Page 1 User Guide Objet500 3D Printing System DOC-07027 Rev. I...
Page 2 Copyright DOC-07027 Revision I Copyright © 2006–2021 Stratasys Ltd. All rights reserved. This documentation contains proprietary information of Stratasys Ltd. This information is supplied solely to assist authorized users of Stratasys Objet500 3D printing systems. No part of this document may be used for other purposes. The specifications on which this document is based are subject to change without notice. Trademarks Stratasys, Objet, Connex, Objet Studio, Job Manager, GrabCAD Print, GrabCAD PolyJet Server, FullCure, and PolyJet are trademarks of Stratasys Ltd. and/or i ts subsidiaries or affiliates and may be registered in certain jurisdictions. All other product n ames and trademarks are the property of their respective owners. FCC Compliance The equipment referred to in this guide has been tested and found to comply with the limits for a Class A device pursuant to part 15 of the FCC rules. These limits provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. Stratasys 3D printing systems generate, use and can radiate radio- frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be r equired to correct the interference at his own expense. The 3D printer referred to in this guide contains a transmitter module, FCC ID YH6-MATCAB. NOTE: Stratasys is not responsible for radio or TV interference caused by unauthorized modification to this equipment. Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate the equipment. Equipment Recycling In the European Union, this symbol indicates that when the last user wishes to discard a product, it must be sent to appropriate facilities for recovery and recycling. For information about proper disposal, check your purchase contract, or contact the supplier of the equipment. Limitation of Liability The product, software or services are being provided on an “as is” and “as available” basis. Except as may be stated specifically in your contract, Stratasys Ltd. expressly disclaims all warranties of any kind, whether express or implied, including, but not limited to, any implied warranties of merchantability, fitness for a particular purpose and non- infringement. You understand and agree that Stratasys Ltd. shall not be liable for any direct, indirect, incidental, special, consequential or exemplary damages, including but not limited to, damages for loss of profits, goodwill, use, data or other intangible losses (even if Stratasys has been advised of the possibility of such damages), resulting from: (i) the use or the inability to ...
Page 3 Patents This product is covered by one or more of the following U.S. patents and other granted or pending patents. 6,569,373 7,209,797 7,364,686 7,369,915 7,500,846 7,604,768 7,628,857 7,658,976 7,725,209 7,896,639 7,958,841 7,991,498 7,996,101 8,219,234 8,278,866 8,323,017 8,469,692 8,781,615 8,865,047 8,932,511 9,017,589 9,020,627 9,031,680 9,227,365 Stratasys Ltd. www.stratasys.com DOC-07027 Revision I January 2021 DOC-07027 Rev. I...
Page 4: Table Of Contents
Contents 1 About This Guide Using This Guide For More Information Revision History Terms Used in This Guide Additional Resources Stratasys Academy Stratasys Support Center GrabCAD Community 2 Safety Safety Features Symbols and Warning Labels Safety Guidelines Printer Installation Printer Operation UV Radiation Printer Maintenance Model and Support Materials UV Lamps First Aid for Working with Printing Materials Contact with Skin Contact with Eyes Ingestion Inhalation Waste Disposal 3 Introducing the 3 D Printer Welcome to Connex™ Printing Work Configurations Source Files STL Files SLC Files VRML Files Printing Materials Storage Shelf Life...
Page 5 Safety Considerations Disposal Work Environment Workstation Requirements Preparing Files for Use with PolyJet 3D Printing Systems Converting CAD Files to STL Format Converting CAD Files to WRL Format (VRML) Converting CAD Files to SLC Format 3-10 Software Applications for Preparing Print Jobs 3-10 Workflows 3-11 4 Installing Objet Studio How to Install Objet Studio 5 Using Objet Studio Launching Objet Studio Objet Studio Interface Ribbon Commands Objet Studio Commands Menu Model Tree Pane Assigning Properties to Hidden Objects Preparing Models for Production 5-10 OBJDF Files: Overview 5-10 Model Files 5-10 Placing Objects on the Build Tray 5-11 Opening Objet Tray Files 5-16 Quick-Access Model Commands 5-18 Selecting Objects 5-19 Copying and Pasting Objects 5-20 Surface Finish 5-21 Splitting Objects into Components...
Page 6 Manipulating Objects on the Tray 5-33 Positioning Objects on the Z-Axis 5-33 Valid Object Placement 5-34 Using a Grid to Position Objects 5-35 Measurement Units 5-36 Setting Model Dimensions 5-37 Manually Repositioning Objects 5-38 Changing an Object’s Orientation 5-40 Grouping and Ungrouping Objects 5-42 Freezing Model Orientation 5-43 Display Options 5-44 Viewing Objects 5-44 Screen Layout 5-46 Tray Perspective 5-47 Setting Object Colors 5-49 Loading Large Files 5-50 Large File Manipulation 5-50 Zoom Options 5-52 Handling Trays 5-54 Tray Validation 5-54 Production Estimates 5-55 Printing Modes...
Page 7 Objet Studio Version, Material Module and Licensed Features 5-77 Monitoring and Managing Print Jobs 5-80 Job Manager Screen 5-81 Setting the Printer Connection 5-83 offline Mode 5-84 Setting the Remote Printer Connection (Client Mode) 5-87 Job Manager Commands 5-87 Configuring User Alerts 5-90 Printing from the Jobs Queue 5-91 Additional Server Features 5-91 6 Operating and Maintaining the Printer Starting the P rinter Loading Model and Support Cartridges Producing Models Preparing the Printer Starting Printing Printer Interface Color Key Printing Indicators Resuming Production After Printing has Stopped 6-10 Changing the Printing Material 6-13 Printing With Bio-Materials 6-18 Advanced Settings 6-18 Keeping the Printer in Idle Mode 6-22 Shutting Down the Printer 6-23...
Page 8 Replacing the Odor Filter 6-74 Replacing the UV Lamps 6-75 Built-in Tests 6-84 Replacing the Waste Container 6-90 Cleaning the Exterior Panels 6-92 Cleaning the UV Screen 6-92 7 Handling Printed Models Removing Models After Printing Removing the Support Material Removing Support by Hand Removing Support with Water Pressure Removing SUP705 with Caustic Soda Removing SUP706 with Caustic Soda and Sodium Metasilicate Post-Printing Treatment Photobleaching for Transparent Models Storing Models DOC-07027 Rev. I...
Page 9 About This Guide Using This Guide For More Information Revision History Terms Used in This Guide Additional Resources Stratasys Academy Stratasys Support Center GrabCAD Community DOC-07027 Rev. I...
Page 10: Using This Guide
Objet500 User Guide 1 About This Guide Using This Guide This user guide provides instructions for installing, operating and maintaining Objet500 3D printing systems. It explains how to use features, and provides practical examples to guide you as you use the system. Important: Read the entire Safety chapter before using the system. The text and figures in this guide are based on the Objet500 3D printer, software version 58.2 and Objet Studio software version 9.2. This guide assumes that— • all the hardware, software, and network components of your s ystem are installed, configured, and operating correctly. ® • the operator has a working knowledge of the Windows PC platform. For More Information Visit the Stratasys Support Center to download the latest revision of this document.This document is also available on the Support Center in other languages. If you have any questions or comments about the way information is presented in this guide, or if you have any suggestions for future editions, please send a message to c-support@stratasys.com. Revision History The following table lists the main changes in each revision of this document. Revision Release Date Description Rev. I February 2021 • About this Guide was updated.
Page 11: Terms Used In This Guide
Objet500 User Guide 1 About This Guide Terms Used in This Guide Build tray In the print preparation application: The surface displayed on the screen that represents the actual build tray in the printer. In the printer: The surface upon which models are produced. Cleaning fluid Cleanser for flushing material feed tubes and the printing block, used to completely remove Model and Support material from the system before loading another type of material in the printer and before long-term shutdown. The cleaning fluid is supplied in material cartridges. Client/user The workstation on which s oftware is installed for preparing build trays workstation for production on PolyJet printers. (There is no limit to the number of client workstations.) Connex™ The technology of printing models by jetting multiple materials simultaneously from the print heads. This technology enables Objet500 printers to print in Digital Material mode. Digital Material Combinations of model materials fabricated in the printer from the basic model materials installed.
Page 12 Objet500 User Guide 1 About This Guide OBJTF The extension of a file that contains all of the information needed for a model-printing job on PolyJet 3D printers. An objtf file is used by Objet Studio to send a print job to a PolyJet 3D printer. OBJZF The extension of a compressed “wrapper” file containing all of the files used in an Objet Studio build tray. Using objzf files, a printing job can be saved as a single file, for convenient storage and transfer. Objet™ printer The Stratasys 3 D printer referred to in this guide. Printer The computer inside the Objet500 printer that operates it. computer Printer The GUI (graphical user interface) used for controlling Objet500 interface printers. Printer Software running on the computer in the Objet500 printer, controling all software, printer operations. printer-control application Resin The base substance from which photopolymer printing materials are made for use in Stratasys PolyJet printers. In Objet Studio and printer-application screens, “resin” refers to cartridges of model and support materials. A file that contains bitmaps of individual slices of an object, for printing 3D models.
Page 13: Additional Resources
Objet500 User Guide 1 About This Guide Additional Resources Stratasys encourages you to learn more about your additive manufacturing printer, its capabilities and the technology. A wealth of information is available on our online digital platforms. Stratasys Academy Stratasys Academy is your online learning platform. Here you can browse our extensive and growing course catalog, register to webinars, view t utorials and videos at your own pace, and enroll in face-to-face, in person courses. We encourage you register and start your leaning journey today. DOC-07027 Rev. I...
Page 14: Stratasys Support Center
Objet500 User Guide 1 About This Guide Stratasys Support Center The Support Center is your portal to thousands of knowledge assets, including information on design, applications, and materials. The site also has links to Web-based training, "how-to" videos and the Stratasys blog. In addition, you can check the latest revision of the user guide for your printer, and download documents in different languages. The Support Center is available in multiple languages. You can change the display language using the language drop-down menu in the top-left corner of the homepage. GrabCAD Community The Tutorials section of GrabCAD Community portal is a valuable source for Stratasys-sponsored and user-genertated 3D printing tips. You can also ask 3D- related questions on the portal and download free CAD files. DOC-07027 Rev. I...
Page 15 Safety Safety Features Symbols and Warning Labels Safety Guidelines Printer Installation Printer Operation UV Radiation Printer Maintenance Model and Support Materials UV Lamps First Aid for Working with Printing Materials Contact with Skin Contact with Eyes Ingestion Inhalation Waste Disposal DOC-07027 Rev. I...
Page 16: Safety Features
Objet500 User Guide 2 Safety Safety Features Stratasys 3D printers are designed to comply with CE and FCC standards. They are equipped with the following safety features: Interlock Switch The power supplied to the UV lamp, the tray heater and the motion motors is turned off when the cover is opened. Warning Do not defeat (override) the interlock switch. Doing so could result in serious personal injury. If the interlock switch does not function correctly, do not use the printer, and contact your service provider. Safety Lock The cover is locked while the printer is working. If you do manage to lift it, the UV lamps and the motion motors turn off. Warning Do not defeat (override) the safety lock. Doing so could result in serious personal injury. If the safety lock does not function correctly, do not use the printer, and contact your service provider. UV Screening The transparent section of the cover blocks harmful UV radiation, ...
Page 17 Objet500 User Guide 2 Safety UV-Lamp Overheating Protection The power supplied to the UV lamp and the motion motors is turned off if the temperature around the lamp reaches 90°C (194°F). A label on the UV-lamp cover indicates if the temperature has exceeded 65°C (150°F). Grounded Chassis The chassis of the printer is grounded, to prevent electrical shock. Note: The power outlet must be grounded in accordance with the local electric code to provide this protection. If the printer is not used as specified in this guide, these safety features may not provide adequate protection. DOC-07027 Rev. I...
Page 18: Symbols And Warning Labels
Objet500 User Guide 2 Safety Symbols and Warning Labels The following table lists the warning labels located on or in the printer. Warning Symbol Meaning Location Comments Hazard (general) On the name plate on the Read the instructions in back of the printer. this document before operating the printer. Hot surface On the print block. Risk of burns. Do not touch this surface after printing. High voltage Near the UV lamp Risk of electric shock. connectors. Disconnect the power before servicing. Near the power-supply enclosures. Ultraviolet radiation Near the UV lamps. Risk of injury to skin and eyes from ultraviolet radiation. Disconnect the power before servicing. Moving parts On the panel that is ...
Page 19: Safety Guidelines
Objet500 User Guide 2 Safety Safety Guidelines The following general guidelines, together with the instructions provided throughout this user guide, ensure user safety while operating and maintaining the system. If the system is not operated as specified, the user's safety may be compromised. Printer Installation ➢ Installation and removal of the printer should only be done by qualified service personnel. ➢ Connect the printer (and the UPS unit) to the electric outlet using a power cable that is safety-certified. ➢ The electric outlet should be easily accessible, near the printer. ➢ Never connect the power plug to an outlet that does not have a ground (earth) wire, and never disconnect the ground. Doing so might expose the operator to serious danger from electric shock. ➢ The following safety statement is followed by translations to Finish, Norwegian, Swedish and Danish, as required by local regulations: “The machine must be connected to a grounded power outlet.” ❒ FI: Laite on liitettävä suojakoskettimilla varustettuun pistorasiaan.
Page 20: Uv Radiation
Objet500 User Guide 2 Safety UV Radiation The UV lamps used in the printer emit dangerous radiation ➢ If the UV lamps remain on when the printer is open, do not stare directly at the UV light. Shut down the printer and call your Stratasys service provider. Printer Maintenance ➢ Service operations should be performed only by qualified personnel who have been instructed in relevant safety precautions. ➢ Notify co-workers and those who have access to the printer before beginning non-routine and hazardous work. Report any potential dangers and safety-related accidents to your safety officer or to other appropriate authorities. Model and Support Materials Model and Support materials are made of chemical substances. Although precautions must be taken when handling these materials directly, all Model and Support materials used by the printer are handled in sealed cartridges. Normally, operators of the printer should never be directly exposed to hazardous materials. In the unlikely event of a leak or spill, follow the instructions that are included with the material cartridges used. ➢ Store Model and Support materials indoors, in a dry area with adequate ventilation, between 15-25 degrees Celsius (59-77 degrees Fahrenheit). Never expose them to flames, heat, sparks, or direct sunlight. ➢ Keep Model and Support materials away from areas where food and drink are stored, prepared and consumed. ➢ Uncured printing material is considered a hazardous substance, requiring certain precautions when directly handling it. To prevent skin irritation, wear neoprene or nitrile gloves. If there is any chance that Model and Support materials might splash into the eyes, wear safety goggles. Prolonged direct contact with printing materials can cause an allergic reaction.
Page 21: Uv Lamps
Objet500 User Guide 2 Safety ➢ Dispose of contaminated shoes, belts and other leather items in accordance with any applicable regulations. Absorbed printing material may re-expose the user when these items are worn. UV Lamps UV lamps used by the printer to cure printing materials contain a small amount of mercury. In the unlikely event of lamp breakage, avoid inhaling mercury vapor, and ventilate the room. If the lamp ruptures (breaks) during operation, leave the room and ventilate it thoroughly for about 30 minutes. Use protective gloves to prevent contact with mercury and other lamp components. Carefully remove spilled mercury with a method that prevents the generation of mercury vapor, such as a syringe, packing tape or paper. Place the broken lamp, mercury and contaminated materials in an air-tight, non- metallic container. Dispose of the container in accordance with applicable regulations. DOC-07027 Rev. I...
Page 22: First Aid For Working With Printing Materials
Objet500 User Guide 2 Safety First Aid for Working with Printing Materials In general, try to avoid direct contact with uncured printing material. If skin or eyes come into contact with it, wash the area immediately and thoroughly with water, and follow these first-aid instructions. The Material Safety Data Sheet (MSDS) that accompanies printing materials contains important safety information. Keep this in an accessible place where these materials are used and stored. Contact with Skin If uncured printing material comes in contact with skin, wash the affected area immediately and thoroughly with soap and cool water, then remove contaminated clothing. Pay particular attention to flushing the hair, ears, nose and other parts of the body that are not easily cleaned. ➢ Use cool water to prevent skin pores from opening, so that the liquid material does not easily penetrate the skin. ➢ Do not use solvents to clean skin. ➢ If large areas of skin have been exposed, or if prolonged contact results in blisters, seek medical attention. In any case, if irritation persists, seek medical attention. ➢ Avoid the accidental transfer of printing material from the hands to other areas of the body, especially to the eyes. ➢ If protective cream was used, do not reapply it until the skin has been completely cleansed. Contact with Eyes If uncured printing material comes in contact with the eyes, flush immediately with large amounts of water for 15 minutes and seek medical attention. ➢ Avoid sunlight, fluorescent light, and other sources of ultraviolet radiation. Wearing contact lenses when handling liquid printing materials is not recommended. If the liquid splashes into the eyes when contact lenses are worn, immediately remove the lenses and flush the eyes with water. ...
Page 23: Inhalation
Objet500 User Guide 2 Safety Inhalation Vapors from printing materials can be irritating to the respiratory system. If respiratory irritation occurs, expose the victim to fresh air immediately. ➢ If the victim has stopped breathing, perform artificial respiration or cardiopulmonary resuscitation. ➢ Seek medical attention immediately. ➢ Keep the victim warm but not hot. ➢ Never feed anything to an unconscious person. ➢ Oxygen should be administered by authorized personnel only. Waste Disposal Fully cured printed models can be disposed of as ordinary office trash. However, special care is required when handling printer waste (uncured printing material). Printing Materials ➢ When removing the waste container from the printer, wear neoprene or nitrile gloves. ➢ To prevent liquid waste from splashing into the eyes, wear safety goggles. ➢ Liquid waste from the printer is classified as hazardous industrial waste. Therefore, printing-material waste must be packaged and disposed of in a manner that prevents human contact with it and contamination of water sources. ➢ Empty Model-material and Support-material cartridges contain residue of their contents. Some leakage of this residue may occur through the broken cartridge seal. Therefore, handle and store empty cartridges with care. ➢ Do not attempt to reuse empty cartridges, and do not puncture them. ➢ Dispose of used cartridges and waste containers in accordance with local ...
Page 24 Introducing the 3D Printer Welcome to Connex™ Printing Work Configurations Source Files STL Files SLC Files VRML Files Printing Materials Storage Shelf Life Exposure to Light Safety Considerations Disposal Work Environment Workstation Requirements Preparing Files for Use with PolyJet 3D Printing Systems Converting CAD Files to STL Format Converting CAD Files to WRL Format (VRML) Converting CAD Files to SLC Format 3-10 Software Applications for Preparing Print Jobs 3-10 Workflows 3-11 DOC-07027 Rev. I...
Page 25: Welcome To Connex™ Printing
Objet500 User Guide 3 Introducing the 3D Printer Welcome to Connex™ Printing The advanced capabilities of Connex printing systems are made possible by technology specially developed by Stratasys for printing models simultaneously with different model materials. Printing models with combinations of basic materials (digital materials) enables you to choose from a wide range of mechanical properties—from flexible to rigid—and colors. With Connex printers, you can achieve the following results when printing 3D models: • You can prepare objects for printing with two or three designated model materials and then print them at the same time. This enables you to assign specific mechanical and color properties to objects. • You can print parts of the same model—simultaneously—with different materials (or material combinations • You can print objects that have a “coating” made from a different material than the main part of the object. Because Connex printers can be loaded with different materials, you can streamline and economize the process of producing models: • Printing models made from different materials on the same build tray (“mixed tray”), in the same print job, eliminates the time-consuming need and expense of loading another material, flushing the system, and sending a separate job to be printed. • You can quickly alternate printing jobs using the model materials loaded (or material combinations)—again, without the need and expense of replacing materials. Print jobs can be set up and sent to the printer with either of these applications: • Objet Studio • GrabCAD Print (Connex3 printers only) These applications are described in the following chapters. Objet Studio enables you to split models into component parts (“shells”) so you can isolate, manipulate and print parts of a model. Then, you can assign model materials and other characteristics to the shells. However, you have ultimate control when separating models into shells by preparing stl files with your CAD ...
Page 26: Work Configurations
Objet500 User Guide 3 Introducing the 3D Printer Work Configurations Objet500 3D printing systems can be set up as single-station systems or as multi- station systems. When connected to a local computer network, the system can serve multiple users. In such configurations, each user (client) prepares files f or production. A server, typically next to the printer, sends jobs to the printer. Figure 3-1 shows the printer set up in a multi-client configuration. Figure 3-1 Multi-client network configuration When jobs are sent to the printer, Job Manager, on the server computer, arranges them according to their priorities, model-material type, and other factors. In multi-workstation configurations, the operator of the server—typically the production administrator—has total control over the jobs sent to the printer, and can prioritize jobs, delete jobs, review job history and reprint jobs. DOC-07027 Rev. I...
Page 27: Source Files
Objet500 User Guide 3 Introducing the 3D Printer Source Files Objet500 printing systems produce three-dimensional models designed with most CAD tools and some other 3D applications. Objet Studio supports these file formats: • STL • SLC • VRML GrabCAD Print (for Connex3 printers) supports STL, VRML, OBJ and 3MF files. In addition, GrabCAD Print supports native CAD formats from these programs: Creo, SOLIDWORKS, NX, CATIA and Inventor. To see the complete list of file formats supported by GrabCAD Print, go to: help.grabcad.com/print/file-formats. All Objet500 systems feature the capability of producing different types of model files simultaneously. STL Files STL is short for STereoLithography or Standard Triangulation Language. This language views any object as a collection of surfaces, and describes each surface of the object as a collection of triangles. For example, a square can be described as two triangles; a cube (six squares) as 12 triangles. Curved surfaces need more triangles to describe them. The higher the tolerance (for smooth surfaces), the more triangles are needed. Most CAD software can export STL files. Objet Studio/GrabCAD Print opens these files for printing models on the p rinter. SLC Files SLC is short for Stereo-Lithography Contour. SLC files describe two- dimensional contours of the three-dimensional models. These contour lines are ...
Page 28 Objet500 User Guide 3 Introducing the 3D Printer When you create a VRML file in a CAD program, two files are created: a wrl file, containing the model's geometric information, a nd a picture file ( bmp, png, jpg, or tiff), containing the model's color information. When you create a VRML file in most CAD programs, two files are created: a wrl file, containing the model's geometric information, including texture, and a picture file ( bmp, png, jpg, or tiff), containing the model's color information. Before placing a VRML file on the b uild tray, make sure that the VRML file and its corresponding picture file are in the same folder. DOC-07027 Rev. I...
Page 29: Printing Materials
Objet500 User Guide 3 Introducing the 3D Printer Printing Materials Objet500 printers produce models by jetting thin layers of printing materials on the build tray, until the complete model is formed. Two types of material are used in this process: • Model material—which makes up the finished model • Support material—which fills gaps and spaces in the model during printing, and is removed after printing For up-to-date information about PolyJet printing materials and their properties, go to www.stratasys.com/materials/polyjet. Storage Materials used for printing models with Objet500 printers are made of resins, which are composed of reactive monomers and oligomers. Although printing materials are supplied in sealed, UV-proof cartridges, care must be taken when storing and handling them. Follow these guidelines to protect operators and the environment, and to ensure optimum results. • To ensure product stability, do not allow these materials to come into contact with metal. Plastics made from monomer-soluble substances (such as polystyrene or polyvinyl chloride) are not suitable for storing PolyJet printing materials. • When not in use, keep material cartridges tightly sealed to prevent contamination, the effects of exposure to UV radiation, and accidental spillage. • Store material cartridges indoors, in a dry area with adequate ventilation, between 15–25 degrees Celsius (59-77 degrees Fahrenheit). If exposed to heat or flames, cartridges might burst or ignite. • Signs of premature polymerization in material cartridges include bulging, leaking, the emission of heat, and unusual odor. Exposure to heat can cause resin to gel in the cartridges. • Make sure that material cartridges are stored in accordance with all local regulations and other applicable requirements. Shelf Life Materials used for producing models have a limited shelf life. The expiry date on ...
Page 30: Safety Considerations
Objet500 User Guide 3 Introducing the 3D Printer mercury-vapor lights. Exposure to UV radiation causes an increase in viscosity and, eventually, solidification. Safety Considerations Before being cured, resins are hazardous materials. To prevent possible health hazards, follow these precautions regarding printing materials: • Do not expose to flames, heat or sparks. • Prevent contact with skin and eyes. • Ventilate areas where they are handled. • Keep them separate from food and drink. Cured plastic parts, however, are safe. They can be handled and stored without precautions. You can find more safety information about resins in: "Safety Guidelines" on page 2-5 "First Aid for Working with Printing Materials" on page 2-8 Disposal Dispose of cartridges of model and support material in accordance with all applicable laws and regulations. Work Environment Extreme heat and humidity conditions can adversely affect the operation of your Objet500 3D printer. Use ventilation or air-conditioning systems, if necessary, to keep the work area within the following ranges: • 18°–25° C (64°–77° F) • 30%–70% relative humidity Workstation Requirements Objet Studio Workstation The requirements for client computers running Objet Studio are listed in the Objet500 Site Preparation Guide. You can download this document from stratasys.com.
Page 31 Objet500 User Guide 3 Introducing the 3D Printer • To see the requirements for client computers running GrabCAD Print, go to: help.grabcad.com/print/system-requirements. • In addition, GrabCAD PolyJet Job Manager is required on the server (host) computer. This program controls the actual printing. To download it, go to: help.grabcad.com/print/polyjet. DOC-07027 Rev. I...
Page 32: Preparing Files For Use With Polyjet 3D Printing Systems
Objet500 User Guide 3 Introducing the 3D Printer Preparing Files for Use with PolyJet 3D Printing Systems Before printing design files with the Objet500 printer, make sure that they are in a file format supported by the applications you are using to send print jobs to the printer—Objet Studio or GrabCAD Print. (See "Source Files" on page 3-4.) Converting CAD Files to STL Format This procedure may vary slightly, depending on the CAD software used, but the following instructions generally apply. To convert a file to STL format (in a CAD program): 1. From the File menu, select Save As. 2. In the Save As dialog box, open the Save As Type drop-down list and select *.STL. 3. Click Options and set the following parameters: ❒ Total Quality—approximately 0.01 mm (deviation tolerance / linear- dimension tolerance) ❒ ...
Page 33: Converting Cad Files To Slc Format
Objet500 User Guide 3 Introducing the 3D Printer Converting CAD Files to SLC Format When converting files to SLC format, it is recommended that you set a layer thickness of 15 microns (0.015 mm). Since SLC files cannot be orientated in Objet Studio, it is important that models are properly orientated before being saved as SLC files. Considerations for suitable model orientation are explained in "Manual Positioning" in Chapter 3 on page 5-31. Software Applications for Preparing Print Jobs Both Objet Studio and GrabCAD Print (for Connex3 printers) offer you a wide variety of file-preparation options that follow this basic procedure: 1. Defining the materials you want to use on the build tray 2. Inserting one or more objects on the build tray 3. Positioning the object(s) on the build tray 4. Configuring object and tray parameters 5. Sending the file to a 3 D printer for production Objet Studio Objet Studio is an application for preparing print jobs on Stratasys 3D printing systems. It consists of two main screens: • Studio • Manager In the Studio screen, you prepare source files for production in the printer. Using Objet Studio to perform these tasks is described in detail in Chapter 5, "Using Objet Studio". The Manager screen d isplays the queue and status for all jobs sent to the 3D ...
Page 34: Workflows
Objet500 User Guide 3 Introducing the 3D Printer Workflows With Objet500 printing systems, you have great flexibility in preparing model files and printing them. Below are the major workflows available. Stage Workflow A Workflow B Workflow C CAD program * • Design a 3D object. • Design a 3D object. • Design a 3D object. • Save it as a single stl • Save it as an assembly • Apply colors to parts file. of stl files. (Connex3 only). • Save the object as a VRML/wrl file.
Page 35: 4 Installing Objet Studio
Installing Objet Studio How to Install Objet Studio DOC-07027 Rev. I...
Page 36: How To Install Objet Studio
Objet500 User Guide 4 Installing Objet Studio How to Install Objet Studio Objet Studio software is installed during printer installation. This section is provided in case you need to reinstall Objet Studio, or install it on a remote (client) computer. The Objet Studio setup wizard guides you when installing this software. Objet Studio is installed on the printer-server (“host”) computer, but it can also be installed on remote, “client” computers and on computers used to prepare files for printing models, or for training and demonstration purposes. During installation, you choose to install either the printer-server (“host”) application or the client application. To install Objet Studio software: 1. Connect the USB flash drive (supplied with the printer) to a USB port. 2. On t he U SB flash drive navigate to the Objet Studio installation file, and run it. 3. To install Objet Studio, you must agree to the license agreement. After reading its terms, click Yes to continue, or No to close the wizard. If you click Yes, the following screen should appear. Figure 4-1 Objet Studio compatibility check 4. Make sure that your printer is compatible with Objet Studio by checking the list displayed. Note: The printers displayed are legacy printers that are not compatible with ...
Page 37 Objet500 User Guide 4 Installing Objet Studio 5. In the Installation type screen, select the required installation option. Select Objet Studio for a Server computer— ❒ if you are installing Objet Studio on the server (“host”) computer—the computer directly connected to an Objet500 printer. ❒ if you are installing Objet Studio on a standalone (offline) computer. Select Objet Studio for Client workstations if you are installing Objet Studio on a “client” workstation—a remote computer that prepares print jobs and then sends them to a server computer. Figure 4-2 Objet Studio configuration selection DOC-07027 Rev. I...
Page 38 Objet500 User Guide 4 Installing Objet Studio 6. In the Choose Destination Location screen, verify the destination folder and click Next. Figure 4-3 Objet Studio installation-folder selection It is recommended that you do not change the default destination folder. 7. In the Select Printer Type screen, select the 3D printer used for producing models and click Next. Figure 4-4 Printer selection DOC-07027 Rev. I...
Page 39 Objet500 User Guide 4 Installing Objet Studio 8. When the following screen appears, click Install to begin installation. Figure 4-5 Ready to Install screen After clicking Install, a progress bar shows the progress of the installation process. Figure 4-6 Installation progress bar ® ® Objet Studio requires that Microsoft DirectX is installed on the computer. If necessary, an installation screen for this program will appear. To continue with Objet Studio installation, accept the DirectX agreement. DOC-07027 Rev. I...
Page 40 Objet500 User Guide 4 Installing Objet Studio When i nstallation is complete, the final InstallShield wizard screen appears. Figure 4-7 Final installation screen 9. To complete the software installation, click Finish. The installation process ends when the appropriate icon(s) appear on the computer desktop: • Objet Studio • Stop Job Manager (for servers and standalone stations) How to Uninstall Objet Studio If there is ever a need to uninstall the Objet Studio software, do not attempt to do so from the Windows Control Panel. (This does not completely remove all software components.) Instead— ➢ From the Start menu, select All Programs > Stratasys > Uninstall Objet Studio. DOC-07027 Rev. I...
Page 41 Using Objet Studio Launching Objet Studio Objet Studio Interface Ribbon Commands Objet Studio Commands Menu Model Tree Pane Assigning Properties to Hidden Objects Preparing Models for Production 5-10 OBJDF Files: Overview 5-10 Model Files 5-10 Placing Objects on the Build Tray 5-11 Opening Objet Tray Files 5-16 Quick-Access Model Commands 5-18 Selecting Objects 5-19 Copying and Pasting Objects 5-20 Surface Finish 5-21 Splitting Objects into Components 5-21 Model-Material Settings 5-22 Changing the Model Material 5-24 Changing the Support Material 5-24 Digital Materials 5-25 Assigning a Model Material to Objects 5-26 Coating Objects 5-27 Positioning Objects on the Build Tray 5-29 Automatic Orientation 5-29...
Page 42 Positioning Objects on the Z-Axis 5-33 Valid Object Placement 5-34 Using a Grid to Position Objects 5-35 Measurement Units 5-36 Setting Model Dimensions 5-37 Manually Repositioning Objects 5-38 Changing an Object’s Orientation 5-40 Grouping and Ungrouping Objects 5-42 Freezing Model Orientation 5-43 Display Options 5-44 Viewing Objects 5-44 Screen Layout 5-46 Tray Perspective 5-47 Setting Object Colors 5-49 Loading Large Files 5-50 Large File Manipulation 5-50 Zoom Options 5-52 Handling Trays 5-54 Tray Validation 5-54 Production Estimates 5-55 Printing Modes 5-56 E-mailing Objet Digital Files...
Page 43 Default Settings 5-74 OpenGL Driver Configuration 5-75 Getting Additional Objet Studio Assistance 5-77 Objet Studio Version, Material Module and Licensed Features 5-77 Monitoring and Managing Print Jobs 5-80 Job Manager Screen 5-81 Setting the Printer Connection 5-83 offline Mode 5-84 Setting the Remote Printer Connection (Client Mode) 5-87 Job Manager Commands 5-87 Configuring User Alerts 5-90 Printing from the Jobs Queue 5-91 Additional Server Features 5-91 DOC-07027 Rev. I...
Page 44: Launching Objet Studio
Objet500 User Guide 5 Using Objet Studio Launching Objet Studio After you install Objet Studio, a launch icon appears on the Windows desktop. Open the application by double-clicking this icon, or by selecting Objet Studio from the Start menu. Objet Studio Interface When Objet Studio opens, the Tray Settings screen appears, showing an empty build tray. Figure 5-1 Objet Studio opening screen The Objet Studio interface consists of two main screens: • Tray Settings—for arranging models and preparing them for printing. • Job Manager—for monitoring and managing print jobs. This screen is described in "Monitoring and Managing Print Jobs" on page 5- Each screen is controlled by menus and icons on its own ribbon. An additional ribbon, Model Settings, displays controls for configuring and manipulating selected models. Objet Studio anticipates your workflow by displaying and enabling the options relevant to your current task. For example, when you first open Objet Studio, the Model Settings ribbon is disabled until you place a model on the build tray. Similarly, options available from the standard toolbar menus are enabled or disabled to match the current workflow. DOC-07027 Rev. I...
Page 45 Objet500 User Guide 5 Using Objet Studio The ribbon, colors used, and several other interface features can be customized. How to change the appearance of the interface is explained in "Customizing Objet Studio" on page 5-67. Instructions for using the commands for preparing models for production and sending jobs to the printer, appear later in this chapter. Figure 5-2 Tray Settings ribbon Figure 5-3 Model Settings ribbon DOC-07027 Rev. I...
Page 46: Ribbon Commands
Objet500 User Guide 5 Using Objet Studio Ribbon Commands The following table lists the Tray Settings and Model Settings ribbon command groups, and shows when they are enabled, and where they appear. Group Purpose When enabled Tray Model Settings Settings Ribbon Ribbon Setting display colors. Always. Selecting perspective Models are on and zoom level. the build tray. Choose to select a plane, Models are on elements, or element the build tray.
Page 47 Objet500 User Guide 5 Using Objet Studio Group Purpose When enabled Tray Model Settings Settings Ribbon Ribbon Pre-build/build Models are on commands. the build tray. Setting model A model is dimensions. selected. Cutting, copying, pasting A model is and deleting models. selected. ...
Page 48: Objet Studio Commands Menu
Objet500 User Guide 5 Using Objet Studio Objet Studio Commands Menu Clicking the icon in the upper-left corner opens the Objet Studio Commands menu. This menu displays basic application commands and options. Figure 5-4 Objet Studio Commands menu The Options button opens a dialog box for customizing Objet Studio. Figure 5-5 Options dialog box DOC-07027 Rev. I...
Page 49: Model Tree Pane
Objet500 User Guide 5 Using Objet Studio Model Tree Pane The Model Tree pane lists the objects placed on the build tray in a parent-child hierarchy. By default, the pane “floats”— that is, you can move it to another position on the screen and resize it. Alternatively, you can fix its position at the left of the application window, and even hide it. Assigning Properties to Hidden Objects To enable you to assign materials and other properties to parts of objects that are hidden from view on the build tray display, you can temporarily turn off the display of some objects. To prevent the display of objects: 1. Right-click an object, either on the build tray or in the model tree. 2. From the menu that opens, select one of the following options— ❒ Hide, to cause the selected object to disappear. ❒ Hide Others, to cause all other objects on the build tray to disappear, so that only the selected object is displayed. Alternately, you can clear the check box next to the name of the object in the model tree to cause that object to disappear. Figure 5-6 Left: All objects displayed; Right: Display with object hidden DOC-07027 Rev. I...
Page 50: Preparing Models For Production
Objet500 User Guide 5 Using Objet Studio Preparing Models for Production Model preparation involves the following basic steps: 1. Place objects or assemblies on the build tray. 2. If necessary, manipulate the object’s orientation and position. 3. Select the materials and model finish. Just as Objet500 printers can produce different models on the build tray using different materials, you can produce components of a model with different materials. To do this, each part of the model must be a separate stl file. If the model’s component parts were not saved in the CAD software as separate stl files, you can use Objet Studio to separate the model into component parts. (This is described in "Splitting Objects into Components" on page 5-21 and in "Dividing Objects" on page 5-61.) OBJDF Files: Overview An objdf file describes both the geometry of a single object and the materials, and finish required to print it. The objdf file can represent an object that is a single stl file, or an object assembled from component stl files. Objet Studio enables you to split an stl file representing a complex object into an assembly of component stl files, and save the assembly as an objdf file. Each part (stl file) described by the objdf file can have its own model-material characteristic, so that the Objet500 printer produces the component parts from specific materials. Another use for objdf files is for saving a group of separate objects on the build tray as one unit, together with their relative positions and materials. This is especially useful for producing models in the future with the same materials. In fact, when you save objdf files, you specify materials for printing models without regard to the material cartridges loaded in the printer. The same object can later be placed on build trays for printing. Each time you send a build tray to the printer, you decide whether to allow printing with substitute materials or only with the materials specified.
Page 51: Placing Objects On The Build Tray
Objet500 User Guide 5 Using Objet Studio • by pasting objects that you copied to the Windows clipboard. Placing Objects on the Build Tray To place an object on the build tray: 1. Open the Insert dialog box— ❒ From the Object menu, select Insert. or— ❒ On the Tray Settings ribbon, click or— ❒ Right-click on the build tray, and select Insert from the context menu. The Insert dialog box appears. Figure 5-7 Insert dialog box 2. In the Look in field, display the appropriate folder. 3. In the Files of type field, select the file type to display. 4. Select the desired file, and make sure that it appears in the File name field. If the Preview check box is selected, the object is displayed in the dialog box, as shown in Figure 5-7. Note: When selecting a VRML (wrl) file, the object is displayed in the dialog box only if there is an equivalent bmp file in the same folder. Therefore, when DOC-07027 Rev. I...
Page 52 Objet500 User Guide 5 Using Objet Studio saving VRML files in a CAD program, a bmp file of the assembly should be saved. You can open several stl files (and VRML files) to place several models on the build tray. If you select multiple stl files that make up an assembly, you can select all or some of the parts. To print the entire model, select all of an assembly’s component stl files, and select the Assembly check box. This positions the parts as a complete, integrated model instead of as independent parts. The effects of selecting the Assembly check box—in both the model tree and the build tray display—are shown in the following figures. Figure 5-8 Assembly check box selected—stl files are placed as an assembly Figure 5-9 Assembly check box not selected—stl files are placed as parts The Model Settings ribbon is displayed when objects are placed on the build tray. DOC-07027 Rev. I 5-12...
Page 53 Objet500 User Guide 5 Using Objet Studio 5. Select any of the following options, as required: ❒ Units—Millimeters or inches for the object’s units of measure. The 3D file contains the object's proportions, but not its units of measure. Therefore, make sure to correctly select either millimeters or inches when inserting an object. Otherwise, the size of the object on the build tray will be either much too large or much too small. To change the measurement units of objects already placed on the tray, see "Measurement Units" on page 5-36. ❒ Number of copies—How many copies of this object to place on the build tray. ❒ Orient Automatically—Automatically orient objects on the build tray for efficient model building. ❒ Assembly—Mark this check box if you selected multiple stl files that are part of an assembly. Note: The Extents values displayed in the Coordinates section of the Insert dialog box, represent the maximum dimensions of the object on each axis. These dimensions correspond to the virtual “bounding box” surrounding the object see Figure 5-51 on page 5-45). 6. Click Insert. Objet Studio places the object on the build tray, and in the model tree. Figure 5-10 Default screen layout The Model Settings ribbon is displayed when objects are placed on the build ...
Page 54 Objet500 User Guide 5 Using Objet Studio If the object is over a certain size, the Loading Placed Elements dialog box appears. Figure 5-11 Loading Placed Elements dialog box You can speed up the opening of large files by changing the Large Files settings—see "Loading Large Files" on page 5-50. DOC-07027 Rev. I 5-14...
Page 55 Objet500 User Guide 5 Using Objet Studio Opening objdf Files Before placing objdf files on the build tray, Objet Studio must extract the component stl files together with information about their relative position and model materials. To do this, Objet Studio creates a folder with the same name as the objdf file, in the same location. If you are opening an objdf file, the Insert dialog box also includes a Materials field that shows the object’s printing material assignment (see below). Figure 5-12 Insert dialog box (objdf file) A warning message appears if a part is defined with materials not supported by your system, or if an object already on the build tray uses different materials. (If this happens, see "Model-Material Settings" on page 5-22 for printing options.) DOC-07027 Rev. I 5-15...
Page 56: Opening Objet Tray Files
Objet500 User Guide 5 Using Objet Studio Opening Objet Tray Files You can open trays that were saved as objtf files. (Saving objtf files is described in "Saving Build Trays" on page 5-65). To place an object saved as an Objet Tray File (objtf) file on the build tray: 1. From the File group, click or— From the Objet Studio Commands menu , select Open. The Open dialog box is displayed. Figure 5-13 Objet Tray File Open dialog box 2. Select the desired file, and make sure that it appears in the File name field. If the Preview check box is selected, the object is displayed. 3. Click Open. Objet Studio opens the tray file.
Page 57 Objet500 User Guide 5 Using Objet Studio STL file loading preference If there are identically named stl files in more than one location, you need to ensure that the correct component stl files are linked to the objtf file. For example, if there are identically named stl files on one drive and on a flash drive (this can occur if you copy the original files to a working folder), you can set the default location from which files are loaded. To set the Load Order: 1. From the Tools menu, select Options. or— In the Objet Studio Commands menu , click Options. 2. In the Options dialog box, display the Settings tab. Figure 5-14 Options dialog box, Settings tab 3. Under Load Search Order, select an option: ❒ Local—to load files from the location where they were last saved. ❒ Original—to load files in their original location. 4. Click OK. DOC-07027 Rev. I...
Page 58: Quick-Access Model Commands
Objet500 User Guide 5 Using Objet Studio Quick-Access Model Commands You can access common commands for working with objects on the build tray with the convenient Model Toolbar and context menus. Model Toolbar Select an object in the tray to display the Model Toolbar that contains icons to perform common tasks. Figure 5-15 Model Toolbar The table below describes the Model Toolbar icons. Icon Description Applies a matte finish to the model. Applies a glossy finish to the model. Opens the Advanced Properties dialog box for setting the Grid Style and the Hollow option. Enables dragging an object (see page 5-38). Opens the Transform dialog box for changing the object’s position and scale. Toggles the Lock Model Orientation setting. Allows you to choose the printing materials. Enables you to apply a coating to the model, or change the coating previously applied. Right-click model menu If you right-click on an object, a pop-up context menu is displayed from which you can also select the model finish, change its position and scale, and set the Grid Style and Hollow options. You can also create a Quick Access toolbar with your most commonly used icons grouped together. See "Creating a Quick Access Toolbar" on page 5- DOC-07027 Rev. I 5-18...
Page 59: Selecting Objects
Objet500 User Guide 5 Using Objet Studio Selecting Objects To manipulate an object on the build tray or assign characteristics to it (model material, building style etc.), you must first select the object. You select an object by clicking it, either on the tray or in the model tree. Its image on the build tray changes color (to light blue, by default) and its name is highlighted in the model tree. You can select multiple objects by drawing a box around them with the mouse cursor, or by pressing the Ctrl or Shift keys while clicking additional objects. Alternatively, select or de-select objects using the following Edit menu commands: • Select All • Invert Selection • Undo Select object Figure 5-16 Edit menu Sometimes, you need to select individual elements of an assembly. Other times, you need to select the entire assembly. The Selection icon displayed on the ribbon determines what will be selected when you click on the model: or To change the selection action: 1. ...
Page 60: Copying And Pasting Objects
Objet500 User Guide 5 Using Objet Studio Copying and Pasting Objects If you need to duplicate objects on the build tray, you can insert the same object from its file more than once. An easier way, however, is to copy and paste the object. You can copy objects from the build tray or the model tree—individual or multiple parts or assemblies. The objects copied remain in the Windows clipboard until you paste them onto the build tray. You can also copy objects from one tray and paste them onto another, in the same way as you copy text from one document and paste it into another one. However, Objet Studio allows only one tray to be open at a time. For each build tray you need to work with (at the same time), you must open a separate Objet Studio window, by running the application again (from the Windows Start menu). Having multiple Objet Studio windows open can be convenient when you need to manipulate or configure objects before inserting them in your production build tray. For example, if you need to change the model material of an object saved as an objdf file to match the model material already used in the production build tray, you must do so on another tray before inserting the object. Copying and pasting also allows you to use objects already configured on previously-used build trays for newer projects. You perform the Copy and Paste commands as in other Windows applications: • from the right-click context menu. • by using keyboard shortcuts (Ctrl+C and Ctrl+V, respectively). The Paste Special command (from the object’s right-click context menu) enables you to place duplicate objects even more efficiently: • You can specify the number of duplicates to place on the build tray at once. • You can set the distance, on each axis, between the duplicate objects. • You can manipulate mirror images of the original object, and flip them on selected axes. Figure 5-18 Paste Special dialog box DOC-07027 Rev. I 5-20...
Page 61: Surface Finish
Objet500 User Guide 5 Using Objet Studio Surface Finish Models can be printed with a matte or glossy surface finish. To create a matte finish, the printer surrounds models with a thin layer of support material. To set the model finish: 1. Select the model. 2. Select Matte or Glossy in one of the following places: ❒ Model Settings ribbon, Options group ❒ Model Toolbar ❒ right-click context menu (when selecting the model) You can configure Objet Studio to distinguish between objects’ surface finish on the build tray by color. To configure how Objet Studio displays objects, see "Setting Object Colors" on page 5-49. Splitting Objects into Components You can convert a complex object to an assembly of component parts. To do so, you split the stl file that represents the object into a group of separate stl files, each one representing a component. (This is referred to in the Objet Studio interface as separating the object into shells.) You can then assign a model material to each stl file, and you can save the newly-created assembly as an objdf file. To split an object into an assembly of component parts: 1. ...
Page 62: Model-Material Settings
Objet500 User Guide 5 Using Objet Studio 2. With the object selected: ❒ From the Object menu, select Separate into Shells. or— ❒ On the ribbon, click A dialog box opens in which you can specify where to save the component stl files. (By default, Objet Studio offers to save the new files in a folder in the same location as the original stl file.) Figure 5-20 Folder selection for saving stl files after splitting into shells 3. Click OK. Objet Studio splits the object into an assembly of component parts, each a separate stl file (“shell”). The object appears—on the build tray and in the model tree—as an assembly of parts (“shells”). You can assign each part a different model material (This is explained in "Model-Material Settings" below). Figure 5-21 Object after being converted to an assembly of component parts Model-Material Settings Before placing objects on the build tray in Objet Studio, you should pay attention to the material selection settings on the Tray Settings ribbon. Figure 5-22 Material selection settings DOC-07027 Rev. I 5-22...
Page 63 Objet500 User Guide 5 Using Objet Studio • By default, the material selection settings on the ribbon correspond to the three Model cartridges loaded in the printer. • The materials displayed are basic model materials. With Connex2 and Connex3 printers, these materials can be combined to create digital materials (see "Digital Materials" on page 5-25). • The material displayed on the top (VeroBlack, in the figure above) is considered the primary model material (“Model-1”). It is assigned to objects that do not have a material assignment when you place them on the build tray. For example, since stl files do not contain information about the model material, Objet Studio assigns the primary model material to them. Also, if you try to insert objdf files whose assigned materials are not recognized by your version of Objet Studio, you can insert the file by substituting the primary model material for the missing materials. • Select Single Material if you want to print using only one material—all of the material drop-down menus contain the same material. If you decide to print with multiple materials, the material in the top drop-down menu remains assigned to the object until you select another material. • If you insert an objdf file into an empty build tray, and the model-material assignment does not match the settings on the Tray Settings ribbon, these settings are changed automatically. However, if there is an object already on the build tray whose materials do not match the material assignment in the objdf file, you cannot place the new object on the tray. To print this object, you have the following options: ❒ Instead of printing it on the same build tray, print the new object as a separate job. ❒ Change the materials assigned to objects on the build tray to match those assigned to the new object (see "Changing the Model Material" on the next page and "Assigning a Model Material to Objects" on page 5-26).
Page 64: Changing The Model Material
Objet500 User Guide 5 Using Objet Studio Changing the Model Material When you design a build tray in Objet Studio, you can use model materials that might not be currently installed in the printer. Because the installed materials are displayed by default, change the material selection settings on the Tray Settings ribbon, if necessary. Figure 5-23 Selecting a new model material Changing the Support Material To change the type of Support material: 1. In the printer application, run the Material Replacement Wizard (see "Changing the Printing Material" on page 6-13). 2. In Objet Studio: ❒ When changing to SUP706, the recommended Grid Style is "Lite." Note: Cleaning models printed with Standard or Heavy grid style can clog the filter in DT3 and CS P cleaning stations. If necessary, clean these models with a WaterJet cleaning station. ❒ When changing to SUP705, the recommended Grid Style is "Standard." You can override the default grid style settings for the current print job in the Advanced Properties dialog box (see "Choosing the Support Strength" on page 5-62). You can set the default grid style in the User Preferences dialog box (see "Setting User Preferences" on page 5-72). When you send a print job to the printer, the new Support material a ppears in the ...
Page 65: Digital Materials
Objet500 User Guide 5 Using Objet Studio Figure 5-24 Available Resources in Job Manager Digital Materials When different model materials appear on the ribbon, you can produce objects from any of them or from a combination of them—digital materials. Different combinations of model materials enable you to print objects with a wide range of color and mechanical characteristics. To view the digital materials available for printing objects (using three basic model materials): 1. Make sure that you have selected the appropriate model materials, and that Multiple Materials is selected. Figure 5-25 Material selection with three basic model materials DOC-07027 Rev. I 5-25...
Page 66: Assigning A Model Material To Objects
Objet500 User Guide 5 Using Objet Studio 2. Click The Material Selection Guide appears, showing the basic model materials and the digital materials available (combinations of them). Figure 5-26 Material Selection Guide, showing the digital materials available with the basic model materials Assigning a Model Material to Objects You can assign any of the available materials to objects on the build tray. To assign a model material to objects: 1. Select an object on the build tray (see "Selecting Objects" on page 5-19). When an object is selected, its properties—including model materials—are displayed on the Model Toolbar and on the ribbon. Figure 5-27 Object properties, on ribbon and Model Toolbar 2. Display the material drop-down list and select the desired material. Figure 5-28 Menu for assigning materials to objects When you de-select the object on the build tray, it is displayed, by default, with the color of the material you selected. In the same way, you can assign model materials to each of the independent objects on the build tray. DOC-07027 Rev. I 5-26...
Page 67: Coating Objects
Objet500 User Guide 5 Using Objet Studio To separate an object into independent, component parts (each an stl file), see "Splitting Objects into Components" on page 5-21. Color Selection You can assign materials to models using a color palette if certain combinations of materials are available. Figure 5-29 Color palette To change the material selection method—color palette or material list: ➢ From the Tools menu, select Color material selection. Figure 5-30 Setting the color material selection method Coating Objects You can print composite models where the surface layer is a different material than the inside. This can be useful to achieve unique mechanical and textural characteristics. This technique is called “coating.” To coat an object with a different model material: 1. ...
Page 68 Objet500 User Guide 5 Using Objet Studio 3. Select Coat With and, from the drop-down list, select the coating material. Figure 5-31 Coating material selected 4. In the Thickness field, enter a coating thickness between 0.3 and 3 millimeters. Note: The coating thickness does not affect the external dimensions of the object, which remain unchanged. The coating layer replaces part of the main model material. 5. Click Apply. Note: When you de-select objects, they are displayed, by default, with colors representing the model-material. Even after adding a coating to an object, its color remains that of the main material, not the color of the coating material. To inspect, modify or remove the coating applied to an object: 1. On the Model Toolbar or the Model Settings ribbon, click The Coat with dialog box opens.
Page 69: Positioning Objects On The Build Tray
Objet500 User Guide 5 Using Objet Studio Positioning Objects on the Build Tray To produce models efficiently and with the required finish, it is important to carefully position objects on the tray. Objet Studio supports the automatic positioning of objects. However, you should check to make sure that the objects are orientated optimally for your needs, according to the considerations explained in "Manual Positioning" on page 5-31. Two things that affect the positioning of objects on the tray are orientation and placement. You can let Objet Studio determine the optimum orientation and position, or you can control them. Automatic Orientation By default, Objet Studio automatically orients objects, when placed on the build tray, for the shortest printing time. (You can later change the orientation manually.) However, you can cancel automatic orientation when placing an object on the build tray. To place an object on the build tray without automatic orientation: ➢ In the Insert dialog box, make sure Orient Automatically is not selected. Figure 5-32 Orient Automatically option disabled You can change the default setting, so that automatic orientation is not applied unless you select the Orient Automatically check box each time you ...
Page 70: Automatic Positioning
Objet500 User Guide 5 Using Objet Studio Automatic Positioning After placing several objects on the build tray, you can let Objet Studio arrange them before printing. This ensures that the objects are positioned properly, and that they will be printed in the shortest time and with a minimum of material. To automatically arrange objects on the build tray: ➢ On the Tray Settings ribbon, click or— From the Tools menu, select Automatic Placement. The effects of automatic positioning are shown in the figures below. Figure 5-33 Tray before objects are properly arranged Figure 5-34 Tray arrangement after applying Automatic Placement For best results, arrange the tray with Automatic Placement,on the TraySettings ribbon, even if you inserted the objects with the Orient Automatically option. ...
Page 71: Manual Positioning
Objet500 User Guide 5 Using Objet Studio Manual Positioning You can change the position of objects on the build tray—even if they were inserted with the Orient Automatically option. Tools for changing the position of objects are presented in "Manipulating Objects on the Tray" on page 5-33. The orientation of models on the build tray affects how quickly and efficiently they will be produced by the printer, where and how much Support material is used, and whether or not model parts will have a glossy finish. Therefore, you should consider a variety of factors when deciding how to place models on the build tray, using the following positioning rules. X-Y-Z Rule This rule considers a model's outer dimensions. ➢ Since the print heads move back and forth along the X-axis, the printing time along this axis is relatively short, compared to printing time along the Y-axis and Z-axis. From this point of view, it is advisable to place the object's largest dimension along the X-axis. ➢ Surfaces that come into contact with Support materials become matte. ➢ Since models are built up, on the Z-axis, in 16- or 30-micron layers (according to the printing mode), it is very time-consuming to print a tall object. From this point of view, it is advisable to place the object's smallest dimension along the Z-axis. ➢ Since the print heads measure about 2 inches (5 centimeters) on the Y-axis, models measuring less than this (on the Y-axis) are printed in one pass. From this point of view, it is advisable to place the object's intermediate dimension along the Y-axis. Tall-Left Rule This rule considers models where, after being orientated on the build tray ...
Page 72 Objet500 User Guide 5 Using Objet Studio Fine-Surface Rule This rule considers models that have one side on which there are fine details (like the keypad side of a telephone). ➢ The side of the model containing fine details should, when possible, be positioned face-up. This results in a smooth finish. Avoid Support-Material Rule This rule considers models that have large holes or hollows, open on at least one side (like a pipe or a container). ➢ It may be advantageous to print a model standing up, so Support material does not fill the hollow, even though printing the model lying down would be much faster. DOC-07027 Rev. I 5-32...
Page 73: Manipulating Objects On The Tray
Objet500 User Guide 5 Using Objet Studio Manipulating Objects on the Tray Positioning Objects on the Z-Axis When you use the automatic positioning option to arrange objects on the build tray (see "Automatic Orientation" on page 5-29), the objects are positioned directly on the tray. If you do not insert objects with automatic positioning, they often appear either above or below the tray. In practice, the Objet500 system prints all models on the build tray on a one- millimeter bed of support material. The importance of positioning objects directly on the build tray with Objet Studio is to correctly display the objects on the screen. To position objects directly on the tray: 1. Select the object. 2. From the Object menu, select Lay On. To ensure that objects are always positioned directly on the tray: 1. ...
Page 74: Valid Object Placement
Objet500 User Guide 5 Using Objet Studio Valid Object Placement You can ensure that models do not overlap when you position them on the build tray, and that they do not extend beyond the tray. To ensure valid object placement: 1. From the Tools menu, select Constraints Settings. Figure 5-36 Constraints Settings dialog box 2. Select Dynamic check to identify— ❒ invalid object placement while placing objects—On Drop selected. ❒ invalid object placement after moving objects—While Drag selected. ❒ objects placed beyond the tray’s boundaries—Outside Tray selected. ❒ objects that overlap—Object Collision selected. Even if you do not use Dynamic Check when placing objects on the build tray, ...
Page 75: Using A Grid To Position Objects
Objet500 User Guide 5 Using Objet Studio Using a Grid to Position Objects Displaying a grid on the image of the build tray can be useful when positioning objects. To use the grid features, select the following menu options. Menu Option Result Tools > Grid Displays a grid on the build tray. Tools > Snap to grid When moving the object, it aligns with the nearest grid line. Tools > Options > Grid Enables you to change the grid origin (X- and Y-axis meeting point) and appearance. You can review and configure grid settings—and apply them—from the Options dialog box. To view and change grid settings: 1. From the Tools menu, select Options, and display the Grid tab. The current grid settings are displayed. Figure 5-37 Options dialog box, Grid tab 2. As required, change the settings, and select or clear the check boxes. 3. Click Apply or OK. DOC-07027 Rev. I 5-35...
Page 76: Measurement Units
Objet500 User Guide 5 Using Objet Studio Measurement Units 3D files contain an object's proportions, but not its units of measure. Therefore, make sure to correctly select either millimeters or inches when inserting an object. Otherwise, the size of the object on the build tray will be either much too large or much too small. To set the measurement units when inserting an object: ➢ In the Insert dialog box, Units field, select Millimeter or Inch: Figure 5-38 Units field in the Insert dialog box To change measurement units for a selected object from the Model Settings ribbon: 1. Open the Units flyout toolbar. Figure 5-39 Units flyout toolbar 2. ...
Page 77: Setting Model Dimensions
Objet500 User Guide 5 Using Objet Studio To change measurement units for a selected object from the standard toolbar: 1. From the Object menu, select Change Units. Figure 5-40 Model Units dialog box 2. In the Model Units dialog box, change the setting and click OK. Setting Model Dimensions You can change an object’s dimensions by changing its size on the X-, Y-, and Z- axes, from the Dimensions group on the Model Settings ribbon. Figure 5-41 Dimensions on the Model Settings ribbon • If Uniform Scale is enabled, changing the object’s dimension on one axis affects the other dimensions, proportionately. • After changing a measurement, press Enter or click in another field in the Dimensions group. Note: You can change the height of the objects on the build tray only if this is ...
Page 78: Manually Repositioning Objects
Objet500 User Guide 5 Using Objet Studio Manually Repositioning Objects You can manually move and rotate an object on the build tray with the arrow keys, or by dragging it with the mouse. To manually manipulate an object: 1. Select an object by clicking it on the build tray, or in the model tree pane. 2. Click on the Model Toolbar, or on the Model Settings ribbon. A frame appears around the object, and the cursor changes to indicate that the object can be moved. Figure 5-42 Manually moving an object 3. If you click on a corner of the frame, the cursor changes to indicate that the object can be rotated. Figure 5-43 Manually rotating an object 4. Manipulate the object with the arrow keys or with the mouse. DOC-07027 Rev. I 5-38...
Page 79 Objet500 User Guide 5 Using Objet Studio Using the Transform Dialog Box You can make precise changes to an object by changing the properties in the Transform dialog box. To access the Transform dialog box (when an object is selected): • Click on the Model Toolbar or on the Model Settings ribbon. • From the right-click context menu, select Transform. • From the Object menu, select Transform. Figure 5-44 Transform dialog box To change an object with the Transform dialog box: ➢ Change any of the values, then click Apply to see how the object changes on ...
Page 80: Changing An Object's Orientation
Objet500 User Guide 5 Using Objet Studio Changing an Object’s Orientation There are several methods for changing the orientation of objects on the build tray. To rotate an object: ➢ Select the object and use the Object menu options (see also "Manually Repositioning Objects" on page 5-38). To re-align an object’s plane: 1. On the Tray Settings or Model Settings ribbon— a. Click the icon in the Selection group: or b. On the flyout toolbar, click the Select Plane icon: or— From the Tools menu, select Plane Alignment > Select Plane. 2. Click on part of an object on the build tray.
Page 81 Objet500 User Guide 5 Using Objet Studio 3. On the Alignment toolbar, click an appropriate icon to change the alignment. or— From the Tools menu, select Plane Alignment, and select an alignment option. Figure 5-46 Tools menu, Plane Alignment options To cancel plane selection after re-aligning objects on the build tray: ➢ On the Tray Settings or Model Settings ribbon— a. Click the icon in the Selection group: or b. On the flyout toolbar, click the Select Element or Select Group icon: or—...
Page 82: Grouping And Ungrouping Objects
Objet500 User Guide 5 Using Objet Studio Grouping and Ungrouping Objects You can manipulate two or more objects on the build tray, at the same time. • Selecting multiple objects Manipulating done to one object affects all selected objects. For example, turning one object on its axis causes all selected objects to turn on their respective axes. • Converting the objects to an assembly Separate objects become parts of one unit. For example, turning the assembly on its axis causes all its component parts to turn as one unit. To convert objects to an assembly: 1. Select the objects (see "Selecting Objects" on page 5-19). 2. From the Object menu, select Group to Assembly. In the model tree, the objects now appear as children of a parent (assembly). Figure 5-47 Assembly in the model tree The model tree does not display the assembly file name unless you open (insert) it as an objdf file. After creating an assembly, you can save it as an objdf file, for re-use. (Saving the assembly is not necessary for manipulating and printing it.) To save an assembly: 1. Select the assembly (either on the build tray or in the model tree).
Page 83: Freezing Model Orientation
Objet500 User Guide 5 Using Objet Studio To separate assemblies into individual objects (stl files): 1. Select the assembly (either on the build tray or in the model tree). 2. From the Object menu, select Ungroup. In the model tree, the elements are not parts of an assembly. Figure 5-48 Separate objects in the model tree Freezing Model Orientation If you manipulate an object on the build tray, you can freeze its orientation so that it does not change when you position it automatically (see "Automatic Positioning" on page 5-30). To freeze an object: 1. Select an object on the build tray. 2. On the Model Settings ribbon, in the Manipulate group, or on the Model Toolbar, click To unfreeze an object: ➢ ...
Page 84: Display Options
Objet500 User Guide 5 Using Objet Studio Display Options Viewing Objects From the View menu, you can change the way objects are displayed. The default method for displaying models on the build tray is as solid (“shaded”) objects. Figure 5-49 Tray and model displayed in Shaded view The other display options are WireFrame and Points. To display the build tray in WireFrame view: ➢ From the View menu, select WireFrame. Figure 5-50 Tray and model displayed in WireFrame view To revert to the shaded view: ➢ From the View menu, select Shaded. DOC-07027 Rev. I 5-44...
Page 85 Objet500 User Guide 5 Using Objet Studio To display objects as boxes, showing their maximum dimensions instead of their shape: ➢ From the View menu, select Display Bounding Box. Figure 5-51 Model displayed with bounding box To display the area around objects needed for support material (to produce a matte finish): ➢ ...
Page 86: Screen Layout
Objet500 User Guide 5 Using Objet Studio To display objects without the build tray: ➢ From the View menu, clear (de-select) the Display Tray option. Screen Layout Objet Studio automatically adjusts the default screen layout to display the optimum views of the build tray and the model tree. You can view models from different perspectives by changing the screen layout. To change the screen layout: ➢ On the View flyout toolbar, select Single View, or 4 Views. Figure 5-54 Screen layout icons ❒ Single View is the default screen layout. ❒ 4 Views displays perspective, top, front and right views. Figure 5-55 Single-view screen layout DOC-07027 Rev. I...
Page 87: Tray Perspective
Objet500 User Guide 5 Using Objet Studio Figure 5-56 4-view screen layout Tray Perspective The default perspective of the build tray is “isometric.” You can change the perspective of the active window with one of ten options. To change the perspective of the build tray in the active window: 1. On the Tray Settings ribbon, open the Perspective flyout toolbar. Figure 5-57 Perspective toolbar 2. Click the icon that represents the desired perspective. DOC-07027 Rev. I 5-47...
Page 88 Objet500 User Guide 5 Using Objet Studio Tray Positioning To view the tray and models from different directions, you can move the tray around the screen and change its display angle. To move the tray in the Objet Studio screen: ➢ Press the mouse wheel while moving the mouse. Figure 5-58 Tray after moving it in the Objet Studio display To manually rotate the tray: ➢ Press Alt and press the mouse wheel while moving the mouse. Figure 5-59 Tray after rotating it upside-down To view the tray and models from different directions, you can change its display angle. DOC-07027 Rev. I 5-48...
Page 89: Setting Object Colors
Objet500 User Guide 5 Using Objet Studio Setting Object Colors The color of objects on the build tray can indicate how they are printed. Objet Studio enables you to choose the color display so that you can easily see the material, surface and coating of objects. To choose how colors are applied on the display: ➢ On the Model Settings ribbon, in the Colors group, select one of the options from the flyout toolbar. Figure 5-60 Colors display options Before sending a build tray to the printer, or when you perform tray validation, Objet Studio checks if there is a problem with the stl files or the positioning of objects on the tray. If so, the affected objects are displayed with special colors (see "Tray Validation" on page 5-54). DOC-07027 Rev. I 5-49...
Page 90: Loading Large Files
Objet500 User Guide 5 Using Objet Studio Loading Large Files Very large stl files can be slow to load and may be difficult to manipulate easily on the build tray. If this is the case, you can display just an image of the object on the build tray without loading the entire file. The stl file itself is not changed, and the complete file is sent to the printer. To display an image of stl files when you place objects on the build tray: 1. From the Tools menu, select Options, and display the Settings tab. Figure 5-61 Options dialog box, Settings tab 2. In the Large Files section, select Load Partial (reduced). Large File Manipulation If you need to work with a detailed model that is composed of a large number of polygons, you can speed up its display and manipulation in Objet Studio by reducing the number of polygons on the screen. Although this may reduce the ...
Page 91 Objet500 User Guide 5 Using Objet Studio Figure 5-63 Object displayed with only five percent of its polygons showing To use polygon reduction: 1. From the Tools menu, select Options. or— From the Objet Studio Commands menu , click Options. 2. In the Options dialog box, display the tab. Display Figure 5-64 Options dialog box, Display tab 3. Select Enable Polygon Reduction . 4. Select Polygon Reduction (Percent). 5. Enter the percentage of total polygons to display. When you click Apply, the display changes. Note: The setting affects the static display (when the object is not being moved). 6. Set display options when the object is being moved (Display while changing view): DOC-07027 Rev. I...
Page 92: Zoom Options
Objet500 User Guide 5 Using Objet Studio ❒ Bounding Box—A box representing the object’s maximum dimensions is displayed. ❒ Adaptive Polygon Reduction—Varying degrees of polygon reduction are applied, as necessary. ❒ Entire Object—No polygon reduction is applied. 7. To save these settings, so that they will be applied every time you place this object on the build tray, click Save Polygon Reduction Data. 8. Click Apply to see the results of the settings without closing the dialog box. Selecting the Entire Object option cancels polygon reduction. Object display options The display format affects how quickly objects display. For example, if you select Bounding Box, objects display faster than they do when you select Entire Object. You can choose display formats for objects when they are stationary (static view) and for when you are dragging them (changing view). To select the object display preference while changing view, and in static view: 1. ...
Page 93 Objet500 User Guide 5 Using Objet Studio ❒ Zoom by Rectangle allows you to display a section of the tray by selecting it with the mouse. You can also zoom in and zoom out with the mouse wheel. You can configure Objet Studio to automatically zoom in on the objects placed on the build tray. See "Automatic Zoom" on page 5-75. DOC-07027 Rev. I 5-53...
Page 94: Handling Trays
Objet500 User Guide 5 Using Objet Studio Handling Trays After preparing models on the build tray, you can do the following: • Test that it can be printed ("validation"). • Calculate the time and material resources needed to print it. • Send it to the printer for production. • Save it for later completion or printing. • Save it as a compressed file for convenient storage and transfer. Tray Validation Before sending a job to the printer for production, you should check that the tray is “valid” and can be printed. Note: Because of the unique characteristics of each type of modeling material, make sure that the correct material is selected before performing Tray Validation. To validate that the tray can be printed: ➢ On the Tray Settings ribbon, in the Build Process group, click or— From the Tools menu, select Placement Validation. If the tray is not valid, the color of the problematic models on the tray changes according to a pre-set code. Figure 5-66 Color code Note: The “Both” color also indicates a problematic stl file.
Page 95: Production Estimates
Objet500 User Guide 5 Using Objet Studio The validation status appears on the bar at the bottom of the screen. Figure 5-67 Validation details in status bar Production Estimates Objet Studio enables you to calculate the time and material resources needed for producing trays before sending them to the printer. The time it takes Objet Studio to perform this calculation depends on the number of objects on the tray and their complexity. Calculating the production estimate for a full tray could take up to 15 minutes, depending on your computer’s specifications. To calculate the time and materials needed for producing the current tray: ➢ On the Tray Settings ribbon, in the Build Process group, click While the estimate is being calculated, a progress bar is displayed—on the right side of the status bar (at the bottom of the screen). Figure 5-68 Estimate progress bar When Objet Studio finishes calculating the production resources, the results are displayed in a dialog box. Figure 5-69 Production resource calculations for different printing modes As shown in the Production Estimates dialog box, the resources needed for ...
Page 96: Printing Modes
Objet500 User Guide 5 Using Objet Studio Printing Modes Objet500 printers can build models using three possible printing modes. HQ (High Quality) Mode— • Models are printed in 16-micron layers, resulting in smooth surfaces, suitable for producing fine-detailed and delicate items. • Almost twice as much time is required to print most trays, compared to the High Speed setting. • This setting is only available when model material can be used in four print heads, in single-material printing. Single-material printing: All print heads print models without regard to the source of the model material. This happens in the following situations: All print heads are supplied with one model material. Each pair of print heads is supplied with a different model material, but models are printed as if they were the same material. The result is an arbitrary mixture of materials in the printed model. HS (High Speed) Mode— • Models are produced in 30-micron layers, suitable for producing larger ...
Page 97: E-Mailing Objet Digital Files
Objet500 User Guide 5 Using Objet Studio printer. At that time, you can select the printing mode, including an option that enables Objet Studio to print the tray by the most efficient method (see "Printing- Mode Selection" on page 1). E-mailing Objet Digital Files ® ® You can easily e-mail objdf files using Microsoft Office Outlook . Sending objdf files is recommended (instead of stl files) because the size of a file is typically reduced by more than half. An added benefit is that the objdf file contains the model-material information for the object. To e-mail a file: 1. From the Tools menu, select Email Objet Digital File. Outlook opens with the file attached and Subject details added to the e-mail form. 2. Enter the e-mail address and send the file. Printing the Tray When a tray is ready to be printed, it is placed in the Jobs Queue. When the job reaches the head of the queue, Objet Studio pre-processes the tray file to create slices, and feeds them to the printer. To send the tray to the print queue: ➢ ...
Page 98 Objet500 User Guide 5 Using Objet Studio ❒ If printing the tray requires only one model material, the Printing Mode Selection dialog box opens. Figure 5-71 Printing Mode Selection dialog box Note: The values displayed are the result of a quick calculation, and represent a rough estimate of the materials and time input required to print the job. For a more accurate calculation, click Fine Estimation. ➢ Select the appropriate printing mode. For an explanation of printing modes, see "Printing-Mode Selection" on page 1. • If you require the job to be printed in High Quality mode, select this option. Note: The availability of High Quality mode depends on the material selected. • If you require the job to be printed in High Speed mode, select this option. • If you do not require the job to be printed either in High Quality or High Speed mode, select Automatic. This setting enables the Objet500 software to determine (just before printing) the most efficient way to print the tray. Digital Material mode is used if this removes the need to perform the Material Replacement procedure. Otherwise, High Speed mode is used. For example, if printing the tray requires only one of the model ...
Page 99 Objet500 User Guide 5 Using Objet Studio On the other hand, if printing the tray can be done using four print heads without running the Material Replacement procedure, High Speed mode is used. This is possible if all print heads are supplied with one model material, or if you allow printing with an arbitrary mixture of similar materials (see below). Model Quality When Digital Material Mode is Used Near-high-quality is achieved for most models. If all objects on the tray are inserted from individual stl files, they are printed with the standard resolution of 600 dpi (dots per inch) along the Y-axis—unless glossy finish is required (see "Surface Finish" on page 5-21). If there is an assembly on the tray, all of the models on the tray are printed with a resolution of 300 dpi along the Y-axis. ➢ Click Next. • If no other selections are required, the Job Summary dialog box opens. ➢ Click Build and continue on the next page ❒ ...
Page 100 Objet500 User Guide 5 Using Objet Studio Continue Here If the build tray file has not been saved when you click Build, the Save As dialog box opens for you to save it. Objet Studio checks if there is a problem with the positioning of objects on the tray. If so, the affected objects are displayed with special colors (see "Tray Validation" on page 5-54), and a warning message appears. Figure 5-73 Tray validation warning message ➢ To cancel the Build command so you can correct the problem, click No. ➢ To print the models as they are positioned on the tray, click Yes. The Job Manager screen opens, so you can monitor the progress of your trays—before, during, and after printing. See "Monitoring and Managing Print Jobs" on page 5-80. DOC-07027 Rev. I 5-60...
Page 101: Applying Additional Objet Studio Features
Objet500 User Guide 5 Using Objet Studio Applying Additional Objet Studio Features Dividing Objects You can use the Split Object feature to produce objects larger than the tray area by dividing the model into separate parts. With this feature, you produce only a specific section of a model. To split an object: 1. Select the object. 2. From the Object menu, select Split. 3. In the Split Object dialog box, enter the values to determine how Objet Studio will divide the object. You can divide an object along any of its axes, by entering either exact measurements or the number of parts. Figure 5-74 Split Object dialog box 4. In Save to Folder, enter the folder name. 5. Click OK. The composite parts are saved as new stl files with “Part 1,” “Part 2,” etc., added to the original file name. Note: Before printing the newly created stl files, it is recommended that you check them for defects in an STL-repair application, such as Magics™, by ® Materialise . ...
Page 102: Choosing The Support Strength
Objet500 User Guide 5 Using Objet Studio Choosing the Support Strength When producing models, support material fills some hollow and empty sections (see "Manual Positioning" on page 5-31). Objet Studio allows you to adjust the strength of the structure formed with the support material. This adjustment is useful when producing either large/massive models or small/delicate models. For most purposes, the default setting provides adequate support strength. To change the strength of the support structure used when printing a model: 1. Select a model on the tray. 2. On the Model Settings ribbon, in the Options group, click ...
Page 103: Hollow"- Filling Models With Support Material
Objet500 User Guide 5 Using Objet Studio “Hollow”— Filling Models with Support Material Many objects placed on the tray from stl files are “solid.” This means that, when printed, the model will be completely filled with model material. Often, especially with large objects, this is unnecessary. Instead, the model can be filled with support material, which is less costly. It is also advisable to fill models with support material when preparing them for investment casting, since this material burns off more quickly during the process of making the cast. Objet Studio enables you to print objects on the tray with an outer shell of model material and a center filled with support material. When using this feature, called “Hollow,” the thickness of the shell should be no less than 0.5 millimeters. To use the Hollow feature: 1. Select a model on the tray. or— ❒ On the Model Toolbar click or— ❒ From the right-click context menu, select Advanced Properties. The Advanced Properties dialog box opens. 2. Select Hollow. Figure 5-76 Advanced Properties dialog box 3. Set the shell thickness, in millimeters.
Page 104: Displaying The Cross Section Of Objects
Objet500 User Guide 5 Using Objet Studio Displaying the Cross Section of Objects The Section feature enables you to view the interior of an object by “slicing” it on any axis. You can then manipulate the object to inspect the interior from different angles. This may be important for deciding on the type of support necessary when producing the model (see "Choosing the Support Strength" on page 5-62). Displaying an object’s cross section only affects how the tray is displayed on the screen; it does not change the object itself. To display a cross section of the tray: 1. From the Tools menu, select Section. The Section dialog box opens. Figure 5-77 Section dialog box 2. Select Enable Clipping. 3. Use the slider controls for the X-, Y-, and Z-axes to cut the tray so that you see the cross section you want. Figure 5-78 Left: Whole view; Right: Cross section view after using the Z-slider DOC-07027 Rev. I 5-64...
Page 105: Saving The Screen Display As An Image File
Objet500 User Guide 5 Using Objet Studio Saving the Screen Display as an Image File You can save the image displayed in the active viewing screen as a graphic file. To save the screen display as an image: 1. Press Ctrl+B. or— From the Objet Studio Commands menu , select Save Bitmap. The Save Bitmap dialog box opens. Figure 5-79 Save Bitmap dialog box 2. At the top of the dialog box, select the appropriate folder. 3. At the bottom of the dialog box, enter a file name. 4. Open the Save as type drop-down list, and select the file format. 5. Click Save. Saving Build Trays You can save your work in different Objet Studio file formats, depending on how you want to use them later.
Page 106 Objet500 User Guide 5 Using Objet Studio Note: Because the objtf file references the stl files used, they must remain in the same file location as when the objtf file was saved. To save the tray as an objtf file: ➢ In the Tray Settings tab, File group, click To open trays saved as objtf files, see "Opening Objet Tray Files" on page 5-16. OBJZF Files To conveniently save all of the files as they are positioned on the build tray, for storing the job, or for transferring it to another location, Objet Studio compresses them into one objzf file. To later use the objzf file, the file must first be expanded in Objet Studio and its component files saved. Note: If you export an objzf file containing a stl file originally saved as read-only, you cannot open (import) this objzf file to the folder where the read-only stl file is saved. To create an objzf file: 1. From the Objet Studio Commands menu , select Export Packed Job.
Page 107: Customizing Objet Studio
Objet500 User Guide 5 Using Objet Studio Customizing Objet Studio You can customize Objet Studio to suit your particular working needs and preferences. Features that you can customize include: ❒ Creating a quick-access toolbar for frequently used commands. ❒ Changing the position of the Quick Access toolbar. ❒ Minimizing the ribbon. ❒ Changing the Objet Studio color theme. ❒ Configuring default settings for objects placed on the build tray. Creating a Quick Access Toolbar As you work with Objet Studio, you may use certain commands frequently. You can create a quick-access toolbar to make your work easier. To create a quick-access toolbar: 1. Above the ribbon tabs, click The Customize Quick Access Toolbar menu opens. Figure 5-80 Customize Quick Access Toolbar menu 2. Select a command you want to add to the toolbar.
Page 108 Objet500 User Guide 5 Using Objet Studio 3. To choose from a wider range of commands: ❒ From the Customize Quick Access Toolbar menu (see Figure 5-80 on the previous page), select More Commands. or— ❒ Right-click on the Objet Studio Commands icon , or elsewhere on the ribbon, and select Customize Quick Access Toolbar. Figure 5-82 Right-click ribbon menu The Options dialog box opens. Figure 5-83 Quick Access Toobar Options dialog box 4. Open the drop-down list and select either Popular Commands or Commands not on the Ribbon. 5. Select a command and click Add. 6. Click OK.
Page 109: Hiding The Ribbon
Objet500 User Guide 5 Using Objet Studio Hiding the Ribbon To make more room for displaying the build tray, you can hide the Objet Studio ribbons. To hide the ribbons: 1. Right-click anywhere on the ribbon or on the menu bar, or in the Objet Studio Commands menu 2. Select Minimize the Ribbon. The ribbons disappear, but you can temporarily display the ribbon icons by clicking Tray Settings or Job Manager on the menu bar. When you next click outside of the ribbon, it disappears again. To return the permanent ribbon display: ➢ Repeat the steps above to cancel Minimize the Ribbon. Display Colors You can customize some of the colors used for displaying Objet Studio screens and for displaying objects on the build tray.
Page 110 Objet500 User Guide 5 Using Objet Studio 2. In the Appearance tab of the Options dialog box, you can configure the display. ❒ The Mode selection determines how models appear on the build tray. The default method for displaying models on the build tray is as solid (“shaded”) objects. The other options are WireFrame and Points. ❒ If Shaded is selected, you can display the model on the tray as a see- through object. Figure 5-85 Transparent display ❒ Double-click the color patches to customize colors. ❒ The Windows Background Color settings enable you to change the color behind the build tray—with either a solid or a two-color gradient. ❒ To return to the default display settings, click Default. Changing Color Themes Objet Studio offers a choice of four background color themes—blue, black, silver ...
Page 111: Keyboard Shortcuts
Objet500 User Guide 5 Using Objet Studio Keyboard Shortcuts You can define shortcut keys for frequently used commands. To define shortcut keys: 1. Above the ribbon tabs, click The Customize Quick Access Toolbar menu opens. Figure 5-87 Customize Quick Access Toolbar menu 2. Select More Commands. The Options dialog box opens (see Figure 5-83 on page 5-68). 3. Click Customize. The Customize Keyboard dialog box appears. Figure 5-88 Customize Keyboard dialog box DOC-07027 Rev. I 5-71...
Page 112: Setting User Preferences
Objet500 User Guide 5 Using Objet Studio 4. Select command Categories to display all the commands in that category, for example, all the Model Settings commands. Current shortcut keys are displayed. 5. Enter the shortcut key in the Press new shortcut key field, and click Assign. 6. If you want to redefine all shortcut keys, click Reset All. Setting User Preferences You can change several Objet Studio settings that affect objects placed on the build tray. To change default settings: ➢ From the Objet Studio Commands menu , select User Preferences. Figure 5-89 Setting work preferences • Building Style—see "Surface Finish" on page 5-21. • Grid Style—see "Choosing the Support Strength" on page 5-62. • Application Settings: ❒ Lock Orientation—see "Freezing Model Orientation" on page 5-43. ❒ Hollow—see "“Hollow”— Filling Models with Support Material" on page 5- DOC-07027 Rev. I...
Page 113: Professional Mode Features
Objet500 User Guide 5 Using Objet Studio Professional Mode Features Some advanced features of Objet Studio are only accessible in Professional Mode. To see the current Objet Studio setting: ➢ Open the Tools menu. Figure 5-90 Tools menu, showing Professional Mode selected If Professional Mode is selected, advanced features are displayed. To change the Professional Mode setting: 1. From the Tools menu, select Professional Mode. The following message is displayed, reminding you that the change will only take effect the next time you open Objet Studio—even though the check mark next to the Professional Mode option appears immediately. Figure 5-91 Configuration-change message 2. ...
Page 114: Default Settings
Objet500 User Guide 5 Using Objet Studio Default Settings You can control the default settings of several Objet Studio features from the Advanced tab of the Options dialog box. To display the Options dialog box ➢ From the Tools menu, select Options. or— In the Objet Studio Commands menu , click Options. Figure 5-92 Options dialog box, Advanced tab The Advanced tab is only accessible when Professional Mode is active (see "Professional Mode Features" on the previous page). Automatic Orientation By default, when Objet Studio places objects on the build tray, it orients them optimally, for the shortest printing time. If necessary, you can choose to cancel automatic orientation each time you place an object on the build tray (see "Automatic Orientation" on page 5-29). In any case, when objects are on the build tray, you can change their orientation manually (see "Manual Positioning" on page 5-31.) To change the default setting so that Automatic Orientation is disabled: ➢ ...
Page 115: Opengl Driver Configuration
Objet500 User Guide 5 Using Objet Studio Automatic Zoom When Auto Zoom is selected in the Advanced section of the Options dialog box, the display zooms in, to display the objects placed on the build tray. This allows you to carefully inspect and manipulate the objects. By default, this feature is not enabled. In any case, you can change the zoom level, as necessary (see "Zoom Options" on page 5-52). OpenGL Driver Configuration The OpenGL driver displays 3D graphics on your screen. There is normally no reason to adjust its settings. If you suspect a problem with the way Objet Studio displays objects, you can use the OpenGL Driver Configuration tool to check and configure the driver settings. To access the OpenGL Driver Configuration dialog box: 1. From the Tools menu, select Options. or— In the Objet Studio Commands menu , click Options. 2. In the Options dialog box, display the Troubleshooting tab. Figure 5-93 Access to OpenGL Driver configuration The Troubleshooting tab is only accessible when Professional Mode is active (see "Professional Mode Features" on page 5-73). DOC-07027 Rev. I 5-75...
Page 116 Objet500 User Guide 5 Using Objet Studio 3. Click OpenGL Driver Configuration. The dialog box that opens displays details of the pixel format ID (index) for the window and the memory. Figure 5-94 OpenGL Driver Configuration dialog box If you want to display the values and change them, click . Alternately, you can select Choose Format and change the values in this dialog box. To perform a test of the driver configuration and enter the suggested pixel format ID: 1. Select Choose Format. 2. Click Test.
Page 117: Getting Additional Objet Studio Assistance
Objet500 User Guide 5 Using Objet Studio Getting Additional Objet Studio Assistance Objet Studio Help provides on-screen instructions and information, as you work. To view Objet Studio Help: ➢ On the standard toolbar, click and then click Objet Studio Help. Figure 5-96 Help options You can also view information on the following subjects: ❒ Troubleshooting opens a list of error messages and their explanations. ❒ Check for Updates checks if you are using the latest Objet Studio version. Objet Studio Version, Material Module and Licensed Features You can view details of the Objet Studio version, the material module installed, and the features available with your license. To view details of your Objet Studio installation: ➢ On the standard toolbar, click ...
Page 118 Objet500 User Guide 5 Using Objet Studio Figure 5-98 About Objet Studio tab Materials Module tab The Materials Module tab shows details of the material module installed. Figure 5-99 Materials Module tab • Module version If a Materials Module upgrade (patch) was installed, the new Materials Module version is displayed. If no patches were installed, the Module version is the same as the Objet Studio version. • Module date If a Materials Module upgrade (patch) was installed, the date of its creation is displayed. If no patches were installed, the Module date is the date of the Objet Studio version. DOC-07027 Rev. I 5-78...
Page 119 Objet500 User Guide 5 Using Objet Studio • Module properties If a Materials Module upgrade (patch) was installed, its description is displayed. If no patches were installed, “Default” is displayed. Feature License tab The Feature License tab shows the Objet Studio features available with your license. Figure 5-100 Feature License tab Click to expand the details for each feature. • Modes shows the printing modes available. See "Printing Modes" on page 5-56. • Materials shows the basic model materials available. • Digital Materials shows the digital materials available. • Mixed Tray shows if your license enables printing a build tray containing objects, using a different model material for each. DOC-07027 Rev. I 5-79...
Page 120: Monitoring And Managing Print Jobs
Objet500 User Guide 5 Using Objet Studio Monitoring and Managing Print Jobs In the Job Manager screen of Objet Studio, you monitor and manage jobs sent to the printer. There are a few differences between Objet Studio on client workstations and on the computer connected directly to the 3D printer—the server workstation. • Objet Studio installed on a client computer only displays the queue and status for jobs sent to the 3D printer server from that computer, and it allows the user to edit only these jobs. Note: If there are several PolyJet printers on the local network, client computers can connect to any of them, but only one at a time. • Objet Studio installed on the computer directly connected to a specific 3D printer (server), displays the queue and status for all jobs sent to that 3D printer by the server and by all client computers on the network. It also allows editing and manipulation of all jobs, and enables re-sending previously- printed jobs to the printer. If Objet Studio is not connected to a printer (or printer server), you can prepare tray files for any PolyJet printer. Later, these files can be used by Objet Studio on the appropriate printer server. DOC-07027 Rev. I 5-80...
Page 121: Job Manager Screen
Objet500 User Guide 5 Using Objet Studio Job Manager Screen The Job Manager screen on the client and server workstations looks identical. The only difference is that options only relevant to the server workstation are disabled for client installations. Figure 5-101 Job Manager screen The Job Manager screen is divided into panels: • Jobs Queue • Printing Progress • H istory • Available Resources • Material Consumption • Tray Preview • Waste DOC-07027 Rev. I 5-81...
Page 122 Objet500 User Guide 5 Using Objet Studio Jobs Queue On the server, the Jobs Queue lists the last 15 jobs sent from client computers. On client workstations, it l ists jobs sent from that computer to the server. Information for each of the queued jobs is displayed, including the job status. Status Meaning Waiting Printing of this job has not started. Building Printing of this job is in progress. Stopped Printing of this job was interrupted. Printing can later be continued (Resume) or begun again (Restart). Error Errors occurred during the printing of this job, and it was placed in the Jobs Queue again. Editing Objet Studio . This job is now being edited in Spooling The job file is being spooled in the printer. Preprocessing The 3D printer is readying itself for printing: the cover locks, the print heads warm up and are put in starting position, the UV lamps are turned on, and the build tray level is adjusted. On Schedule The job is scheduled to be printed at a specified time. In addition, the following information is displayed: • Owner—the computer that sent the job • Build Time—the estimated building time for the job...
Page 123: Setting The Printer Connection
Objet500 User Guide 5 Using Objet Studio Material Consumption • Actual—the amount of material used till now • Required—the amount of material still needed to finish the job Tray Preview The Tray Preview panel displays the build tray view of the job selected in the Job Queue or the History list. On a server, you can open an enlarged preview window by clicking on the Tray Preview display (see "Additional Server Features" on page 5-91). Waste The amount of waste appears when the cursor is over the Waste display. Setting the Printer Connection When your printer is installed, the server computer is connected to that printer. Normally, there should be no reason to change this connection. Occasionally, however, you may need to reset the connection, to connect the server to another printer, or to use Objet Studio in offline mode (without a printer connection). To set (or change) the printer connection: 1. On the Job Manager ribbon, in the 3D Printer group, click 2. In the Set Printer dialog box, click Connect.
Page 124: Offline Mode
Objet500 User Guide 5 Using Objet Studio 3. Enter the computer name or its IP address, or click Browse to find and select Figure 5-103 Connecting to a printer (B) 4. Click OK. When the connection is established, Objet Studio is configured to prepare print jobs for that printer. If you can see the material levels in the "Job Manager Screen" (see Figure 5- 101 on page 5-81), Objet Studio is connected to the printer. Note: A printer can be listed by its name or by its computer's I P address. Offline Mode You can use Objet Studio to prepare trays for printing in offline mode, on a remote computer or when the printer connection is not available. You also use offline mode to prepare trays for printing with other printers. In this case, if Objet Studio is currently connected to a printer, you must change to offline mode by removing this connection. DOC-07027 Rev. I 5-84...
Page 125 Objet500 User Guide 5 Using Objet Studio To disconnect Objet Studio from the printer: 1. On the Job Manager ribbon, in the 3D Printer group, click 2. In the Set Printer Features dialog box, click Connect (see Figure 5-102 on page 5-83). Figure 5-104 Disconnecting Objet Studio from a printer (A) 3. In the Printer Connection dialog box, delete the computer name/IP address. Figure 5-105 Disconnecting Objet Studio from a printer (B) 4. Click OK. “Unknown” appears in the printer-name field. 5. Click OK. DOC-07027 Rev. I 5-85...
Page 126 Objet500 User Guide 5 Using Objet Studio 6. In the pop-up message, confirm that you want to work in offline mode by clicking No. Figure 5-106 offline message When Objet Studio is in offline mode, you can configure it for preparing print jobs for different printers. To change the Objet Studio offline configuration: 1. In the Set Printer Features dialog box, select a printer type. Figure 5-107 offline printer selection 2. Click OK (not “Connect”). DOC-07027 Rev. I 5-86...
Page 127: Setting The Remote Printer Connection (Client Mode)
Objet500 User Guide 5 Using Objet Studio Setting the Remote Printer Connection (Client Mode) When you open Objet Studio for the first time in a client installation, you are prompted to connect to a server computer that sends jobs to a 3D printer. To do this, the server computer must be operating and connected to the local network. To set (or change) the connection to the server-computer: 1. On the Job Manager ribbon, in the 3D Printer group, click 2. Enter the name of the server computer or its IP address, or click Browse to find and select it. 3. Click OK. Figure 5-108 Printer Server Connection dialog box Job Manager Commands The Job Manager ribbon has three icon groups: ❒ 3D Printer ❒ Queue ❒ Job ...
Page 128 Objet500 User Guide 5 Using Objet Studio The following operations are available on the Job Manager ribbon: Group Icon Purpose 3D Server: Sets the printer connection. See "Setting the Printer Printer Connection" on page 5-83. Client: Sets the server connection. See "Setting the Remote Printer Connection (Client Mode)" on the previous page. Configures options for printer alerts. See "Configuring User Alerts" on page 5-90. Queue Server: Moves a job to the head of the Jobs Queue. Client: Disabled. See "Jobs Queue" on page 5-82. Server: Moves a job to a higher position in the Jobs Queue. Client: Disabled. See "Jobs Queue" on page 5-82 Server: Moves a job to the bottom of the Jobs Queue. Client: Disabled. See "Jobs Queue" on page 5-82. Server: Moves a job to a lower position in the Jobs Queue. Client: Disabled. See "Jobs Queue" on page 5-82.
Page 129 Objet500 User Guide 5 Using Objet Studio In addition to using ribbon command icons, you can use commands on context (pop-up) toolbars and from the Job menu on the standard toolbar. Figure 5-110 Icons on pop-up toolbar (server) Figure 5-111 Icons on pop-up toolbar (client workstation) Note: Most icons and menu commands are only enabled when a job is selected. When you position the cursor over an item, a tooltip displays the name of the command. Figure 5-112 Job menu options (server) DOC-07027 Rev. I 5-89...
Page 130: Configuring User Alerts
Objet500 User Guide 5 Using Objet Studio Configuring User Alerts Objet Studio can alert you (and others) to the status of jobs sent to the server for printing. This is especially useful during long printing jobs, when the operator is away from the printer. The following events can be reported: • The level of model or support material is low. • The job was interrupted. • The job was completed successfully. To send e-mail and SMS alerts, make sure that e-mail software supporting MAPI is installed on the server computer. To send SMS alerts, the cellular phone service must support the transmission of e-mail messages by SMS. Only the subject line of the e-mail message is transmitted by SMS. To configure Objet Studio to send notifications and alerts: 1. On the Job Manager ribbon, in the 3D Printer group, click Figure 5-113 Notifications dialog box (server) Figure 5-114 Notifications dialog box (client workstation) 2. Set the desired reporting options. 3. Click Details. DOC-07027 Rev. I 5-90...
Page 131: Printing From The Jobs Queue
Objet500 User Guide 5 Using Objet Studio Figure 5-115 Event selection for alerts 4. In the Reports Events dialog box, select the alert events and click OK. 5. In the Notifications dialog box, click OK. Printing from the Jobs Queue If there is a job in the Jobs Queue, it is sent automatically to the Stratasys PolyJet printer—as long as it is on, there is a connection to the printer, and the printer is on line. Chapter 6 describes starting and operating the printer. Additional Server Features Objet Studio on the printer server includes the following additional features: • Extended Tray Preview • Editing Jobs • Restarting Jobs • Resuming Jobs • Scheduling Jobs • Exporting Jobs (objzf) • Modifying the Job Manager Screen These features are described below. Extended Tray Preview In this window, you can view the tray from different angles and magnifications without leaving the Job Manager screen. In addition to displaying the selected job in the Tray Preview pane, you can open an enlarged build tray window. To display the build tray window: 1. ...
Page 132 Objet500 User Guide 5 Using Objet Studio 2. Click the Tray Preview pane. Figure 5-116 Job Preview ❒ To change the tray magnification, turn the mouse wheel. ❒ To view the tray from a different perspective, click the relevant icon. ❒ To resize the window, drag its edge or corners. If there are several objects on the build tray, you can exclude one or more from being printed, without actually deleting the object from the tray file. To prevent the printing of an object on the build tray: 1. Double-click on the object you do not want to print. 2. Display the Build tab. 3. Select Exclude from Build. Figure 5-117 Excluding a model from the build 4. ...
Page 133 Objet500 User Guide 5 Using Objet Studio Editing Jobs You can open jobs in the Jobs Queue for editing. To edit a job: 1. Select the job. 2. Click the Edit icon The Tray Settings screen opens, displaying the build tray. The status of the job in the Job Manager screen changes to “Editing.” 3. Edit the job. 4. On the Tray Settings ribbon, click The status of the job in the Job Manager screen changes back to “Waiting.” Restarting Jobs You can restart jobs from the Jobs Queue and the History list. To restart a job: 1. Select the job.
Page 134 Objet500 User Guide 5 Using Objet Studio Scheduling Jobs You can schedule jobs to be printed at a future time. For example, you can configure Objet Studio to start long printing jobs in the late evening and early morning hours. To schedule a job: 1. Select a job in the Jobs Queue, and click on the pop-up toolbar. 2. In the Scheduler dialog box, set the Start Date and Start Time for the job. Click on the Start Date arrow to open a calendar. Figure 5-118 Scheduler with calendar displayed 3. Click OK. Exporting Jobs (objzf) You can save print jobs as compressed files. For an explanation of objzf files, see "Saving Build Trays" on page 5-65. To export a print job: 1. Select a job. 2. On the pop-up toolbar, click 3. In the Save As dialog box, select a folder.
Page 135 Operating and Maintaining the Printer Starting the P rinter Loading Model and Support Cartridges Producing Models Preparing the Printer Starting Printing Printer Interface Color Key Printing Indicators Resuming Production After Printing has Stopped 6-10 Changing the Printing Material 6-13 Printing With Bio-Materials 6-18 Advanced Settings 6-18 Keeping the Printer in Idle Mode 6-22 Shutting Down the Printer 6-23 Maintaining the Printer 6-26 Routine Maintenance Schedule 6-26 Maintenance Counters 6-27 UV Lamp Check 6-29 Cleaning the Print Heads and the Roller 6-29 Cleaning and Replacing the Wiper 6-32 Pattern Test 6-35 Improving Print Quality 6-37 Cleaning the Roller Waste Collector and Inspecting the Roller Scraper 6-37 Replacing the Roller Scraper 6-41 Aligning the Print Heads...
Page 136 Installing the New Head 6-61 Testing and Calibrating the UV Lamps 6-65 Calibrating the Load Cells 6-73 Replacing the Odor Filter 6-74 Replacing the UV Lamps 6-75 Built-in Tests 6-84 Replacing the Waste Container 6-90 Cleaning the Exterior Panels 6-92 Cleaning the UV Screen 6-92 DOC-07027 Rev. I...
Page 137: Starting The P Rinter
Objet500 User Guide 6 Operating and Maintaining the Printer Figure 6-1 The Objet500 3D Printer Starting the P rinter Caution Do not attempt to operate the printer before being trained by an authorized Stratasys representative. Observe all safety warnings and follow the safety guidelines described in Chapter 2. 1. Turn on the main power switch, located at the back of the printer. Figure 6-2 Main power switch and cable The main power switch turns on the Objet500 printer, which includes the built-in computer. DOC-07027 Rev. I...
Page 138 Objet500 User Guide 6 Operating and Maintaining the Printer 2. After the printer-control computer boots, log in to Windows and launch the printer-control program: ❒ On the printer-computer desktop, double-click the Objet500 printer icon. or— ❒ From the Windows Start menu, select (All) Programs > Objet > Objet500. A HASP plug containing a valid product activation key is required on the printer computer. This is supplied during printer installation or upgrade. If the application does not open and a HASP message appears, contact your Stratasys dealer or service provider. All monitoring and controlling of the printer is done from this interface. Figure 6-3 Printer interface Objet500 installations use one monitor for displaying both the computer running Objet Studio and the computer installed inside the printer. Make sure that the KVM (keyboard-video-mouse) switch is in the correct position so that the printer interface is displayed. DOC-07027 Rev. I...
Page 139: Loading Model And Support Cartridges
6 Operating and Maintaining the Printer Loading Model and Support Cartridges Objet500 printers use up to six cartridges of Model material and two cartridges of Support material, each weighing 3.6 kilograms when full. The material cabinet contains a module that identifies loaded printing materials. Tampering with this module will render the printer inoperable and may void Stratasys warranties and service contracts. Important: If you need to replace the printing material currently installed with another type, see "Changing the Printing Material" on page 6-13. Otherwise, make sure to replace the material cartridge with one containing the same type of material. To load Model and Support material: 1. Load Model and Support cartridges into their respective compartments.
Page 140: Producing Models
Objet500 User Guide 6 Operating and Maintaining the Printer Producing Models Models can be printed after they are arranged on a virtual build tray in a 3D printing application. Two such applications are available for preparing trays for printing on the Objet500 printer: • Objet Studio • GrabCAD Print (for Connex3 printers) For information about preparing model files for printing, see the relevant documentation— • "Using Objet Studio" chapter in this user guide or Help in the Objet Studio application. • GrabCAD Print online documentation. Preparing the Printer Before beginning to produce models, it is recommended that you check the current printing quality of the print heads by performing the Pattern Test. To prepare the printer for producing models: 1. Make sure that the build tray in the printer is empty and clean. If not, remove cured material with the scraper, and clean the tray thoroughly with a cleaning cloth soaked with 90% alcohol (IPA or ethanol). Caution Use protective gloves when cleaning the build tray, and be careful of the sharp edges of the scraper blade. 2. Make sure that there is sufficient Model and Support material loaded, as indicated on the printer interface (see the figure on page 6-4). You may want ...
Page 141: Starting Printing
Objet500 User Guide 6 Operating and Maintaining the Printer You can monitor printer status by switching the printer interface display. To do this, click the display toggle button on the printer interface screen. Figure 6-4 Printer status Starting Printing To begin printing: ➢ On the printer interface, click the red button to switch the printer to online mode. The color of the button changes from red to green (see the figure on page 6- 4). If there is a job in the Job Manager queue, it is sent to the printer. If there is a job in the printing queue, it is sent to the printer. When switching the printer to online mode, a message is displayed if a maintenance activity is required to ensure optimum printing quality. (See "Routine Maintenance Schedule" on page 6-26.) Maintenance notifications can be disabled/enabled from the Options menu. In the printer interface, the printer mode changes from Idle to Pre-print, as the printer’s components prepare themselves for production: • The print block is heated. • The UV lamps are powered and they warm up. When printing begins, the print manager program sends a number of slices to the printer-control application. This fills the b uffer between the print manager a nd the printer to ensure continuous printing. As each slice is printed, as a layer of the models on the build tray, another slice is sent to the printer.
Page 142: Printer Interface Color Key
Objet500 User Guide 6 Operating and Maintaining the Printer During printing, the server computer must remain on and it must communicate with the Objet500 printer. Do not log-off Windows until printing is finished. The Objet500 printer uses one, two or three Model-material cartridges and one Support-material cartridge to produce models. If additional cartridges are installed and they are not immediately needed for printing, the printer interface indicates this (see "Printer Interface Color Key" below). Printer Interface Color Key The background colors in the printer indicator fields tell you at a glance whether or not the value or item is suitable or ready for printing. • Green—suitable/ready for printing For example, in Figure 6-4 on the previous page: ❒ Heads (°C)—The heads have reached the temperature required for printing models. ❒ Ambient—The ambient temperature of the printing chamber is within the acceptable range. ❒ Heads Liquid—The level of Model and Support material in the print-block reservoir is OK. ❒ Heads Vacuum—The vacuum level in the system is within the acceptable range. ❒ Pre-Heaters—The Model and Support resins have been heated to the required temperature before being supplied to the print block. ...
Page 143: Printing Indicators
Objet500 User Guide 6 Operating and Maintaining the Printer Printing Indicators The printer interface screen changes when you send a print job to the printer, if the printer is online: • The mode changes from Pre-print to Printing. • The specific activity being performed is shown in the “current activity” field. • Current job-printing information is displayed. • The printing progress bar is displayed. • The Stop and Pause buttons are enabled. When the weight of a cartridge drops below 100 grams, the display of the material level in the printer interface is red. Figure 6-5 P rinter interface during printing DOC-07027 Rev. I...
Page 144: Resuming Production After Printing Has Stopped
Objet500 User Guide 6 Operating and Maintaining the Printer Resuming Production After Printing has Stopped If the printing process is interrupted, the print manager stops sending slices to the printer. This can happen, for example, if the printing material runs out in the middle of a print job, and you do not replace the empty cartridge immediately. After the printer changes to Standby or Idle mode, you need to resume printing from the Job Manager screen of Objet Studio. After the printer changes to Standby or Idle mode, you need to resume printing from the print manager (in Objet Studio or in GrabCAD Print). After printing stops, the printer goes into Standby mode, when heating of the print heads is reduced. About 10 hours later, the printer goes into Idle mode, when heating of the print heads is stopped. To continue printing the model from GrabCAD Print: 1. If the printer is in offline mode, switch it to online mode by clicking the red button at the bottom of the p rinter interface (see the figure on page 6-4). The button changes from red to green. 2. If you don’t know why printing has stopped, make sure that the connection between the printer and the server computer is active. 3. In the Manager screen of Objet Studio, or in the Schedule screen of ...
Page 145 Objet500 User Guide 6 Operating and Maintaining the Printer 5. In the job-preparation application, make sure that the correct slice number is entered in the d ialog box. Figure 6-6 Slice confirmation in Objet Studio Figure 6-7 Slice confirmation in GrabCAD Print Figure 6-8 Printer interface after interrupted printing 6. If, for any reason, the correct number does not appear in the dialog box, enter the number and click OK. You cannot continue printing the model if: • The number of the last slice printed does not appear in the printer interface, even if the server computer displays the Continue from Slice confirmation dialog box. • There was a relatively long interruption in printing, even if the “last slice” and “continue from slice” indicators are correct. This is because the part already DOC-07027 Rev. I 6-11...
Page 146 Objet500 User Guide 6 Operating and Maintaining the Printer printed might slightly deform or shrink before printing continues, causing a visible difference between it and the part of the model printed later. The effects of a printing stoppage depend on the model size and structure, the Model material used, ambient temperature and the length of the stoppage. If you cannot continue printing: 1. Cancel the job in the printing application (Objet Studio or GrabCAD Print). In GrabCAD Print, you do this from the Schedule screen: ❒ Right-click on the job to display the pop-up menu, and select Cancel job. OR— ❒ Left-click on the job to display the Job Status details, and click the Cancel icon . 2. Remove the partially printed model from the build tray. 3. Restart the job from the Job Manager screen (in Objet Studio). 4. Resend the job to the printer from the printing application. ❒ In Objet Studio, click ❒ In GrabCAD Print, click ...
Page 147: Changing The Printing Material
Objet500 User Guide 6 Operating and Maintaining the Printer Changing the Printing Material Before producing models using a different type of printing material than is currently installed, run the Material Replacement wizard to flush the print block and feed tubes. After changing Support material with the wizard, Head Optimization is required before printing models. You should carefully plan printing models with different materials to avoid unnecessary waste of the materials currently loaded. The amount of material flushed depends on the flushing cycle chosen and if you are replacing one or more cartridges. The Material Replacement wizard suggests the best slot locations for placing different material cartridges, based on the materials currently in the system. This ensures minimum flushing of materials currently loaded. Note: When performing manual material replacement, certain r eplacement options are blocked to protect the system. In these cases, follow the recommendations of the Material Replacement wizard for best replacement options. To replace the printing material with the wizard: 1. Start the Material Replacement wizard from the Options menu. Figure 6-9 Starting the Material Replacement wizard DOC-07027 Rev. I...
Page 148 Objet500 User Guide 6 Operating and Maintaining the Printer 2. In the opening screen, click Next. 3. If the printer cover is not closed, a screen appears, prompting you to close the cover. Confirm that it is closed and click Next. Figure 6-10 Material replacement options In the Material Replacement Options screen, you select the settings that determine how the wizard replaces material currently in the system with newly loaded material. 4. Choose whether you want to produce models in Single Material mode or in Digital Material ( “multiple-materials”) mode. Single Material mode Four print heads are used to print, using one Model material. ❒ This mode is required to produce build trays with the High Quality setting, and to produce trays with the High Speed setting, using only one Model material. Digital Material mode Each of the Model materials loaded is used in two of the print heads. ...
Page 149 Objet500 User Guide 6 Operating and Maintaining the Printer until the print job is completed. When one cartridge empties and the other one is being used, you can replace the empty cartridge with a new one. 7. For Support material, select Both if you need to load two replacement cartridges. 8. In the Flushing cycle section of the wizard screen, choose how thoroughly you want to flush out material currently in the system: ❒ Economy. This cycle can be used when replacing a light-colored Model material with a darker material (such as Agilus30 Black™ or VeroBlack™) or if the exact color of the printed models is unimportant. Use this cycle when replacing cleaning fluid with any Model material. The wizard flushes the system with the minimum amount of material needed to ensure that models have the mechanical properties of the new material. ❒ Full. Use this cycle when the printed models must have the exact color of the new material. The wizard thoroughly flushes t he feed tubes and print heads needed for printing, based on your selections in the previous screens. There are additional settings that you can select for special purposes (see "Advanced Settings"). If necessary, click Advanced Settings before clicking Next. DOC-07027 Rev. I...
Page 150 Objet500 User Guide 6 Operating and Maintaining the Printer 9. Click Next to begin the material replacement process in the printer. The Cartridge Positioning screen appears, showing you the new location of all cartridges in the material cabinet. Figure 6-11 Cartridge placement Symbols: The correct cartridge is in this slot. No cartridge (or the incorrect cartridge) is in this slot. The cartridge in this slot has insufficient weight to complete the material replacement process. The expiration date of the cartridge in this slot has passed. 10. R eplace material cartridges as necessary, according to the instructions in the wizard screen. 11. C lick Start. 12. R ead the warning message, and click OK. If you continue, you must complete the material replacement process before you can produce models. To replace material cartridges at another time, click Cancel. If you continue (by clicking OK) and you do not complete the process, you will need to run the wizard again before producing models. DOC-07027 Rev. I 6-16...
Page 151 Objet500 User Guide 6 Operating and Maintaining the Printer Figure 6-12 Final wizard screen 13. I n the final wizard screen, click Done. The printer-control application is automatically updated, and it restarts. When it opens, the interface displays the new material(s). Objet Studio (on the server computer) is also updated and displays the new material(s). The interface in the job preparation application i s also updated, and it displays the new material(s). 14. I nspect the area around the purge unit and clean it, if necessary. After changing the type of Support material (SUP705/706), you need to run the Head Optimization wizard before printing models. See "Optimizing (Calibrating) Print Heads" on page 6-47 . DOC-07027 Rev. I 6-17...
Page 152: Printing With Bio-Materials
Objet500 User Guide 6 Operating and Maintaining the Printer Printing With Bio-Materials To ensure the bio-compatibility of printed parts when changing from standard printing materials to bio-compatible materials, follow the instructions for loading the relevant material. To download the required document, search for "Biocompatibility Requirements" on the Stratasys Support Center. Advanced Settings The Advanced Settings dialog box enables you to configure the Material Replacement wizard for special purposes. If necessary, click Advanced Settings in the Material Replacement Options screen before clicking Next. Figure 6-13 Advanced Replacement settings Positioning By default, Automatic slot selection determines the best slot locations for the cartridges in the material cabinet, based on materials currently in the system. This ensures minimum flushing of materials currently loaded. Select Manual slot selection— ...
Page 153 Objet500 User Guide 6 Operating and Maintaining the Printer 2. In the Advanced Settings screen, select Manual slot selection, and click Apply. Figure 6-14 Manual slot selection 3. In the Material Replacement Options screen, Both cartridges is selected for each position. To print with only one of the cartridges, clear the check box a nd then select either the left (L) or the right (R) cartridge. Figure 6-15 Manual cartridge selection DOC-07027 Rev. I 6-19...
Page 154 Objet500 User Guide 6 Operating and Maintaining the Printer When printing in High Speed mode (three materials), the same material is used in both sections of each print head. The material selected for one of the cartridge slots is also used in the other print head channel. Figure 6-16 Manual cartridge selection—3 Model Materials 4. After selecting the materials for the appropriate cartridge slots, the Cartridge Positioning screen appears. Place the cartridges in the materials cabinet as shown in this screen. M aterial for Single Material mode If you regularly use a certain material for printing models in single material mode, ...
Page 155 Objet500 User Guide 6 Operating and Maintaining the Printer Additional Flushing Cycles The flushing cycle you select in the Material Replacement Options screen determines how thoroughly to flush out material currently in the system. After selecting the Economy cycle and completing the wizard, you might decide that you require a more thorough flushing, to ensure accurate model color. Or, you may notice that printed models are not satisfactory because they contain traces of the previous material. If so, you can flush out more material, so that the next models will be printed with pure material. To perform additional flushing cycles: ➢ In the Advanced Settings screen, select Enable "flush again" options and click Apply. Figure 6-17 Enable flush again options selected The Material Replacement Options screen appears, where you can select the material(s) you need to flush again. DOC-07027 Rev. I 6-21...
Page 156: Keeping The Printer In Idle Mode
Objet500 User Guide 6 Operating and Maintaining the Printer Keeping the Printer in Idle Mode Between printing jobs, the printer can be left unused for up to one week. If the printer will not be used for more than a week, use the Shutdown wizard to automatically perform the procedures that must be done before turning off the printer (see "Shutting Down the Printer" on the next page). When the printer stops producing models, the printer software automatically reduces the temperature of the print heads, as follows: After printing stops Mode Change in heating of print heads first 15 minutes Standby 1 no change next 10 hours Standby 2 heating reduced (to room temp.) after Standby 2 Idle heating stopped Note: The printer mode is indicated in the upper left of the main printer interface screen (see the figures on pages 6-4, a nd 6-9).
Page 157: Shutting Down The Printer
Objet500 User Guide 6 Operating and Maintaining the Printer Shutting Down the Printer You only need to shut down the printer if it will not be used for 30 days or more. Otherwise, the printer can remain on, in Idle mode. However, if there is a need to turn off the printer sooner, use the Shutdown wizard to automatically perform the necessary processes before turning off the printer The Shutdown process flushes printing materials from printer components. To avoid flushing out valuable material, make sure to print models at least once a week. Many printer operators use this opportunity to print customer samples or test models. To properly shut down, the printer needs to perform several processes. These are controlled by the Shutdown wizard. Except for immediate servicing, do not attempt to shut down the printer by simply closing the computer interface (the printer-control application), and never disconnect power to the printer before completing this wizard.
Page 158 Objet500 User Guide 6 Operating and Maintaining the Printer 3. Select the option corresponding to the length of time that the printer will not be used—less or more than 10 days. Note: Before selecting More than 10 days, make sure that cleaning-fluid cartridges are available. Figure 6-19 Shutdown options 4. In the next screen, verify that the tray is empty and click Next. The shutdown procedure begins. Figure 6-20 Shutdown progress DOC-07027 Rev. I 6-24...
Page 159 Objet500 User Guide 6 Operating and Maintaining the Printer Figure 6-21 Final Shutdown wizard screen 5. After the printer computer shuts down, turn off the main power switch at the back of the printer ( see Figure 6-2 on page 6-3). DOC-07027 Rev. I 6-25...
Page 160: Maintaining The Printer
Objet500 User Guide 6 Operating and Maintaining the Printer Maintaining the Printer Performing routine maintenance tasks is essential for getting satisfactory results from your printer. Perform the tasks at specified intervals. Routine Maintenance Schedule Frequency Task For More Information Before printing Clean the UV lamp lenses. See "Cleaning the Print Heads and the Roller" on page 6- Before / after printing Check the UV lamp overheating indicator. See "UV Lamp Check " on page 6- Before / after printing Clean the print heads and the roller surface. See "Cleaning the Print Heads and ...
Page 161: Maintenance Counters
Objet500 User Guide 6 Operating and Maintaining the Printer Frequency Task For More Information Monthly Clean debris from the Z-axis shaft with a vacuum cleaner. Monthly Inspect the exhaust system (duct, fan, connections). Monthly Calibrate the load cells. See "Calibrating the Load Cells" on page 6-73. Every two years or every 3500 Preventive maintenance visit by service engineer. Contact your hours of printing Stratasys service provider. Maintenance Counters The printer computer application records the dates and frequency for each maintenance task. You can display the Maintenance Counters screen from the Options menu. Figure 6-22 Selecting Maintenance Counters DOC-07027 Rev. I...
Page 162 Objet500 User Guide 6 Operating and Maintaining the Printer If there is a maintenance task due, this is indicated on the main interface screen. Figure 6-23 Maintenance Required indicator If this indicator appears, you can display the Maintenance Counters screen by clicking on it. Figure 6-24 Maintenance Counters screen The Maintenance Required indicator appears by default for most operator- performed maintenance tasks. The check box under “User Warning” controls whether or not it appears when a particular task is due. For maintenance tasks that are controlled by wizards, the dates and printing times are reset automatically when the relevant wizard is run and completed successfully. Manual maintenance tasks (for example, roller inspection and wiper replacement) are reset by clicking the reset button in the Maintenance Counters screen. DOC-07027 Rev. I 6-28...
Page 163: Uv Lamp Check
Objet500 User Guide 6 Operating and Maintaining the Printer UV Lamp Check A heat-sensitive label is fixed to the UV lamp covers as a warning against overheating. Its center changes from white to black if the temperature of the cover reaches 65°C (150°F). If this occurs, do not use the printer, and call your service provider. As a precaution, it is recommended that you check the label before and after printing. Figure 6-25 Heat-sensitive label on UV lamp cover If the UV lamp continues to overheat, and the temperature around the lamp reaches 90°C (194°F), a heat fuse turns off the electricity to the power to the UV lamp and the motors for the X, Y, and Z axes. In the unlikely event that this occurs, the printer cannot be used until it is serviced by an authorized service engineer. Cleaning the Print Heads and the Roller Periodic inspection and cleaning of the orifice plates on the bottom of the print block ensures that the print nozzles are not clogged. A wizard guides you through the procedure, and adjusts components of the printer to enable you to perform it. This procedure takes about 20 minutes, and should be done at the beginning of the work day or before a big printing job. To clean the print heads and the roller: 1. ...
Page 164 Objet500 User Guide 6 Operating and Maintaining the Printer 3. Follow the instructions on the wizard screens, and select the confirmation check boxes. Figure 6-26 Tray and cover confirmation 4. Click Next. The printer prepares for you to clean the print heads. 5. When the following screen appears, open the cover. Figure 6-27 Head cleaning wizard—steps 5–11 Warning: Hot Surface The print head orifice plates (bottom surface) may be hot. Do not touch them with your bare hands, and proceed with caution. 6. Place the mirror on the build tray. 7. Put on the gloves. Caution Uncured printing material on the print heads might cause skin irritation. Use disposable cleaning gloves to protect your hands. 8. Soak the cleaning cloth with alcohol. DOC-07027 Rev. I 6-30...
Page 165 Objet500 User Guide 6 Operating and Maintaining the Printer 9. Clean the orifice plates, with a back-and-forth motion (see Figure 6-28). Use the mirror to make sure that you have removed all of the residue material. Figure 6-28 C leaning the heads 10. C lean the entire roller surface, by rotating it as you clean. Use this opportunity to clean the glass lens on the UV lamps using the supplied sanding sponge. 11. W hen you have finished cleaning, select the confirmation check box in the ...
Page 166: Cleaning And Replacing The Wiper
Objet500 User Guide 6 Operating and Maintaining the Printer Cleaning and Replacing the Wiper A rubber wiper removes excess material from the print heads after the purge sequence. This is done automatically before each print job, and performed manually during maintenance tasks. You should clean the wiper and surrounding area at least once a week. If the wiper is damaged or worn, replace it. To inspect and clean the wiper: 1. Prepare— ❒ 90% isopropanol (IPA—isopropyl alcohol) or ethanol (ethyl alcohol) ❒ disposable cleaning gloves ❒ a supplied cleaning cloth or equivalent ❒ a spare wiper 2. Start the Wiper Cleaning wizard from the Options menu. Figure 6-30 Starting the Wiper Cleaning wizard 3. In the opening wizard screen, click Next. DOC-07027 Rev. I 6-32...
Page 167 Objet500 User Guide 6 Operating and Maintaining the Printer 4. Make sure that the build tray is empty, and close the printer cover. Confirm this in the wizard screen, and click Next. Figure 6-31 Tray and cover confirmation 5. When the following screen appears, open the cover. Figure 6-32 W iper Cleaning wizard during steps 6–10 6. Put on the cleaning gloves. 7. Using a generous amount of alcohol on the cleaning cloth, remove any material remaining on the wiper and the surrounding area. DOC-07027 Rev. I...
Page 168 Objet500 User Guide 6 Operating and Maintaining the Printer 8. Remove any pieces of waste material collected in the purge unit. If necessary, remove the waste collector to clean it. Wipe the rubber seal. Figure 6-33 Purge unit waste collector Note: When returning the waste collector to the purge unit, make sure to insert it as shown. 9. Inspect the wiper. If the wiper is scratched, torn or worn, or if you cannot clean it completely, replace it: a. Grasp it and pull it up and out of its bracket. b. Insert the new wiper blade, making sure that it is straight and secured well on both sides. 10. I n the wizard screen (see Figure 6-32), confirm that the wiper blade is clean, and click Next. 11. R emove all tools and cleaning materials from the printer, and close the cover.
Page 169: Pattern Test
Objet500 User Guide 6 Operating and Maintaining the Printer 12. C onfirm this in the wizard screen, and click Next. Figure 6-34 Tray and cover confirmation 13. I n the final sceen, click Done to close the wizard. Pattern Test The pattern test is the basic verification of the printer’s ability to produce quality models, since it demonstrates the condition of the nozzles in the print heads. Make sure, therefore, that you perform this test weekly, and whenever you suspect a printing problem. To perform the pattern test: 1. Make sure that the build tray is empty. 2. Prepare a sheet of pink paper, A-4 or Letter size. 3. In the printer, tape the pink paper to the surface left of the build tray. 4. Press F3, or open the Options menu and select Pattern Test. Figure 6-35 Selecting Pattern Test 5. Click Yes in the Confirm dialog box to begin. DOC-07027 Rev. I...
Page 170 Objet500 User Guide 6 Operating and Maintaining the Printer Figure 6-36 Pattern Test confirmation 6. If the build tray is not clear, click No in the following dialog box. Figure 6-37 Build tray (Z) level adjustment The build tray is lowered to prevent damage to models on the tray. The printer prints a series of lines on the test paper (see next figure). Figure 6-38 Sample Pattern Test 7. Carefully inspect the test paper to see if there are missing lines. Too many missing lines, especially if they are in the same area, indicates that the quality of printing when producing models will be poor. If this is the case, see "Improving Print Quality" on the next page. Note: Acceptable model quality is subjective, and depends on the type and scale (size) of the models produced. As a rule, however, more than 10 missing lines in one area of a column is considered unacceptable. DOC-07027 Rev. I 6-36...
Page 171: Improving Print Quality
Objet500 User Guide 6 Operating and Maintaining the Printer Improving Print Quality If you suspect that print quality is poor, perform the Pattern Test (see "Pattern Test" on page 6-35). If the results are poor, use the following procedure to improve print quality. If the results of the last pattern test are poor: 1. From the Options menu, select Purge Sequence, or press F4. 2. In the confirmation dialog box, click Yes. The print heads are purged of Model and Support material, and the wiper removes excess material from them. 3. Repeat the purge sequence. 4. Perform the pattern test. If the results of the pattern test are still poor: 1. ...
Page 172 Objet500 User Guide 6 Operating and Maintaining the Printer To clean the roller waste collector: 1. Prepare— ❒ M2.5 and M2 Hex (Allen) keys ❒ disposable cleaning gloves ❒ 90% isopropanol (IPA—isopropyl alcohol) or ethanol (ethyl alcohol) ❒ cleaning cloth ❒ cotton swabs (Q-tips or similar) ❒ mirror ❒ flashlight 2. From the Option menu, select Go to Head Inspection Position. 3. Put on the gloves.
Page 173 Objet500 User Guide 6 Operating and Maintaining the Printer 5. Loosen the two screws securing the suction tube on the print block. Figure 6-40 Lifting the suction tube 6. Lift the suction tube to secure it in a raised position. 7. Remove the two screws securing the covering of the roller waste collector and remove it. Be very careful to save the covering screws. These are special screws; if they are lost, you need to order replacements. Figure 6-41 Removing the roller waste collector screws 8. Remove the covering by pulling it out, and then lower it. DOC-07027 Rev. I 6-39...
Page 174 Objet500 User Guide 6 Operating and Maintaining the Printer 9. Clean the roller waste collector and the scraper blade surface using cotton swabs. Make sure to remove any remaining printing materials. Figure 6-42 Cleaning the roller waste collector Before replacing the covering, you can check the effectiveness of the roller scraper—see below. To check the effectiveness of the roller scraper: 1. Put on the cleaning gloves. 2. Wet a cloth with isopropanol. 3. Use the cloth to wet the bottom of the roller. 4. Turn the roller slowly with your hand. As the blade scrapes the roller, make sure the isopropanol is spread evenly over the entire length of the blade. 5. Inspect the roller. If it is not dry, replace the blade. (See "Replacing the Roller Scraper" on the next page.) 6. Before returning the roller waste collector to the print block, make sure that the pins are clean. Figure 6-43 Roller waste collector pins To re-assemble the components: 1. ...
Page 175: Replacing The Roller Scraper
Objet500 User Guide 6 Operating and Maintaining the Printer 2. Loosen the screws securing the suction tube. Figure 6-44 Positioning the suction tube 3. Lower the suction tube so that the hole in the panel behind the tube is visible, and tighten the screws to secure the tube. 4. Attach the right-UV-lamp assembly to the print block and reconnect the UV power and fan cables. Replacing the Roller Scraper You should replace the roller scraper blade— • after 1,000 hours of printing. • if it does not effectively keep the roller clean. You should periodically test the effectiveness of the roller scraper when you clean the roller waste collector. See "Cleaning the Roller Waste Collector and Inspecting the Roller Scraper" on page 6-37. To replace the roller scraper: 1. Prepare— ❒ a new roller scraper blade ❒ a Phillips 1x75 mm screwdriver ❒ a 2.5-mm and a 2-mm hex (Allen) key 2. Remove the right UV lamp and the roller waste collector covering (see steps ...
Page 176 Objet500 User Guide 6 Operating and Maintaining the Printer 4. Remove the screws that secure the roller scraper assembly. Figure 6-46 Removing the roller scraper screws 5. Remove the scraper blade and discard it. Figure 6-47 Removing the old roller scraper blade 6. Place the new scraper blade onto the pins in the holder, as shown. Figure 6-48 Inserting the new roller scraper blade DOC-07027 Rev. I 6-42...
Page 177: Aligning The Print Heads
Objet500 User Guide 6 Operating and Maintaining the Printer 7. Insert and tighten the roller scraper blade screws. Important: Tighten the screws in the order shown in Figure 6-49. Use the new screws supplied in the replacement kit Figure 6-49 Tightening the roller scraper screws 8. After tightening the screws, inspect the blade and make sure that it is straight. If necessary, loosen the screws and tighten them again, evenly. 9. Return the roller waste collector assembly and the right UV lamp to the print block. (See steps 5 to 7 on page 6-38 in "Cleaning the Roller Waste Collector and Inspecting the Roller Scraper".) Aligning the Print Heads You should check the alignment of the print heads— • once a month • after replacing one or more heads • if model quality is not acceptable even after cleaning the orifice plate on the bottom of the print block (see "Cleaning the Print Heads and the Roller" on page 6-29). This procedure takes about 20 minutes. To check the alignment of the print heads: 1. ...
Page 178 Objet500 User Guide 6 Operating and Maintaining the Printer 3. When instructed to do so, place the transparency on the build tray—next to the left and rear edges of the tray, as shown in the following figure. Figure 6-50 Positioning the transparency on the build tray 4. Make sure that the transparency sheet is lying flat, and tape it to the tray. 5. Close the printer cover. 6. In the wizard screen, select the check box to confirm that the transparency sheet is secured to the build tray, and click Next. When you click Next, the printer prints the head alignment test on the transparency. When printing is finished, the following screen appears. Figure 6-51 Head Alignment wizard—steps 7–9 7. Open the printer and remove the transparency. The transparency sheet is printed with sets of vertical lines in seven columns, each showing the results from a different print head. Figure 6-52 Sample head-alignment test Note: There is no column for head H7 because its alignment is used as a reference for aligning all other heads. DOC-07027 Rev. I 6-44...
Page 179 Objet500 User Guide 6 Operating and Maintaining the Printer 8. For each column of lines, use a magnifying glass or loupe to inspect pairs of consecutive rows printed on the transparency to see where the vertical lines align. Figure 6-53 Comparing rows of alignment lines Note: It does not matter which pair of lines you inspect, since they were all printed by the same head. Choose a pair of clearly printed lines for the inspection. (Since some nozzles may not print clearly, you may have to inspect several pairs of lines to properly view the alignment.) Optimum head alignment is shown when the fourth lines in the upper and lower rows are aligned, as in Figure 6-53. In the example shown, no change to the head alignment is necessary. If other lines in the set are aligned, you need to change the alignment of that head—in the next wizard screens. 9. In the wizard screen shown in Figure 6-51, select the Transparency removed check box, and click Next. The first in a series of alignment screens appears. Figure 6-54 Head alignment selection 10. I n the head-alignment screen, select the number that indicates which lines align in the upper and lower rows of a pair on the transparency (counting from the left) for this print head. Note: Because the alignment of the fourth lines is optimum, the number “4” is selected, by default, in the wizard screen. This does not change the head alignment. If you select other numbers, the wizard adjusts the head alignment, accordingly. 11. C lick Next to display the next head alignment screen, and again select the ...
Page 180 Objet500 User Guide 6 Operating and Maintaining the Printer When you have finished aligning all of the heads, the following screen is displayed. Figure 6-55 Parameter update confirmation 12. C ontinue as follows: ❒ To make the alignment changes in the printer, make sure that Update system with new parameters is selected, and click Next. ❒ To recheck the alignment test results before making the alignment changes in the printer, click Previous. ❒ If you do not want to make alignment changes in the printer at this time, select Keep previous parameters, and click Next. 13. I n the following screen, you can choose to either repeat the head alignment procedure, or close the wizard. Figure 6-56 Repeat head alignment option ❒ If the most closely aligned vertical lines for a print head were at either extreme, choose Repeat the test, then click Next. ...
Page 181: Optimizing (Calibrating) Print Heads
Objet500 User Guide 6 Operating and Maintaining the Printer Optimizing (Calibrating) Print Heads The condition of the print heads directly affects the quality of printed models. To maintain optimum printing, you should routinely test the print heads, and calibrate them to the best working configuration possible by running the Head Optimization wizard every 300 hours of printing. You also need to calibrate the print heads in these cases: • after replacing Vero with Digital ABS or Agilus30 Model materials (and the reverse) • after changing the type of Support material (SUP705/706) • after replacing the Support material with cleaning fluid (and the reverse) During this procedure, you place a scale on the build tray and connect it to the printer. Printing material (resin) is jetted from each head and its weight is automatically recorded and the wizard determines how to optimize the print heads. If, during the optimization process, the wizard determines that a print head is faulty—or that it is negatively affecting layer uniformity with the current head configuration—the wizard instructs you to replace it. If this happens, you can continue the wizard to replace the print head, or abort the wizard, to replace the head at another time. Run the Head Optimization wizard every 300 hours of printing or whenever the condition of print heads is negatively affecting the quality of printed models, or if you suspect that there is a problem with one or more of the print heads. Note: Allow at least 40-50 minutes per mode f or performing this procedure (not including time required for replacing faulty print heads). To accurately test and calibrate print heads, they must be clean. If necessary, run the Head Cleaning wizard before beginning this procedure. To test and calibrate the print heads: 1. ...
Page 182 Objet500 User Guide 6 Operating and Maintaining the Printer 3. Start the Head Optimization wizard from the Options menu. Figure 6-57 Starting the Head Optimization wizard 4. In the opening wizard screen, click Next to begin. The Wizard Conditions screen appears. 5. Read the conditions, select I Agree and click Next. 6. In the following screen, select Continue with Head optimization if you have recently cleaned the print heads. Otherwise, cancel the wizard and run the Head Cleaning wizard. Figure 6-58 Clean print heads screen DOC-07027 Rev. I 6-48...
Page 183 Objet500 User Guide 6 Operating and Maintaining the Printer 7. In the following screen, make sure Optimize all print heads is selected, and click Next. Figure 6-59 Procedure selection screen 8. Select the printing mode for which you want to optimize the print heads and click Next. Figure 6-60 Printing mode selection If your printer is set to print in Single material mode, only the High Speed and High Quality options are enabled. If your printer is set to print in Digital Material mode, only the Digital Material opiton is enabled. DOC-07027 Rev. I 6-49...
Page 184 Objet500 User Guide 6 Operating and Maintaining the Printer 9. Make sure that the build tray is clear and clean, and confirm this in the wizard screen. Figure 6-61 Preparing for head optimization (1) When you click Next, a frame is printed on the build tray. 10. W hen the following screen appears, open the printer and tape a sheet of pink paper to the surface left of the build tray. Figure 6-62 Preparing for head optimization (2) When you click Next, the Pattern Test is printed on the pink paper. DOC-07027 Rev. I 6-50...
Page 185 Objet500 User Guide 6 Operating and Maintaining the Printer 11. W hen the following screen appears, open the printer and remove the Pattern Test paper. Figure 6-63 Enter Missing Nozzles screen 12. C arefully inspect the Pattern Test paper with the Missing Nozzles Ruler to see if there are missing lines. Figure 6-64 Inspecting the Pattern Test Each missing line represents a faulty nozzle in the print head. 13. I n the Missing Nozzles screen, enter the number of missing nozzles for each print head and click Next. DOC-07027 Rev. I 6-51...
Page 186 Objet500 User Guide 6 Operating and Maintaining the Printer 14. T he wizard continues according to the number of missing nozzles you entered. ❒ If there are too many missing nozzles for acceptable printing, the wizard instructs you to replace the defective print head(s). You can do this now, or abort the wizard. If you are prepared to replace print heads now, the wizard guides you through the procedure when you click Next. Make sure you have replacement heads and the required tools (see page 6-56). Then, continue with "Preparing the Print Block" on page 6-57. Figure 6-65 Head replacement due to missing nozzles ❒ If the number of missing nozzles in all print heads is acceptable, the wizard continues with the head optimization process (below). 15. S et up the scale in the printer by performing the steps listed in the wizard screen. Figure 6-66 Setting up the Head Optimization scale DOC-07027 Rev. I 6-52...
Page 187 Objet500 User Guide 6 Operating and Maintaining the Printer 16. A fter confirming all of the items listed in the wizard screen, click Next. Printing material (resin) is jetted from each head and its weight is automatically recorded. Then, the following screen appears. Figure 6-67 Emptying the resin container 17. O pen the printer. Carefully remove the resin container from the scale and empty it into the purge unit. Then return the container to the scale. Caution: The resin in the container is uncured To prevent contact with skin, wear neoprene or nitrile gloves. Dispose of uncured resin in accordance with applicable regulations. By emptying the container into the purge unit, the resin is stored in the printer’s sealed waste container. 18. C lose the printer cover, confirm the items listed in the wizard screen, and click Next. The printer cures the resin in the container. 19. W hen the following screen appears, open the printer and remove the scale. ...
Page 188 Objet500 User Guide 6 Operating and Maintaining the Printer The wizard uses the data collected to analyze the condition of the print heads and optimize them so they print models with a uniform layer of material. ❒ If the heads are in satisfactory condition, the following wizard screen appears. Figure 6-69 Final wizard screen, after optimizing print heads ❒ If the wizard determines that a print head is faulty—or that it is negatively affecting model quality with the current head configuration—you need to replace it. Indicate whether or not you want to do so now. Figure 6-70 Defective print heads found • Select Replace defective head(s) if you are prepared to replace the print heads now (see below). or— • Select Abort wizard if you want to replace the print heads at another time. Replace print heads only after consulting with an authorized Stratasys service provider. DOC-07027 Rev. I 6-54...
Page 189: Replacing Print Heads
Objet500 User Guide 6 Operating and Maintaining the Printer To replace print heads, you need these tools and materials: ❒ replacement print head(s) ❒ 90% isopropanol (IPA—isopropyl alcohol) or ethanol (ethyl alcohol) ❒ disposable cleaning gloves (supplied with the print head; or use any clean, powder-free protective gloves) ❒ a supplied cleaning cloth or equivalent ❒ a mirror ❒ a 5-mm flat-head screwdriver or a 3-mm hex (Allen) key (depending on the type of print block) ❒ the Missing Nozzles ruler ❒ the scale supplied for use in the Head Optimization wizard (Weight Test) Important: Before beginning this procedure, ensure that the scale is calibrated and at least partially charged. If you are replacing print heads now, the wizard guides you through the procedure when you click Next. Continue with "Replacing Print Heads" below. Replacing Print Heads The condition of the print heads directly affects the quality of printed models. You may need to replace a print head if one or more of the following symptoms occurs: • The Head Optimization wizard determines that a print head is defective. (See "Optimizing (Calibrating) Print Heads" on page 6-47.) • There are noticeable grooves in the surface of printed models.
Page 190 Objet500 User Guide 6 Operating and Maintaining the Printer The entire print-head replacement procedure takes 75—90 minutes, and consists of the following phases: A. Identifying the head(s) needing replacement. This is normally done by the Head Optimization wizard. Otherwise, evidence of physical damage to the head surface or a malfunction message indicates which head needs replacing. B. Preparing the print block for head replacement. This is done automatically when you run the wizard. C. Removing the defective print head. D. Installing a new print head. E. Optimizing the print heads (done automatically by the wizard). F. Performing head alignment. To replace a print head: 1. Prepare—...
Page 191 Objet500 User Guide 6 Operating and Maintaining the Printer 5. In the following screen, select Continue with Head optimization if you have recently cleaned the print heads. Otherwise, cancel the wizard and run the Head Cleaning wizard. Figure 6-71 Clean print heads screen 6. In the following screen, select Replace faulty heads, and click Next. Figure 6-72 Procedure selection screen Preparing the Print Block 7. Select the print head(s) needing replacement, and click Next. Figure 6-73 Head selection screen DOC-07027 Rev. I 6-57...
Page 192 Objet500 User Guide 6 Operating and Maintaining the Printer The printer heats and empties the print block, and prepares the printer. (This should take up to 15 minutes.) Figure 6-74 Printer preparation progress screen The following screen appears when the printer is ready for you to replace print heads. Figure 6-75 Printer ready for head replacement 8. Put on the protective gloves and open the printer cover. Note: The printer disconnects power to the heads for your safety. DOC-07027 Rev. I 6-58...
Page 193 Objet500 User Guide 6 Operating and Maintaining the Printer Removing the Defective Head 9. On the print block, release the upper and lower screws that secure the print head in the block. (If necessary, you may use a screwdriver to loosen the screws.) Figure 6-76 Releasing the locking screws 10. P ress down on the upper and lower locking screws to release the print head. Figure 6-77 Releasing the print head DOC-07027 Rev. I 6-59...
Page 194 Objet500 User Guide 6 Operating and Maintaining the Printer 11. L oosen the screws on the door of the compartment protecting the print-head driver cards (A), then pull and lift up the door (B). Figure 6-78 Opening the print-head compartment 12. P ull the print-head driver card out of its socket so that the head is free (A), and remove it from the bottom of the print block (B). Figure 6-79 Releasing the print-head driver card to remove the head 13. M ake sure that along with the head, you remove the two rubber O-ring seals. Figure 6-80 O-ring seals on the print head Important If the seals are not removed with the head, they are probably stuck to the print block housing. If so, remove them. DOC-07027 Rev. I 6-60...
Page 195: Installing The New Head
Objet500 User Guide 6 Operating and Maintaining the Printer Figure 6-81 Making sure the O-rings are not stuck to the print block Installing the New Head 14. I nspect the replacement head, and make sure that the O-ring seals are in place (see Figure 6-80 on the previous page). 15. G ently insert the replacement head into the vacant slot in the print block, and push the print-head driver card into its socket. Note: Make sure to insert the head with the driver card facing its socket, in the rear of the print block. Figure 6-82 Inserting the print-head driver card into its socket DOC-07027 Rev. I...
Page 196 Objet500 User Guide 6 Operating and Maintaining the Printer 16. P ush the head up until you hear it click into place, in both front and rear holders. Figure 6-83 Pushing the head into place in the print block 17. L ower the door of the print head compartment, and tighten the screws to lock it in place. 18. T ighten the upper and lower screws that secure the print head in the print block (see Figure 6-76 on page 6-59). Note: Hand-tighten these screws. Do not use a screwdriver. 19. I n the Replace print heads screen, select the check box to confirm that you have replaced the head(s), and click Next. Figure 6-84 Head replacement confirmation DOC-07027 Rev. I 6-62...
Page 197 Objet500 User Guide 6 Operating and Maintaining the Printer 20. W ith your fingers, make sure that the new head is level and even with the other heads. Figure 6-85 Checking the level of the new head 21. C onfirm that the heads are level by selecting the check box in the following wizard screen, and click Next. Figure 6-86 Installation-check screen 22. I n the next wizard screen, confirm that you have removed all tools and objects from the printer. Figure 6-87 Cleared-tray confirmation screen DOC-07027 Rev. I 6-63...
Page 198 Objet500 User Guide 6 Operating and Maintaining the Printer 23. C lose the printer cover. The wizard continues by heating the heads, then filling and purging them. If there are no installation problems, the optimization procedure begins, to calibrate the print heads to the best working configuration—see "Optimizing (Calibrating) Print Heads" on page 6-47. If installation problems are detected, the wizard alerts you and instructs you how to continue (see "Installation Problems" below). 24. A fter replacing print heads, you should run the wizard again, to optimize the new heads, and to make sure that they are optimized for printing with the other heads. In the final wizard screen, select Optimize all print heads and click Next. Figure 6-88 Final wizard Screen Installation Problems If the printer detects that there is a problem after you install print heads, a relevant warning screen appears. ➢ If the printer software does not detect the replaced head: a. Open the print head compartment (see Figure 6-78 on page 6-60). b. Re-insert the print-head driver card into its socket (see Figure 6-82 on page 6-61). DOC-07027 Rev. I...
Page 199: Testing And Calibrating The Uv Lamps
Objet500 User Guide 6 Operating and Maintaining the Printer ➢ If the replacement head was not calibrated by Stratasys, remove the head and replace it with another one. Figure 6-89 Invalid-head warning Contact your Stratasys service provider about the uncalibrated head. Testing and Calibrating the UV Lamps The level of UV radiation from the lamps used for curing models can change over time. To ensure optimum curing of models during printing, a pop-up message reminds you to test the lamps and calibrate the level of UV radiation after every 300 hours of printing. You do this by running the UV Calibration Wizard. To measure the UV radiation, you need: • Stratasys TOL-03005-S (UV sensor and cable) or— • a stand-alone UV radiation meter, approved for use with the printer The wizard compares the measured radiation to the recommended radiation level for each of the lamps, at each printing mode—High Speed and High Quality / Digital Material. When calibrating the lamps, the wizard attempts to adjust the radiation level, if necessary. • If the reading is within the acceptable range, the wizard continues to the next phase. • If further adjustment is necessary, the current phase is repeated. • If the level of UV radiation is too low to be properly adjusted, the wizard continues to the next phase, but the final wizard screen indicates that the lamp’s radiation for the printing mode is unacceptable. Before testing and calibrating the UV lamps: Make sure the glass lens on each of the UV lamps is clean. For easy access, run the Head Cleaning Wizard, and use the special sanding sponge supplied in the Start-Up Kit. ...
Page 200 Objet500 User Guide 6 Operating and Maintaining the Printer To test and calibrate UV lamp radiation: 1. Start the UV Calibration Wizard from the Options menu. 2. In the following screen, select Calibrate UV Intensity to adjust the lamp’s radiation level to the acceptable range. Figure 6-90 UV Test/Calibration selection 3. In the following screen, select the UV sensor and measuring device to be used. Figure 6-91 UV device selection UV Measuring Device When you use the Stratasys UV sensor box (TOL-03005-S), you connect it to the printer. The wizard automatically measures and calibrates the UV radiation. If you use a stand-alone UV radiation meter, you need to manually enter the readings from the meter in the wizard screens. DOC-07027 Rev. I 6-66...
Page 201 Objet500 User Guide 6 Operating and Maintaining the Printer 4. Make sure that the build tray is empty. Confirm this in the wizard screen and click Next. Figure 6-92 Printer preparation ➢ When using a Stratasys UV sensor box that you connect to the printer (TOL-03005-S), continue with "UV Sensor Connected to Printer" on the next page. ➢ When using a stand-alone UV radiation meter, continue with "External UV Meter" on page 6-70. DOC-07027 Rev. I 6-67...
Page 202 Objet500 User Guide 6 Operating and Maintaining the Printer UV Sensor Connected to Printer The following steps apply when using the Stratasys UV sensor box that you connect to the printer. They do not apply when using a U V external radiation measuring device. 1. To synchronize the wizard and the UV sensor, enter the CF number from the label on the back of the UV sensor box. Figure 6-93 UV sensor synchronization Figure 6-94 Label on the bottom of the UV sensor box DOC-07027 Rev. I 6-68...
Page 203 Objet500 User Guide 6 Operating and Maintaining the Printer 2. Click Next. The build tray lowers so you can connect the UV sensor box. Figure 6-95 UV sensor connector 3. Confirm the items listed in the wizard screen and click Next. Figure 6-96 Sensor positioning Figure 6-97 Final UV sensor position Continue with "UV Measurement " on page 6-71. DOC-07027 Rev. I 6-69...
Page 204 Objet500 User Guide 6 Operating and Maintaining the Printer External UV Meter The following steps apply when using a stand-alone UV meter. This section does not apply when using the Stratasys UV sensor box connected to the printer. 1. When the following screen appears, open the printer and place the UV sensor (probe) at the rear edge of the tray, in the center. Figure 6-98 Sensor placement screen 2. Lead the cable out of the printer so that you can close the printer, and tape it down to make sure that it does not interfere with the moving print block. Figure 6-99 Correct UV-sensor placement 3. Close the printer, while checking that the sensor does not move out of position. 4. Set the UV meter to measure mJ/cm2. 5. Set the range on the meter to 2,000. 6. Connect the cable from the sensor to the UV meter. 7. Turn on the UV meter, and wait until “0 0 0.0” appears on the display. 8. In the wizard screen, confirm that the sensor is positioned correctly, and click Next. Continue with "UV Measurement " on the next page. ...
Page 205 Objet500 User Guide 6 Operating and Maintaining the Printer UV Measurement The UV lamps power up and stabilize. (This takes several minutes.) Then, the print block passes over the sensor and the wizard compares the measured radiation to the recommended level for each UV lamp. During this process, which takes 20–40 minutes, you need to monitor the progress as displayed in the wizard screen. Figure 6-100 UV measurement progress When using a stand-alone radiation meter (not the Stratasys UV sensor box connected to the printer): Reset the meter and enter the reading (measurement) when you are prompted to do so. Figure 6-101 UV Measurement dialog box DOC-07027 Rev. I 6-71...
Page 206 Objet500 User Guide 6 Operating and Maintaining the Printer If the UV level measured is not acceptable, the wizard calibrates the UV lamp by adjusting the current supplied to it, and then tests it again. When all UV tests have finished, the results are displayed, showing the condition of the lamps after calibration (see Figure 6-102 below). Figure 6-102 Results and condition of UV lamps after calibration After examining the UV calibration results: 1. Click Next. 2. Remove the UV sensor and close the printer cover. After confirming the items listed in the wizard screen, click Next. If the results are not acceptable for quality printing, this is indicated in the final wizard screen. Figure 6-103 Final UV Calibration Wizard screen DOC-07027 Rev. I 6-72...
Page 207: Calibrating The Load Cells
Objet500 User Guide 6 Operating and Maintaining the Printer Calibrating the Load Cells Load cells are sensors that measure the weight of the material cartridges and the waste container in the printer. It is important that you periodically check that the weight measurements are accurate to prevent unnecessary waste of printing materials or printer malfunctions. To calibrate load cells: 1. Start the Load Cell Calibration wizard from the Options menu. 2. In the following screen, select one or more load cells that you want to calibrate. Figure 6-104 Load cell selection 3. Remove each selected cartridge from the materials cart, and click Next. Figure 6-105 Confirmation of cartridge removal 4. In the next wizard screen, observe the numbers and wait until the weight level is relatively stable—two units above or below the average level shown. DOC-07027 Rev. I 6-73...
Page 208: Replacing The Odor Filter
Objet500 User Guide 6 Operating and Maintaining the Printer Figure 6-106 Weight stabilization 5. Select the check box, and click Next. 6. Click Done in the final wizard screen. Figure 6-107 Final wizard screen Replacing the Odor Filter If the printer exhaust is not connected to an external ventilation system, a built-in activated-carbon filter removes odors from printing materials. This filter should be replaced regularly (as necessary) to keep your working environment pleasant. This is normally done during the preventive-maintenance service visit. If the printer exhaust is connected to an external ventilation system, the odor filter is not needed and should be removed from the printer. Odor filter removal i mproves heat expulsion and system cooling. DOC-07027 Rev. I 6-74...
Page 209: Replacing The Uv Lamps
Objet500 User Guide 6 Operating and Maintaining the Printer Replacing the UV Lamps The UV lamps used for curing models have a long, but limited, working life. You can test and adjust their effective power with the UV Calibration wizard (see "Testing and Calibrating the UV Lamps" on page 6-65). If you need to replace a UV lamp bulb or UV reflector, follow these instructions: To replace the UV lamp bulb or UV reflector: 1. Make sure the printer is in offline mode. Figure 6-108 Offline mode indicator (red) The online/offline button at the bottom of the printer interface should be red. If not, click it to switch the printer to offline mode. Warning Before continuing, make sure that the safety interlock is not defeated, and that the UV lamp is not hot. 2. Start the UV Lamp Replacement wizard from the Options menu. 3. Make sure that the build tray is empty, and confirm this in the wizard screen. Then, close the printer, and click Next. Figure 6-109 Tray confirmation The axes move to the “home” position. DOC-07027 Rev. I...
Page 210 Objet500 User Guide 6 Operating and Maintaining the Printer 4. Select the UV lamp(s) to be replaced and click Next. Figure 6-110 UV lamp selection screen 5. Disconnect the UV-lamp power connector and the UV heat fuse connector. Figure 6-111 Disconnecting the UV lamp Note: Do not disconnect the power connection to the cooling fans. DOC-07027 Rev. I 6-76...
Page 211 Objet500 User Guide 6 Operating and Maintaining the Printer 6. Loosen the screw securing the UV lamp cover (A), and pull the cover up (B), then out (C). Figure 6-112 Removing the UV lamp cover 7. Pull the UV reflector out of the print block. Figure 6-113 Removing the UV lamp reflector 8. Using a 2.5-mm hex key, remove the UV lamp clamp (2 screws). Figure 6-114 Removing the UV lamp clamp DOC-07027 Rev. I 6-77...
Page 212 Objet500 User Guide 6 Operating and Maintaining the Printer 9. Remove the UV lamp bulb from the UV reflector. Figure 6-115 Removing the U V lamp bulb 10. B efore continuing, inspect the spring-loaded pins. If there are burn marks around the pins or if the pins are loose—their springs are not functioning properly—and do not support the bulb, continue with step , to replace the UV reflector. Otherwise, continue with step 8 to replace the UV bulb. Figure 6-116 Spring-loaded pin DOC-07027 Rev. I 6-78...
Page 213 Objet500 User Guide 6 Operating and Maintaining the Printer 11. U sing the polyurethane tube provided in the kit, push the new UV lamp bulb into the UV reflector. Make sure that the tip on the bulb is facing the slot. Figure 6-117 Pushing the new UV bulb into the UV reflector 12. T wist the tube by 180° (a), and continue to insert the UV lamp bulb into the UV reflector (b). Figure 6-118 Twisting the tube and inserting the UV lamp 13. U se the UV lamp clamp to insert the lamp into place in the UV reflector. DOC-07027 Rev. I 6-79...
Page 214 Objet500 User Guide 6 Operating and Maintaining the Printer Figure 6-119 Pushing the UV lamp into place 14. U sing a 2.5-mm hex key, secure the clamp to the UV reflector, and continue with step Figure 6-120 Attaching the UV lamp clamp 15. I nspect the new UV reflector, and make sure that a black strip is attached to the inside of it. If not, install one—on the side of the reflector opposite (not next to) the print block. Note: Extra black strips are included in the printer Start-Up Kit. If necessary, you can remove the black strip from the old reflector and install it in the new reflector (as long as the black paint has not faded). 16. D iscard the old UV reflector and lamp. Dispose of the used UV lamp in accordance with environmental and safety requirements. DOC-07027 Rev. I 6-80...
Page 215 Objet500 User Guide 6 Operating and Maintaining the Printer Warning: Broken UV lamp hazard UV lamps contain mercury. Deal with broken lamps with caution. Ventilate the room thoroughly. Use protective gloves when collecting mercury and lamp components. Remove spilled mercury with a method that prevents the generation of mercury vapor, such as a syringe, packing tape or paper. Place the broken lamp, mercury and contaminated materials in an air-tight, non-metallic container. 17. I nsert the UV reflector unit into the housing, next to the print block. Figure 6-121 Print block and UV lamp assembly, showing correct placement of black strip 18. R eplace the UV lamp cover by inserting it into the slot on the bottom of the housing, and tighten the securing screw on top. Figure 6-122 Replacing the UV lamp cover DOC-07027 Rev. I 6-81...
Page 216 Objet500 User Guide 6 Operating and Maintaining the Printer 19. R econnect the power and heat fuse connectors. Figure 6-123 Connecting the UV lamp 20. I n the wizard screen, confirm that you have replaced the UV lamp(s) and that the black strip is attached, then click Next. Figure 6-124 UV-installation confirmation DOC-07027 Rev. I 6-82...
Page 217 Objet500 User Guide 6 Operating and Maintaining the Printer The wizard operates the UV lamps and checks if their power is within the acceptable range for each printing mode. Note: The mode currently being checked appears in the lower-left corner of the printer interface. Figure 6-125 Status during UV lamp check After replacing a UV lamp, it is recommended that you calibrate its power. The next screen allows you to continue to the UV Calibration wizard (see "Testing and Calibrating the UV Lamps" on page 6-65). Figure 6-126 Calibration selection screen DOC-07027 Rev. I 6-83...
Page 218: Built-In Tests
Objet500 User Guide 6 Operating and Maintaining the Printer Built-in Tests The printer application contains a suite of tests for regularly checking the hardware and software, and for troubleshooting. Because running the tests affects the operation of the printer, you can only open the Built-in Tests interface when the system is not printing. The test suite features: • The organization of printing-related tasks in categories: ❒ Communications ❒ Data cards ❒ Temperatures ❒ Voltages ❒ Encoder repeatability ❒ Print-head heating ❒ Print-head filling • A clear display of test results and the source of any failures, enabling you to determine if printing is possible or worthwhile. • The ability to monitor test results for specific components. • Troubleshooting tips. Running these tests can help identify problems in the printer hardware and software. A large number of hardware defects (or near-defects) warns you of possible printing problems, either for current or future jobs. Stratasys recommends running the built-in tests in the following cases: as a routine test, once every two weeks ...
Page 219 Objet500 User Guide 6 Operating and Maintaining the Printer To open the Built-in Tests screen, do one of the following: • From the Options menu, select Built-In Tests. • Press Ctrl+Alt+B. Figure 6-127 Selecting Built-In Tests from the Options menu The Built In Tests screen lists pre-configured tests, grouped by component categories. In this screen, you select and run tests, and the results are displayed. Figure 6-128 Built In Tests screen DOC-07027 Rev. I 6-85...
Page 220 Objet500 User Guide 6 Operating and Maintaining the Printer Test List Test Name This column lists all of the tests, together with selection check boxes. Click the check boxes to select the tests you want to run. To remove a selection, click the check box again. To quickly select all of the tests in a component category, use the Group drop-down list at the bottom of the screen. Group This column shows the component categories for each test. This tells you which tests are run when selecting a category from the Group drop- down list at the bottom of the screen. Status This column shows the results of each test after you run it: Test successfully completed. Test failed. (Double-click on a failed test’s line to review the failure details.) Unknown results. (The test has not been run yet.) Test Selection Area In the Test Selection area, at the bottom of the screen, you can quickly select or de-select tests by their characteristics: Click to select all of the tests in the list. None Click to de-select all of the tests in the list. Unknown Click to select all test that have not been run yet (Status = ?). Group Use this menu to select tests by component category. Selection Set Use this menu to select a pre-configured set of tests to run at ...
Page 221 Objet500 User Guide 6 Operating and Maintaining the Printer Test Results To save and view a report of all tests: ➢ Use the Save and View command buttons. Command Buttons Click the command buttons, on the right side of the screen to perform the following operations: Click to run the selected tests. Reset Click to clear previously run tests. This returns the status of each test to Unknown (?). Save Click to save a report that summarizes the tests run. The report is saved as an HTML file. You can save any number of reports for the tests you run; the name of the file saved is BITReport [date][time].htm. By default, these files are saved in the printer installation folder, but you can save it in any other folder. View Click to display the latest test report that you saved. (You can view other test reports by opening the relevant files in your Web browser. To do so, open Windows Explorer, and double click the BITReport file.) DOC-07027 Rev. I...
Page 222 Objet500 User Guide 6 Operating and Maintaining the Printer Close Click to close the Built-in Tests screen. Summary On the right side of the screen, a symbol represents the combined results of all the tests run, using the symbols from the Status column. All tests successfully completed. At least one test failed. Not all tests performed. Test Descriptions and Troubleshooting The following table lists the name of each test in the Built-in Tests suite, together with its description and a possible reason for its failure. If you need assistance, contact your Stratasys service provider. Test Name Description Possible Reason for Failure FIFO Non-Interrupt/ • Tests the data queue in the • If both FIFO tests fail: DATA PCI card. Faulty DATA_PCI card. FIFO Interrupt • Tests the Windows interrupt.
Page 223 Objet500 User Guide 6 Operating and Maintaining the Printer Test Name Description Possible Reason for Failure Head Voltages Checks the control of voltages Faulty print-head driver card(s). supplied to the print heads. Head/Block Heaters Tests the heaters in the print heads Faulty heaters or thermistors. and in the print-block body. System Voltages Checks if the following voltages are • VPP power supply: within 5% of the required voltage: Faulty head driver. • 40V to the print heads by the VPP • VDD power supply: power supply Faulty height thermistor. • 12V to the height thermistors by the VDD power supply UV Lamps Tests each UV lamp at the High ...
Page 224: Replacing The Waste Container
Objet500 User Guide 6 Operating and Maintaining the Printer Replacing the Waste Container Printer waste contains partially cured polymeric material, collected during normal operation and maintenance of the printer. For safety and environmental reasons, this material is kept in a special leak-proof, disposable container. The container has a capacity of 10 kilograms of waste material—usually enough for several months of printer use. The printer application displays a warning message when there are 9 kilograms of material in the container, and stops the printing when the net weight reaches 9.5 kilograms. Above 9 kilograms, the software does not allow you to start a printing job or activity until you replace the waste container. You can monitor the weight of the waste container in the Printer Indicators display in the printer interface. You can also visually inspect the level of waste in the container. To access it, see page 6-91. To monitor the waste weight (and other indicators) in the printer: ➢ In the main printer interface screen, click the display toggle to view the printer indicators. Figure 6-129 Printer interface, showing waste weight (red background indicates operator alert) DOC-07027 Rev. I...
Page 225 Objet500 User Guide 6 Operating and Maintaining the Printer The waste container consists of a plastic container inside a cardboard box. You typically dispose of the entire waste container—including the box. Therefore, you must assemble a new box and insert a new plastic container before you can install it in the printer. Replacement boxes, plastic containers, and sealing caps are supplied in the printer start-up kit and in the preventive-maintenance kit. To prepare a new waste container: 1. Assemble the cardboard box, making sure to punch out the perforated sections. 2. Place a new plastic container into the box. Note: Do not close the box until you connect the waste drain tube from the printer. To replace the waste container: 1. Locate the door on the lower-left side of the printer. 2. Push in the top-center of the door to release the latch and open the door. Figure 6-130 Accessing the waste container 3. Carefully slide out the waste container to remove it from the printer.
Page 226: Cleaning The Exterior Panels
Objet500 User Guide 6 Operating and Maintaining the Printer 9. Close the waste compartment door. Dispose of the full waste container in accordance with environmental and safety requirements. Cleaning the Exterior Panels The painted exterior plastic panels of the printer has a durable finish, offering excellent chemical resistance to common cleaning materials. Follow the recommendations below when cleaning these areas of the printer. Acceptable Cleaning Agents • mild soap solution • common household cleaners and window cleaners • common commercial and industrial detergents, 5% solution in water • alcohol (ethanol, isopropanol), 10% to 40% solution in water Wipe the exterior of the printer, using a soft cloth moistened with the cleaning solution. Unacceptable Materials • industrial solvents • cleaning agents containing hydrocarbons, ketones, esters and lacquer thinners • spray disinfectants • abrasives and agents which could wear away the panel finish Cleaning the UV Screen The transparent section of the cover is made of strong, acrylic material that screens out harmful UV radiation. Use extreme care when cleaning it to prevent the appearance of scratch marks. Caution Do not use abrasive cleaners or cleaning fluids containing ammonia, alcohol, acetone, benzine, carbon or tetrachloride. These materials can cause ...
Page 227 Objet500 User Guide 6 Operating and Maintaining the Printer Do not use paper towels, which can cause scratch marks. 4. Thoroughly wet the surface with the cloth. Do not wipe! 5. Rinse the cloth with clean water. 6. Absorb the solution from the acrylic surface with the cloth, without applying pressure. 7. If necessary, repeat to remove any remaining marks, or apply clean water to rinse the surface. 8. If the surface is still wet, you can dry it with a clean, micro-fiber cloth by gently wiping in one direction. If convenient, you can apply the cleaning solution and water to the acrylic surfaces with a spray bottle instead of with the cloth. DOC-07027 Rev. I 6-93...
Page 228 Handling Printed Models Removing Models After Printing Removing the Support Material Removing Support by Hand Removing Support with Water Pressure Removing SUP705 with Caustic Soda Removing SUP706 with Caustic Soda and Sodium Metasilicate Post-Printing Treatment Photobleaching for Transparent Models Storing Models DOC-07027 Rev. I...
Page 229: Removing Models After Printing
Objet500 User Guide 7 Handling Printed Models Removing Models After Printing After printing models, you should allow them to cool as much as possible before handling them. If additional models do not have to be produced on the printer, it is best to let the printed models cool in the printer, with the cover closed, as long as possible. If the printer must be used to produce additional models as soon as possible: 1. Let the printed models cool on the build tray for at least 10 minutes. 2. Very carefully, remove the models from the tray with a scraper or spatula (supplied in the tool kit), taking care not to pry or bend the model. Warning: Wear protective gloves when handling printed models before they are washed. 3. Place the models on a flat surface, and cover them with a cardboard box or paper hood. This allows the models to cool slowly and evenly. 4. Let the models cool for several hours.
Page 230: Removing Support By Hand
Objet500 User Guide 7 Handling Printed Models SUP705 (FullCure705) and SUP706 Support material can be removed from printed models using the following methods, in this order: 1. by hand 2. water pressure (in a suitable cleaning unit) 3. SUP705: 1% caustic soda solution (recommended for a smooth finish) SUP706: 2% caustic soda and sodium metasilicate solution Removing Support by Hand While wearing protective gloves, break away excess Support material on the outside of the model. For delicate models, use a toothpick, pin or small brush after dipping the model in water. • For SUP705, after breaking away excess Support material, soak the model in a 1% caustic soda solution (see "Removing SUP705 with Caustic Soda" on page 7-4). • For SUP706, after breaking away excess Support material, soak the model in a 2% caustic soda and sodium metasilicate solution (see "Removing SUP706 with Caustic Soda and Sodium Metasilicate" on the next page). Removing Support with Water Pressure For most models, the most efficient way to remove Support material is by using a high-pressure water jet. One suitable system is the Balco WaterJet cleaning unit. This device is marketed by Stratasys. Figure 7-1 B alco WaterJet Cleaning Unit ...
Page 231: Removing Sup705 With Caustic Soda
Objet500 User Guide 7 Handling Printed Models Removing SUP705 with Caustic Soda Soak models in a 1-percent solution of caustic soda (sodium hydroxide) to remove Support material from difficult-to-reach areas and to give the model a smooth, clean finish. The amount of time you soak the model in the solution depends on how delicate it is and how much Support material needs to be removed, but it is typically between half-an-hour and several hours. In any case, you should remove as much Support material as possible before the caustic soda treatment, and rinse the model thoroughly (with a water jet) afterwards. Warning Caustic soda may cause chemical burns, scarring and blindness. Mixing it with water generates heat that could ignite other materials. Never pour water into caustic soda. When diluting the solution, always add caustic soda to water. Take adequate safety precautions; always use nitrile gloves when handling caustic soda and models soaked in it. Removing SUP706 with Caustic Soda and Sodium Metasilicate Soak models in a 2-percent solution of caustic soda (sodium hydroxide) and sodim metasilicate (Na ) to remove Support material. The amount of time you soak the model in the solution depends on how delicate it is and how much Support material needs to be removed. Rinse the model thoroughly under running water afterwards. SUP706 will dissolve into the caustic soda and sodium metasilicate solution and saturate it, reducing its effectiveness. Replace the solution when the Support material reaches 15% of the solution (after approximately one month of average use). Warning Caustic soda may cause chemical burns, scarring and blindness. Mixing it with water generates heat that could ignite other materials. Never pour water into caustic soda. When diluting the solution, always add caustic soda to water. Take adequate safety precautions; always use nitrile gloves when handling caustic soda and models soaked in it. DOC-07027 Rev. I...
Page 232: Post-Printing Treatment
Objet500 User Guide 7 Handling Printed Models Post-Printing Treatment Post-printing treatment is recommended for models printed with several special- purpose materials or for special applications. Recommendations for treating and finishing models after printing are described in the Best Practices for the desired printing material available on the Stratasys Support Center. Photobleaching for Transparent Models Models printed with clear materials, such as VeroClear (RGD810) have a slight yellow tint when removed from the printer. This is especially true for models printed with a glossy finish. The yellow tint fades naturally over time, but you can greatly accelerate this process by using a suitable photobleaching treatment. This involves exposing models to intense light immediately after printing. Photobleaching methods and instructions are described in the Best Practices for the relevant clear material. These are available on the Transparent materials page on the Stratasys Support Center. Refer to the Best Practices for: VeroClear RGD810 Storing Models Models are cured as they are printed, making them safe and stable for a long time. However, proper storage conditions are necessary to prevent deforming. • Keep printed models at room temperature and in a low-humidity environment. • Do not expose models to direct sunlight and other heat sources. DOC-07027 Rev. I...

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