Summary of Contents for W2P Engineering PowerVat 250
- Page 1 SolFlex 3D Printers Original Instructions www.way2production.at © Copyright 2023 W2P Engineering GmbH / Rev06...
- Page 2 © Copyright 2023 W2P Engineering GmbH The information in this document is subject to change without notice to improve reliability, function or design. The manufacturer makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose.
- Page 3 Version Datum Description Rev06 01.08.2023 − PowerVat 250 added. − Instructions for using the film tension regulator Rev05 18.04.2023 − Added Vaseline (petroleum jelly) as an additional option for a bonding agent for the O-ring Rev04 11.06.2019 − PowerVat PV36301 replaces PV35001: graphics and labels updated −...
- Page 4 − Conversion factors adapted for scaling − Note that the beamer positions must be entered before the scaling job has been added Rev01 29.11.2018 − Installation descriptions simplified − Chapter 'Printer Settings' revised − Contact addresses added Rev00 19.11.2018 Initial Release...
- Page 5 Weight (without resin): 1.300 g Material capacity: 100 ml to 600 ml...
- Page 6 Weight (without resin): 1.120 g Material capacity: 100 ml to 400 ml...
- Page 7 Weight (without resin): 1.360 g Material capacity: 100 ml to 500 ml...
- Page 8 Getting Started ____________________________________________________________ 8 Introduction ________________________________________________________________ 8 Safety Instructions __________________________________________________________ 8 Cleaning Equipment ________________________________________________________ 9 Accessory Checklist ________________________________________________________ 10 Overview ___________________________________________________________________ 11 Preparation _______________________________________________________________ 14 Removing the Transport Protection ________________________________________ 14 Preparing the SolFlex for Use with the PowerVat ___________________________ 16 Preparing the SolFlex for Use with the FlexVat _____________________________ 17 Pre-Cleaning and Installation of the PowerVat _____________________________ 17 Filling the Vat with Material ________________________________________________ 20...
- Page 9 The PowerVat features a rigid vat design for use with SolFlex 3D printers. The newly developed design enables manufacturing of models with large cross- sections as well as using highly viscous resins. The vat frame’s solid metal construction combined with the translucent glass/film construction allows a long service life, perfect printing results and low maintenance.
- Page 10 Avoid excessive pressure when using cleaning instruments. This can lead to scratches or cracks in the film. Check the condition of the film regularly. If damage occurs (e.g. cracks, holes, deformations), the film must be replaced immediately. If the printer is used to produce medical products it is necessary to use separate PowerVats for each printing material.
- Page 11 Material vat (incl. transport protection) PowerVat Cover incl. for PowerVat 250 Torx wrench TX10 Torx wrench TX20 4 countersunk screws M3x8 (spare parts) 2 countersunk screws M4x16 (spare parts) 2 countersunk screws M4x20 (spare parts) If any items are missing, appear damaged or if the unit does not work properly, please contact your reseller immediately.
- Page 12 Pos. Name Unit PowerVat bottom part piece PowerVat clamping plate piece PowerVat top part piece PowerVat glass piece Locking disc pieces Non-stick film piece Rubber O-ring sealing, Ø 1.6 mm piece Countersunk screw ISO 14581 - M3x8 pieces Countersunk screw ISO 14581 - M4x20 pieces Countersunk screw ISO 14581 - M4x16 pieces...
- Page 13 Pos. Name Unit PowerVat bottom part piece PowerVat clamping plate piece PowerVat top part piece PowerVat glass piece Locking disc pieces Non-stick film piece Rubber O-ring sealing, Ø 1.6 mm piece Countersunk screw ISO 14581 - M3x8 pieces Countersunk screw ISO 14581 - M4x20 pieces Countersunk screw ISO 14581 - M4x16 pieces...
- Page 14 Pos. Name Unit PowerVat bottom part piece PowerVat clamping plate piece PowerVat top part piece PowerVat glass piece Locking disc pieces Non-stick film piece Rubber O-ring sealing, Ø 1.6 mm piece Countersunk screw ISO 14581 - M3x8 pieces Countersunk screw ISO 14581 - M4x20 pieces Countersunk screw ISO 10642 - M5x16 pieces...
- Page 15 In order to minimize the tension of the film during storage and transport, 4 spacers are installed between the upper and lower part as transport protection before delivery. Prior to the first use, the transport protection must be removed: TX20 Loosen the 8 screws on the underside of the vat with the supplied Torx wrench TX20 by about half a turn.
- Page 16 TX20 Tighten the 8 screws on the bottom of the vat with the Torx wrench TX20. The figure above shows the recommended sequence for tightening the screws (red numbers): a) Slightly tighten the screws crosswise (see picture for order) b) In analogy to a), tighten with the nominal tightening torque The film of the PowerVat now has the required tension and is ready for use.
- Page 17 This section is only applicable if the FlexVat has been previously installed. During the print job, an automatic locking mechanism is engaged to securely lock the PowerVat in place. After the print job, the vat is released and can be removed. To enable this function, the 4 clamping bolts of your SolFlex 3D printer must be equipped with the supplied locking discs [5].
- Page 18 Important: Make sure that the locking discs are always in perfect condition, otherwise the PowerVat may not be fully locked in place during printing. 3. In the JOG MODE menu click on the button Vat Type to select the vat type PowerVat and initialize the machine by clicking the Initialize button.
- Page 19 Particles can finally be removed with compressed air. The final cleaning of the PowerVat with compressed air must not be carried out in the SolFlex 3D printer as this may lead to unwanted contamination in the printer. Please note that cleaning may need to be done on both the inside (film) and the bottom (glass) of the PowerVat.
- Page 20 If inserting the PowerVat is not possible without applying pressure, the stretcher zero position must be readjusted (see section Stretcher Zero Position). The vat will only be locked during the printing process which requires no further action by the user. Before starting the printing process, the PowerVat can be moved slightly horizontally Important: Do not start a print job unless the vat has been inserted correctly.
- Page 21 400 ml (PowerVat 363), 500ml (PowerVat 650) or 600ml (PowerVat 250). In between are indicators which are arranged in 100 ml increments. The PowerVat must not be filled beyond the top mark, as this may result in leakage of the printing resin during the printing process which would inevitably damage the SolFlex 3D printer.
- Page 22 PowerVat 250 600 ml (maximum material level) 100 ml (minimum material level) PowerVat 363 400 ml (maximum material level) 100 ml (minimum material level) PowerVat 650 500 ml (maximum material level) 100 ml (minimum material level)
- Page 23 Avoid large distances between the material bottle and the PowerVat while inserting the printing resin as this leads to increased bubble formation. Bubbles may be imaged during the printing process of the object leading to faulty prints. Spilled printing resin should be immediately wiped with a cloth. Lingering printing material may polymerize if not removed immediately and, in the worst case, leads to damage of the SolFlex 3D printer.
- Page 24 The PowerVat is designed to store printing material for longer periods. Between two printing processes please ensure that the liquid printing resin is not permeated with cured material, as this can lead to poor printing results. In the case of using sedimenting materials (especially model materials), the material should be stirred with a suitable instrument (no sharp edges) to avoid uneven printing results or misprints caused by non-homogeneously distributed material.
- Page 25 Before disassembling the PowerVat, make sure to remove any resin residues in the vat. Despite careful cleaning, small amounts of 3D printing material can be found in the gap between the upper part [3] and lower part [1] of the vat. For this reason, the use of isopropanol-resistant rubber gloves (e.g.
- Page 26 [Step B] Removing the Film TX10 Loosen the screws [8] that secure the clamping plate [2] by using the enclosed Torx angle wrench TX10 and remove the clamping plate. The film [6] and the film tension regulator [13] (only for PV650 and PV250) can then be removed and, if necessary, cleaned with an isopropanol-soaked paper towel.
- Page 27 When assembling the PowerVat, ensure a clean working environment which is as dust-free as possible. It is recommended to use a suitable pad (cardboard, wooden table, etc.) to avoid scratches on the vat parts. In order to avoid fingerprints on transparent surfaces in the exposure area (glass, film), the use of rubber gloves is strongly recommended.
- Page 28 Important: Ensure that the adhesive joint does not lie in the curved area of the groove in order to avoid additional stress on the bonded adhesive joint. When attaching the sealing, attention must be paid to a central alignment in the groove. Glue residues outside the groove must be removed immediately.
- Page 29 [Step E] Assembling the Film Important: In the gap between the film and the glass plate any dust particles, grease residues, detergent residues etc. must be avoided. Avoid dusty environments and always use rubber gloves during installation of the film as dust particles, fingerprints, grease or other contaminants could otherwise be deposited between the film and the glass.
- Page 30 Place the film [6] centered above the glass and the film tension regulator [13] (only for PV650 and PV250) on top as shown above. Important: The film shall not overlap the threaded holes as this can lead to uneven film tension which can result in faulty printing results. See section Uneven Film Tension for further information.
- Page 31 The film [6] and the film tension regulator [13] (only for PV650 and PV250) is then secured with the clamping plate [2]. Place the clamping plate in the middle of the PowerVat bottom part [1] and use the screws [8] to attach the clamping plate to the PowerVat bottom part, using the provided Torx wrench TX10.
- Page 32 The PowerVat top part [3] including the rubber O-ring [7] must be positioned on the PowerVat bottom part [1], film [6] and clamping plate [2] as shown above. Now insert the 8 countersunk screws M4x20 [9] and M4x16 [10] and tighten them by using the supplied Torx wrench TX20.
- Page 33 cleaning and maintenance of the PowerVat will ensure a lifetime of up to 1.000 print jobs . Perform the following steps to replace the film: 1. [Step A] Removing the Top Part (follow cleaning instructions) 2. [Step B] Removing the Film (follow cleaning instructions) 3.
- Page 34 material enters the printer, remove it immediately to avoid damage. Be sure to contact the SolFlex service team (support@way2production.at). In the following sections, typical signs of wear and possibly occurring defects of the film as well as the necessary troubleshooting steps will be explained. Cracks or Holes Causes: Usually, cracks or holes in the film are caused by improper handling, e.g.
- Page 35 Dulling Causes: Dulling of the film is a regular wear phenomenon (mainly when using abrasive fillers in 3D printing material). In this case, the transparency of the film decreases due to microdefects that are caused by the printing (tear-off) and cleaning process (scratches).
- Page 36 of the exposure field, the film may adhere to the glass surface after a large-area or longer-acting pressure. In this case, the film can be separated carefully from the glass surface (for example by pulling up the film with adhesive tape) before the Knocking Test is carried out.
- Page 37 Note: For SolFlex printers shipped with a PowerVat, you do NOT need to carry out the following steps. The PowerVat can be used immediately for printing without further adjustments. Due to the different design of the PowerVat compared to the FlexVat, the stretcher position has to be determined and adjusted to allow insertion of the vat and secure locking during the printing process.
- Page 38 1. Do not insert the PowerVat yet, remove the building platform and platform cover first 2. Move the z-stage to the lower end position JOG MODE → Move To Bottom 3. Go to Home Screen → Settings → Positions → PowerVat → Stretcher 0 4.
- Page 39 1. Insert PowerVat (without material) 2. Move the z-stage of your SolFlex 3D printer to the upper end position: JOG MODE → Move To Top 3. Mount the building platform and make sure that the washers of the platform are aligned exactly over the magnet 4.
- Page 40 7.1. Reduce Z-Axis Z-Axis 0 in 0.1 mm increments until the steel washers of the building platform firstly lift off the magnets of the z-stage (see "Knocking Test"). Make sure to check all 3 washer/magnet contacts and stop reducing Z-Axis 0 if one or more washers lift off. 7.2.