, the motor is cooled by a cold air cooling system. Stratasys suggests you unload the material and lower the temperature whenever you open the head °...
  • Page 110 Always make sure your filament is loaded and your liquefiers are up to modeling temperature BEFORE you put on a tip. 11. Use the tool provided by Stratasys and make sure the tips are tight. The motor shaft specifications are designed to load at 50%. Exceeding this limit may cause the motor shaft to break.
  • Page 111 When creating models, better resolution and quality is normally achieved by using the smallest possible tips. At Stratasys, our engineers run 90% of the benchmarks using default road settings, and 99% using a 0.012” tip. They are the most successful settings for creating a high quality model.
  • Page 112 Reference slice, we have noticed the toolpaths tend to become too wide and have diffi- culty bonding between levels. We suggest you decrease your Z-slice height in these cases. Overflow and loose tips lead to excess material on the tips, which is the primary cause for burn marks on the models.
  • Page 113 Note: Use high temperature, anti-seize lubricants designed to prevent seizing, galling, and corrosion. These lubricants are easily obtained from most automo- bile parts and supply stores. If you have additional questions, please call Stratasys Customer Service at 952-906-2283. 10MAY01 Notes...
  • Page 114 The T10 tip (0.010-inch) is designed for small, thin-walled, fine featured or highly detailed parts. When used with the .007-inch slice increment, superior surface is also achieved. The T10 tip is currently available on the FDM 2000/ 3000/8000. T10 Features...
  • Page 115 N-12 Reference T10 Tip Modeling Techniques • For best results, run two or three parts at a time. • Be careful not to damage the end of the tip. • Make sure to use dry ABS material only. • Do not use the Sparse fill feature on the part. Use the T12 tip if you need to use the Sparse fill feature with a .007-inch slice.
  • Page 116 The following procedures describe how to lubricate the FDM 8000 XY table. Even though your FDM was lubricated at the factory, you should lubricate the XY table monthly to ensure continued, optimal performance. If you have questions about the procedure contact Stratasys customer support at 952- 906-2283. Before You Start The supplied lubrication kit includes a grease gun that contains a special- ized lubrication and grease gun fitting.
  • Page 117 N-14 Reference Insert the tip of the grease gun into the small, flush miniature fitting on the X-axis bearing housing (see illustration below). Pump the grease gun handle three times, or until the bearing is full. The bearing is full when grease starts oozing from the upper center of the bearing housing.
  • Page 118 Before You Start A high temperature Teflon lubricant must be used to lubricate the Z- stage lead screws and guide rods. Stratasys recommends “Krytox”. Do not use any other type of lubricant. If you are unable to locate this type of lubricant, contact Stratasys customer support.
  • Page 119 When cleaning the interior components, check for signs of wear like metal shavings or debris inside the machine. Note any problems found and contact Stratasys customer support. Clean or vacuum out any remaining debris Step 2 - Apply Lubricant Apply lubricant to a clean towel or small brush.
  • Page 120 Safety gloves • Teflon-based synthetic lubricant • If you have any questions regarding this procedure, contact Stratasys Cus- tomer Support at (952) 906-2283. 1) Set FDM Modeler model, support, and envelope teperatures to 0° and allow envelope to cool. WARNING! The interior components of the FDM are hot! Prior to applying lubricant, wait for the FDM to cool down to a safe working temperature.
  • Page 121 N-18 Reference Changing Filament during a Part Build in the FDM When the FDM Modeler runs out of material during a part build, the modeler will pause, the head will be park in the front of the build envelope and a “filament out” message will display on the control panel.
  • Page 122 Reference N-19 4. Using both hands, press the spool onto the mount until it locks into place. Make sure the spool does not rest on the tension ball. 5. Toggle to the other liquefier tip by selecting it on the keypad. 6.
  • Page 123 Reference F2/3/8000-43 Reference FDM 2000/3000/8000 Release 2.0 Stratasys Document no. 105210-0001 Rev. B ® 10MAY01...
  • Page 124 FDM. The FDM head deposits material as it follows the part geometry for each curve. It starts from the bottom curve and builds up the model to the top curve. Material State: Liquified Solid FDM 2000/3000/8000 Manual 10MAY01...
  • Page 125 Indicates the set temperature. Automatic/Manual Button This button is locked out at the factory. If any of the temperature controls are found set to manual, call Stratasys Customer support. Temperature Adjustment Buttons The up arrow button increases the temperature setting. The down arrow button decreases the temperature setting.
  • Page 126 FDM 2000/3000 CONT ROLLER Temperature Controls WATLOW WATLOW WATLOW Temperature increase Temperature decrease Support Envelope Model S et...
  • Page 127 Descriptions—Control Panel Reference F2/3/8000-47 Front Panel Functions — General Each button produces an immediate effect if it is pressed while the FDM is idle. If the Reset or Stop button is pressed when the FDM head is moving, it takes effect immediately. The Pause button takes effect after the FDM finishes its current tool path.
  • Page 128 Keypad Display Panel Options Below are listed the basic options available through the Keypad Display panel. Most options for the Keypad Display panel are preset at Stratasys. Pressing “Space231” allows the user to access the part material calibration selections. Pressing “Space239” allows the user to access the support material calibration selections.
  • Page 129 Reference F2/3/8000-49 Keypad Display Messages Key pad messages display information about the FDM. PD Time Fault The PD Time Fault message appears when a PD time exceeds five con- tinuous seconds. XY Time Fault The XY Time Fault message appears when there is uninterrupted head movement for five minutes.
  • Page 130 Descriptions—Hardware Reference Hardware Baud and Parity Settings and the EPROM The FDM 2000/3000/8000 is set at the factory to 9600 baud and no parity. RS-232 Serial Interface The FDM 2000/3000/8000 has a 25-pin “D” subminiature connector. The table below describes the functions of these pins.
  • Page 131 Reference Glossary Release 4.0 Stratasys Document no. 105213-0001 Rev. B 10MAY01 Glossary...
  • Page 132 January 1995 February 1996 October 1997 2001 All terms in this glossary are defined within the context of creating a model with Stratasys hardware and software. The following terms are registered trademarks of Stratasys, Inc. ® ® ProtoSlice ® QuickSlice The following terms are trademarks of Stratasys, Inc.
  • Page 133 Reference 2-D Geometry In CAD systems, 2-D geometry consists of points, lines, arcs, and other single plane shapes. It is often used in drafting oriented applications. In Rapid Prototyping, 2-D geometry consists of Polylines (a connected series of X-Y points) all on the same Z-level.
  • Page 134 Reference Contour Fill A fill pattern that follows the shape of the perimeter curve. The thicker circle, in the example, represents a perimeter curve. The two inner circles represent contour fill roads for that perimeter curve Curl A distortion that involves two or more layers, in which shrinkage of a newly- formed layer, while adhering to the previous layer, causes those two layers or more to curl.
  • Page 135 Reference FDM Head Liquefies the thermoplastic modeling material and extrudes it into precise layers that fuse to form the complete model. FDM Liquefier Melts the thermoplastic modeling material to an exact temperature to form the model. It is part of the FDM head. FDM Tip The interchangeable nozzle at the end of the FDM liquefier.
  • Page 136 Insight Unix and Windows NT-based software that slices STL models to create SML code for running Stratasys FDM systems. Keypad The panel on the FDM hardware that controls tip flow and related func- tions. It is located on the upper left corner of the FDM hardware.
  • Page 137 Reference Modeling Envelope The actual volume of space inside FDM hardware in which physical mod- els can be created. Modeling Envelope Temperature Control This is the Watlow controller labelled “Envelope.” It controls the temperature of the envelope in degrees Celsius. Modeling Material A plastic or wax compound that is liquefied and extruded through the modeling tip to create a part.
  • Page 138 Reference Polyline A series of connected X-Y points, sometimes referred to as a “curve.” This is the basic 2-D geometry used by most rapid prototyping systems. Pre-Flow A rate of material flow that is used before the head starts to move. Purge The manual or automatic cleaning and removal of unwanted material from the liquefier and tip.
  • Page 139 Reference SML Code, SML File Stratasys Modeling Language (SML) code is the list of instructions used by FDM hardware to build a physical 3-D model. An SML file is created from a generated tip path or roads. Speed The constant rate the FDM head moves in thousandths of an inch per second.
  • Page 140 G-10 Reference Toolpath A track of material extruded from the FDM tip onto either the foundation, or a previous layer, controlled to a specific width. Toolpath Width Compensation Offset of the center of a road so as to compensate for its width, such that the edge of the road, not its center, lies at the desired position.
  • Page 141 Reference M1-1 Appendix M1 Materials Release 5.0 Stratasys Document no. 105215-0001 Rev. B ® Appendix M1 10MAY01...
  • Page 142 M1-2 Reference Revision Number Date April, 1995 June, 1996 March, 1997 October, 1997 May, 2001 Materials Appendix 10MAY01...
  • Page 143 Reference M1-3 ICW06 - Investment Casting Wax FDM 1600, 1650, 2000, and 3000 FDM Tip Inner Diameter Note: The .025 tip is FDM System only available for the Parameters 0.025" 0.016" FDM 1600 and FDM 1650. Speed inches/sec 0.800 0.800 (maximum) 0.800 0.800...
  • Page 144 M1-4 Reference Materials Plastic P301 - Plastic Material (Polyamide) FDM 1500 and 1600 FDM Tip Inner Diameter FDM System Parameters 0.025" 0.016" Speed inches/sec 0.500 0.700 (maximum) 0.500 0.500 (recommended) Road Height 0.014" 0.020" (maximum) 0.010" 0.010" (minimum) 0.010" 0.010" (recommended) Road Width 0.050"...
  • Page 145 Reference M1-5 P400 - Plastic Material ABS FDM 1600, 1650, 2000, 3000, and 8000 FDM Tip Inner Diameter FDM System 2000/3000/8000 1600, 1650 Parameters 0.012" 0.016" 0.012" 0.010" 0.025" Speed inches/sec 0.800 0.800 1.000 1.000 1.500 (maximum) 0.800 0.800 1.000 1.000 (recommended) 1.000 - 1.5000...
  • Page 146 M1-6 Reference P500 - Plastic Material ABSi FDM 1600, 1650, 2000, 3000, and 8000 FDM Tip Inner Diameter FDM System 2000/3000/8000 Parameters 1600/1650 0.012" 0.012" 0.025" 0.010" 0.016" Speed inches/sec 0.800 0.800 1.500 1.000 1.000 (maximum) 1.000 1.000 (recommended) 0.800 0.800 1.000 - 1.5000 Road Height...
  • Page 147 Reference M1-7 Material Specifications* P500 ABSi is a medium grade, higher impact strength ABS plastic. P500 ABSi meets all FDA USP Class VI requirements and can be gamma sterilized with negligible discoloration. The property specifications below are taken from ASTM injection molded samples. Radiation (Mrad) Properties Tensile strength (psi)
  • Page 148 M1-8 Reference E20 & E20R Elastomer - FDM 1650/2000/3000 FDM System Elastomer (.016" tip) Parameters E20R Speed inches/sec** (maximum) 0.800 0.800 (recommended) 0.800 0.800 Road Height (maximum) 0.010" 0.010" (minimum) 0.010" 0.010" (recommended) 0.010" 0.010" Road Width (maximum) 0.020" 0.040" (minimum) 0.016"...

This manual is also suitable for:

Fdm 3000Fdm 8000

Table of Contents