Related Manuals for Z Corporation Z402C
Summary of Contents for Z Corporation Z402C
- Page 1 Z402C System User Manual November 2001 402C 3D Color Printer User Manual Z Corporation Software Version 5.1.40 Copyright©2001 Z Corporation Part Number 09501...
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Page 2: Table Of Contents
2.10 3D PRINT SETUP ....................19 2.10.1 RECOMMENDED SETUP PROCEDURE* ..............20 2.10.2 CHANGING POWDER PARAMETERS ..............20 2.11 SETTING USER PREFERENCES...............21 2.12 SERVICE MENUS....................23 PREPARING THE Z402C SYSTEM TO PRINT............24 HARDWARE CONTROLS ...................24 PREPARING THE 3D PRINTER................24 3.2.1 FILLING THE FEED BOX WITH POWDER..............25 3.2.2... - Page 3 Z Corporation Z402C System User Manual PRINTING THE PART ................... 29 POST PROCESSING THE PART................32 REMOVING THE FINISHED PART..............32 DEPOWDERING THE PART................33 DRYING THE PART .................... 33 INFILTRATING THE PART.................. 34 5.4.1 TO INFILTRATE THE PART USING RESIN: .............34 ADVANCED USER FEATURES................
- Page 4 Z Corporation Table of Figures Figure 1. The Printing Process....................... 6 Figure 2: The Z402C System Shelling and Infrastructure Features............7 Figure 3: Illustration of Z402C System Print Orientations ..............8 Figure 4: The Main System Software Window ..................11 Figure 5: Carwash Detail ........................
- Page 5 Z Corporation Z402C System User Manual The Z Corporation Rapid Prototyping System is manufactured under patent license to be used for the fabrication of appearance parts and facsimile prototypes. Other uses may be restricted; contact Z Corporation for further information.
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Page 6: Your Z402C System
INTRODUCTION 1.1.1 OVERVIEW This Z402C 3D Color Printer Manual will speed you along the path towards quickly and inexpensively building parts. The manual contains the following sections: 1. Introduction. This section will give you an overview of the principles behind the Z402C System, familiarize you with the terminology we will use to describe the Z402C System and introduce you to some of the features of this manual. -
Page 7: How It Works
The feed piston comes up one layer and the build piston drops one layer. The Z402C System then spreads a new layer of powder and repeats the process, and in a short time the entire part is printed. -
Page 8: Figure 2: The Z402C System Shelling And Infrastructure Features
Because the powder layers support the structures being printed above, the Z402C System prints parts without support structures and can print parts with complex geometries. There are several important features of the Z402C System that will help you print the best parts for your intended purpose. -
Page 9: Figure 3: Illustration Of Z402C System Print Orientations
Strong Figure 3: Illustration of Z402C System Print Orientations Accuracy. The accuracy of the system depends on the materials you choose. You can employ the anisotropic scaling feature in the software to adjust for expected shrinkage and bring your parts into true scale. -
Page 10: Printing A Part Overview
STEP 3: PRINTING THE PART The Z402C 3D Printer prints most parts in minutes and prints even the largest parts in a few hours. You may then remove the part, depowder any excess powder and, if desired, dry and infiltrate the part with wax or other materials to give the part the desired strength and finish. -
Page 11: The Zcorp System Software
WARNING: To avoid problems that may occur during printing, ensure that all screen savers and your power management software are turned off on the computer driving the Z402C Printer. Most screen savers and power management software can be turned off in the main Windows screen settings. -
Page 12: Main Window
• The cross-sectional view displays exactly what the Z402C System will print in that layer. Different window views can be resized for user convenience. To resize a window, place the pointer over the border between views, left-click on the border and drag to create your preferred window size. -
Page 13: Toolbar
You may open zbd, stl, bld, ply, zcp, sfx, zec, or wrl files. The print volume when using the Z402C System in color is 6 x 9 x 8 inches (155 x 225 x 200 mm.) When using the Z402C System in monochrome, the build are is 8 x 10 x 8 (200 x 250 x 200 mm.) - Page 14 Z402C System User Manual Z Corporation When importing VRML files you will be asked to input mesh resolution and texture threshold settings. Mesh resolution is the number of facets in your graphic primitive file. A graphic primitive file is composed of facets that are made up of cones, cylinders, and spheres as opposed to triangles.
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Page 15: Navigating Through The Build Area
Z Corporation Z402C System User Manual If the imported file is rendered dark and no slices show in the cross sectional view, the back faces of the file are showing. The part will not print properly in this orientation. To correct the file, invert all normals. -
Page 16: Transforming The Part
Z402C System User Manual Z Corporation TECHNICAL TIPS…. When setting up your build area with multiple parts, place larger, bulkier parts towards the bottom of the build box. TRANSFORMING THE PART First select your part(s). To select parts within the build area, click on the part with the left mouse button. - Page 17 Z Corporation Z402C System User Manual • You may move the object more precisely by choosing ‘Translate’ from the Transform menu. • To rotate the part, select the part and choose ‘Rotate’ from the Transform menu. In the dialog box, specify the plane and degree of rotation you desire.
- Page 18 Z402C System User Manual Z Corporation • To justify the part, select the part and choose ‘Justify’ from the Transform menu. You may justify the part to the left, right, front, back or bottom of the build box. Justifying the part, lets the software move the part to the edge of the build box optimizing your build area.
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Page 19: Getting Information About The Build
Z Corporation Z402C System User Manual • To change anisotropic scaling factors for a specified part, choose the part and select the ‘Anisotropic Scaling’ option under the ‘Transform’ menu. Enter your custom anisotropic scaling factors for the x, y, and z axes. Click ‘OK’. -
Page 20: Saving Your Work
Z402C System User Manual Z Corporation SAVING YOUR WORK After you have imported the files, oriented parts and have set up your build to print, save your work by selecting ‘Save As’ from the File menu. After you choose a name for your build, select ‘Save’ and your work will be saved as a *.zbd file. -
Page 21: Recommended Setup Procedure
Z Corporation Z402C System User Manual 2.10.1 RECOMMENDED SETUP PROCEDURE* 1) Select the Printer that you will be using. Choose ‘Select Printer’. You may choose any printer that is connected by serial port. If the Printer is busy or offline, the option to select this printer will not be available. -
Page 22: Setting User Preferences
Z402C System User Manual Z Corporation 3. Choose a given layer thickness or to put in your own layer thickness, choose ‘Other.’ 4. Shell Saturation values may be changed based on three factors – Binder/Volume Ratio (%), Saturation Level (%), and Saturation. When changing any value corresponding to Shell Saturation, the relative Core Saturation will also be changed. - Page 23 Z Corporation Z402C System User Manual • Orient imported parts for the fastest print times. When this box is checked, parts are always rotated so that the smallest dimension of the part occurs in the Z direction. Since build times are largely determined by the height of the part, this arrangement produces the fastest build times.
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Page 24: Service Menus
Z Corporation 2.12 SERVICE MENUS The System Software allows you to draw information from the Z Corporation 3D Printer and activate some printer functions. • Get Piston Levels. (Shortcut Key: F1) To check the available powder in the Feed Piston and the remaining room in the Build Box, Select ‘Get Piston Levels’. -
Page 25: Preparing The Z402C System To Print
Z Corporation Z402C System User Manual PREPARING THE Z402C SYSTEM TO PRINT HARDWARE CONTROLS The front control panel on the Z402C 3D Printer has the following features: Feed Up/Down Buttons. Allows users to raise or lower the Feed Online Button. Enables Box. -
Page 26: Filling The Feed Box With Powder
Z402C System User Manual Z Corporation 3.2.1 FILLING THE FEED BOX WITH POWDER 1. Press and hold the Feed Down button until the piston reaches the bottom of the Feed Box. The piston will stop when it reaches the bottom. - Page 27 Make sure that you carefully vacuum up excess powder. It only takes a minute, and the tidier the machine is, the less often it will need maintenance! WARNING: Use only powder supplied by Z Corporation. Use of any other material may impact the performance and/or safety of your Z402C System and will void warranty of equipment.
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Page 28: Rinsing The Carwash
Z402C System User Manual Z Corporation 3.2.2 RINSING THE CARWASH The Carwash cleans the nozzle array of the Print Head during printing. Rinse the Carwash before and after each build. Squeegee Figure 5: Carwash Detail To clean the Carwash: 1. Take the machine Offline. -
Page 29: Checking Overflow Vacuum Bag
CHECK FLUID LEVELS! Make sure you have enough fluid to complete the build. Make sure the waste bottle is empty. Keep your Z402C 3D Printer as clean as possible. The cleaner it is, the better it will function. Z Corp Service (781)852-5050/(877)88-ZCORP... -
Page 30: Printing The Part
Z402C System User Manual Z Corporation PRINTING THE PART Before printing, double check the settings for your print job by choosing the ‘3D Print Setup’ option under the File menu. Make sure the software has chosen the correct COM port. You also want to make sure powder type and parameters are correct. - Page 31 ‘’Remeasure.” You may chose to print even when this warning is given by pressing ‘Go Ahead’. 4. The Z402C System will commence printing your part. During printing, the Z402C System Software will display the progress of the print and will monitor the key operating characteristics of the Z402C Printer.
- Page 32 Z402C System User Manual Z Corporation 5. After completion of your build, the System Software will display a dialog box containing information about print time, time completed, and number of pixels used. www.zcorp-users.com...
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Page 33: Post Processing The Part
WARNING: When performing any vacuuming operation, use the vacuum provided as part of the Z402C System. Vacuuming powder can generate static electricity, and use of a non-grounded vacuum will create static charges, which may affect the operation of the Z402C System and harm the operator. -
Page 34: Depowdering The Part
Z402C System User Manual Z Corporation DEPOWDERING THE PART 1. Place parts inside depowdering unit. 2. Using the compressed air system included in the Depowdering Station, remove any excess powder that remains in any concave surfaces. TECHNICAL TIPS…. The air pressure on your Depowdering Station is adjustable. For bulky parts, turn the air pressure up. -
Page 35: Infiltrating The Part
If you wish to use the parts for focus groups or to send to vendors, you may wish to infiltrate with resin, a two-part epoxy or other material for greater durability and longer life. For information on other possible infiltration materials call us at Z Corporation, or visit our website www.zcorp-users.com 5.4.1... -
Page 36: Advanced User Features
Z402C System User Manual Z Corporation ADVANCED USER FEATURES ORIENTATION FOR SPEED Parts oriented with their largest dimension along the y or “fast” axis (print heads direction of travel), next longest along the x or “slow” axis (gantry direction of travel) and shortest dimension along the z- axis will print the fastest. -
Page 37: Maintenance
Z Corporation Z402C System User Manual 7 MAINTENANCE Maintenance Steps Frequency 1. Change Print Heads When Needed 2. Flush Binder Bi-Weekly 3. Lubricate Fast Axis Weekly 4. Vacuum Filter After Every Build 5. Clean Carwash Before and After Each Build... - Page 38 Z402C System User Manual Z Corporation 3. Although there are no serial numbers available with the color print head used on the Z402C System, we recommend that you input a series of six numbers in the Serial Number box. These numbers will be used when logging all builds printed with this set of print heads.
- Page 39 Z Corporation Z402C System User Manual 7. Lift the green lever and remove the old print head from the carriage. 8. Lay it on the deck next to the new print head. 9. Slide the color binder reservoir out from the old print head by pulling on the groove at the top of the binder reservoir.
- Page 40 Z402C System User Manual Z Corporation 11. Repeat the same procedure, placing the clear binder reservoir into the right side channel of the new print head. Discard the old print head. PLEASE NOTE: Make sure hoses are not twisted. If the hoses bind up, they may pull on the carriage and cause premature print head failure.
- Page 41 Z Corporation Z402C System User Manual 15. Wipe the contacts on the print head. PLEASE NOTE: Check again that the hoses are not twisted. If the hoses bind up, they may pull on the carriage and cause premature print head failure.
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Page 42: Changing Monochrome Print Heads
Z402C System User Manual Z Corporation 19. If the stripe test does not print well all colors will not look like a solid stripe. Choose the ‘Prime Print Head’ option under the Service menu and then run the stripe test again. - Page 43 Z Corporation Z402C System User Manual 4. Wait for the Printer to finish moving and the front panel lights to change to slowly blinking. This indicates that it is safe to remove the print head from the carriage. 5. Remove the cap from the new print head.
- Page 44 Z402C System User Manual Z Corporation 9. Remove the orange cap and tape from the face of the print head. 10. Insert the print head into the carriage. Lower the green lever to secure the print head. 11. Close the top cover and press the ‘Feed Up’...
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Page 45: Flushing The Binder
Z402C System User Manual FLUSHING THE BINDER If you will not be using your Z402C 3D Printer for more than two weeks, it is good practice to flush the binder out of the fluid system with distilled water as follows: 1. -
Page 46: Greasing The Fast Axis
Flush the binder for approximately five minutes. Then press ‘Online’ to complete the flush process. REMEMBER: When printer is ready to be used again, refill the binder reservoirs with Z Corporation binder and repeat the “flush” system process. GREASING THE FAST AXIS Over the coarse of printing, powder may adhere to the fast axis causing friction in the movement of the carriage. -
Page 47: Changing Between Color And Monochrome Adapters
Z Corporation Z402C System User Manual 4. Note the small circle in the center of the gray plate in the print head holder. Insert head of grease tube into hole and apply one quick squeeze of grease found in your tool box. - Page 48 Z402C System User Manual Z Corporation 4. Take the color (or monochrome) print head and store in a resealable bag. (Color print head shown in picture.) 5. Take your monochrome (or color) adapter and insert the two screws into the printer assembly.
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Page 49: Logging Your Builds
0.0040 2_TNO_Color_Palette.zec Above is an example of the log file for the Z402C Printer. There is a log file for each COM port or connection used. The log files can be found in the directory “C:\Z402 Records\Print Logs”. They are tab delimited files for easy import into a spreadsheet. -
Page 50: Troubleshooting
Z402C System User Manual Z Corporation TROUBLESHOOTING THE BINDER SOLUTION IS BEING APPLIED IN ERRATIC STRIPES If the binder appears to be applied in fragmented stripes, check the following: 1. Rinse the squeegee clear of any debris. 2. Make sure binder supply is full. -
Page 51: My Starch-Based Parts Are Unusually "Cakey
PRINTER LOOKS LIKE IT IS PRINTING, BUT IS NOT LAYING DOWN BINDER As you begin printing, carefully watch the Z402C Printer to see if it is printing normally. It may be that the print head are not properly seated in the carriage. This can cause a bad connection with the temperature sensor and the print head will overheat. -
Page 52: Z402C System Details
Serial Port Connection: This is an RS-232 serial port for data transfer to and from the Z402C System Software. The Z402C System uses 115k baud and has the same pin out as a standard PC compatible computer. The connection to the Windows computer running the Z402C System Software requires a 9 pin to 9 pin null modem cable (also known as a ‘laplink’... -
Page 53: Symbols Used
SYMBOLS USED The following symbols are used on the Z402C 3D Printer: This is the international symbol for ‘standby power’. It is used on the Z402C 3D Printer power switch. The Z402C 3D Printer is partially powered as soon as you plug it in. -
Page 54: System Specifications
Operating Conditions: 68 to 85ºF, 20 to 50% Relative Humidity, non-condensing. Lithium Battery: Internal to the Z402C 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 55: Material Storage Precautions
Z Corporation Z402C System User Manual MATERIAL STORAGE PRECAUTIONS Binder Solution: Store in cool, dry place, away from sun. Keep tightly capped. Powder: Store powder on pallets in a cool, dry, ventilated area away from sources of heat, moisture, and incompatible materials. Keep containers tightly closed. -
Page 56: Index
Z402C System User Manual Z Corporation INDEX 3D Print Setup Justify, 17 , 19 Logging Your Build, 48 Anisotropic Scaling, 21 For Specified Part, 18 Massachusetts Institute of Technology, 6 Material Storage, 54 BLD Build Files, 12 Opening a File, 12... - Page 57 Z Corporation Z402C System User Manual Toggle Roller on/off, 23 Z Corp System Software, 10 Translate, 15, 16 3D Print Setup, 19 Troubleshooting, 49 Color Monochrome Parts, 17 Cross Section, 14 Estimating Build Time, 18, 19 Fast Rendering, 22 Import, 13...