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PVA Emergence PRO Operation Manual

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INNOVATION.PRECISION.EXCELLENCE.
Emergence PRO™ 3D Printer
Operation Manual
Revision F

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  • Page 1 INNOVATION.PRECISION.EXCELLENCE. Emergence PRO™ 3D Printer Operation Manual Revision F...
  • Page 2 Emergence PRO™ 3D Printer Manual This document is based on information available at the time of its publication. While efforts have been made to ensure the contents of this manual are accurate, the information contained herein does not purport to cover all specific details or variations in hardware, or to provide for every possible contingency in connection with installation, operation, or maintenance.

  • Page 3: Table Of Contents

    Load Filament Mid-Print ....................29 2.4.6 Unload Filament ......................29 2.4.7 Remove Hot End ......................30 2.4.8 Setting Up the Emergence PRO™ Network Connection ........32 3. Print........................34 Print Screen ..........................34 Starting the Print ........................35 3.2.1 Pre-Print Checklist ......................35 3.2.2...
  • Page 4 Emergence PRO™ 3D Printer Manual Monitoring the Print Process....................44 3.3.1 First Layer ........................44 3.3.2 Next Layers ........................44 3.3.3 Opening the Door and Pausing the Print ..............44 3.3.4 Filament Break Detection System ................44 4. Helpful Recommendations ................45 Best Practices .........................
  • Page 5 Emergence PRO™ 3D Printer Manual 4.5.4 Print Sagging or Drooping .................... 58 4.5.5 Print Appears Cloudy ....................58 4.5.6 Layer Shift ........................58 4.5.7 Clogged Nozzle ....................... 59 4.5.8 Materials Errors ......................60 4.5.9 Printer Warning Messages and Remedies ..............60 5.

  • Page 6: Introduction

    Before you operate this system, read the operation and setup manual. This will help you to become familiar with the product and ensure successful operation. If any questions or problems arise, contact PVA’s Technical Support department. 1.1 PVA Contact Information...

  • Page 7: Safety

    Emergence PRO™ 3D Printer Manual 1.3 Safety Certain warning symbols are affixed to the machine and correspond to notations in this manual. Before operating the system, identify these warning labels and read the notices described below. Not all labels may be used on any specific system.
  • Page 8 Emergence PRO™ 3D Printer Manual In situations where inattention could cause either personal injury or damage to equipment, a warning notice is used. Do not smoke near the machine. Always have a fire extinguisher available for emergency use. Before performing any repairs or maintenance to the system, turn off power and lock out the power disconnect switch.

  • Page 9: Best Practices

    Emergence PRO™ 3D Printer Manual 1.4 Best Practices • Do not wear loose clothes or jewelry when you operate the printer • Do not touch the print head while it is moving • Immediately engage the Emergency Stop button if personnel is in danger •...

  • Page 10: Getting Started

    Emergence PRO™ 3D Printer Manual 2. Getting Started 2.1 Unboxing 1. Remove the packaging straps from the shipping crate. 2. Open the shipping crate by first taking the lid off and then removing the sides. 3. Remove plastic wrapping around the metal ramp and any additional items that may be included.
  • Page 11 Emergence PRO™ 3D Printer Manual 5. Secure the metal ramp to the wooden pallet on the side of the printer with lag screws from prior step. 6. Offload the 3D printer using the metal ramp with two people—one person in front of the printer and one person in the back.

  • Page 12: Local Ventilation Disclaimer

    Emergence PRO™ 3D Printer Manual 2.2 Local Ventilation Disclaimer IMPORTANT: End user should consult manufacturer safety data sheets to identify if local ventilation is required for their application and proceed as recommended. For composite materials please consult local regulations (OSHA PELs, NIOSH RELs, and/or ACGIH) for the particular materials being used and monitor locally to identify if local ventilation is required.
  • Page 13 Emergence PRO™ 3D Printer Manual 3. Install exhaust flange through top hole and secure with four (4) M6X1 hex nuts. Figure 7: Secure Exhaust Flange Page 13 of 70 Revision F July 2023...

  • Page 14: Initial Setup

    Emergence PRO™ 3D Printer Manual 2.3 Initial Setup 2.3.1 Printer Tool Kit Note: The printer tool kit is specific to orthotics and prosthetics and available for printer sales through PVA Med. Before starting the setup process, locate the Tool Kit included with your printer. The following items are included.
  • Page 15 Emergence PRO™ 3D Printer Manual Item Description Grease cartridge Lubricant 7 mm nut driver 10 mm nut driver Bubble level Tweezers Wire brush Spade/Putty knife Side cutters SD card and converter Hex keys Toolbox Storage container Renewable mini dehumidifier 1.1 mm drill bit...

  • Page 16: Setting Up The Printer

    Emergence PRO™ 3D Printer Manual 2.3.2 Setting Up the Printer 1. Remove additional packing material from the outside of the printer. 2. Remove the key tied to the handle on the front door. The key is for the back door.
  • Page 17 Emergence PRO™ 3D Printer Manual 5. Install the nozzle brush in the hole on the front right of the print bed. Figure 12: Install Nozzle Brush 6. Insert the dehumidifier into the dehumidifier holding brackets. Figure 13: Insert Dehumidifier Page 17 of 70...
  • Page 18 Emergence PRO™ 3D Printer Manual 7. Plug the power cord located in the back of the printer in the appropriate 120/220V* outlet. *Refer to the machine serial tag. 8. Plug the provided ethernet cable into the ethernet port located in the back of the printer and connect to the facility’s network.

  • Page 19: Emergence Pro™ Setup

    Emergence PRO™ 3D Printer Manual 2.4 Emergence PRO™ Setup 2.4.1 Printer Control Screen The printer control screen is a touch screen controller consisting of four screens: Control, Print, Console, and Setup. See image on next page. Stop Button Stops and reboots printer.
  • Page 20 Emergence PRO™ 3D Printer Manual Figure 15: Printer Control Screen Page 20 of 70 Revision F July 2023...

  • Page 21: Level Print Surface Relative To Gantry

    Emergence PRO™ 3D Printer Manual 2.4.2 Level Print Surface Relative to Gantry 1. Check the status on the Printer Control Screen in the upper right corner. It should say Idle (Figure 16). 2. If the status reads Standby, undo the red Emergency Stop button located on the front upper left corner of the machine.

  • Page 22: Install And Gap Hot End

    Emergence PRO™ 3D Printer Manual 2.4.3 Install and Gap Hot End 1. Install the hot end using a 2.5 mm hex key. 2. Plug the hot end wires into the appropriate connector. 3. Run the Set Tool Height macro. Figure 17: Set Tool Height 4.
  • Page 23 Emergence PRO™ 3D Printer Manual 5. Slowly jog the bed to the nozzle until the printer paper touches the nozzle. Make sure to select the jog distance that still allows a little distance between the nozzle and the paper. Example: If there is over 2 mm distance in between the nozzle and paper, it is safe to select the 2 mm jog option.

  • Page 24: Load Filament

    Emergence PRO™ 3D Printer Manual 6. Ensure the distance between the nozzle and the print bed is similar to the figure shown below. Figure 21 : Distance Between Nozzle and Print Bed 2.4.4 Load Filament 1. Ensure the tension level on the extruder is at the correct position for the material being used.
  • Page 25 Emergence PRO™ 3D Printer Manual Filament Hot End/Nozzle Bed Temperature Hot End Temperature ClearFit™ Stainless Steel ° ° PCTG Brass 95°C 240°C FlexyFit™ Brass 40°C 235°C Brass 65°C 210°C Nylon 12 Stainless Steel 85°C 275°C PLA/Carbon Fiber Stainless Steel 70°C 210°C...
  • Page 26 Emergence PRO™ 3D Printer Manual 6. Once the intervals have been selected to the preferred value, the active nozzle temperature will display in the field. Press Set to finalize the desired temperature and allow the nozzle to heat up. Figure 26: Set 7.
  • Page 27 Emergence PRO™ 3D Printer Manual 8. Wait until both the bed and nozzle temperature reach the set temperatures. These will be displayed in the Current Temperature field. Figure 28: Current Temperature 9. Slide the appropriate filament onto the filament support roller. The filament roll should be oriented so the filament will be coming off the top of the roll toward the front of the machine (Figure 29).
  • Page 28 Emergence PRO™ 3D Printer Manual 11. Via the Extrusion button on the printer display, extrude 200 mm to prime the hot end (Figure 31). 12. In the Extrusion Amount, select 100. In Speed, select 10. Press Extrude twice. Figure 30: Extrusion 13.

  • Page 29: Load Filament Mid-Print

    Emergence PRO™ 3D Printer Manual 2.4.5 Load Filament Mid-Print If a filament change is needed mid-print, perform the following steps. 1. Select the Pause button on the print screen if the printer is not already paused. Note: If the filament runner sensor has been triggered, a message will display and the print will automatically be paused.

  • Page 30: Remove Hot End

    Emergence PRO™ 3D Printer Manual 2.4.7 Remove Hot End After the filament is removed, perform the steps below: 1. Remove the Heater Cartridge Connector in the upper slot by clicking the lever on the right hand side and gently pulling.
  • Page 31 Emergence PRO™ 3D Printer Manual 3. Unscrew the two 3 mm bolts using a 2.5 mm hex key. Figure 34: Unscrew Bolts 4. Remove the Hot End. 5. Once the Hot End is removed, ensure the PTFE tube remains level with the mount.

  • Page 32: Setting Up The Emergence Pro™ Network Connection

    Emergence PRO™ 3D Printer Manual 2.4.8 Setting Up the Emergence PRO™ Network Connection 1. Upon powering up, the machine will be assigned an IP address by the user’s in- house router. 2. To view the IP address, select the Setup tab from the Control Screen.
  • Page 33 IT group to assign an IP based on the unique MAC address for the Emergence PRO™. 6. To find the Emergence PRO™ MAC address, select the Console tab. Enter M540 in the terminal and the machine’s MAC address will be displayed.

  • Page 34: Print

    Emergence PRO™ 3D Printer Manual 3. Print 3.1 Print Screen Figure 39: Print Screen Gcode File Displays which Gcode file is currently printing. Status Displays the status of the printer. Stop Stops the current print. Bed Button Sets bed to active state or standby.

  • Page 35: Starting The Print

    Emergence PRO™ 3D Printer Manual 12 Pause/Resume Allows you to pause and resume the print. 13 Cancel Cancels the print. 14 Time Left Displays the amount of time left on the print. 15 Control Screen Main menu for the control screen.

  • Page 36: Microsd

    Emergence PRO™ 3D Printer Manual 3.2.2 MicroSD The Emergence PRO™ allows for a G-code to be loaded through a MicroSD card or through a network upload. Once you have acquired your G-code, you can use either option 1. Copy the G-code file from your PC to a MicroSD card.
  • Page 37 Emergence PRO™ 3D Printer Manual 3. Press the MicroSD card button on the Printer Control Screen. Figure 42: MicroSD Button 4. On the MicroSD screen, press the MicroSD card icon to switch between the onboard SD card (Card 0) and the secondary SD card on the top of the machine (Card 1).
  • Page 38 Emergence PRO™ 3D Printer Manual 5. Select a desired G-code to run. Figure 44: Select G-code 6. Select Print. Figure 45: Print Page 38 of 70 Revision F July 2023...

  • Page 39: Internet Upload

    2. To upload a new file from the Web Interface, click Upload & Start in the upper right- hand corner of the Web Interface Home Screen. Figure 46: Emergence PRO™ Web Interface Home Screen 3. When prompted, select the desired G-code to print.

  • Page 40: G-Code Files

    Emergence PRO™ 3D Printer Manual 5. Once Open is selected, the file will be uploaded to the printer and the print will begin. This file will be saved on Card 0, which is inserted into the printer controller. Figure 48: Upload Complete A status bar will show the progress of the G-code file upload as it is being transmitted wirelessly to the printer.

  • Page 41: Run Test Prints

    Emergence PRO™ 3D Printer Manual Right-click on a G-code file to display a list of options. From here, you can run the dispense part (Print File), estimate the dispense path time (Simulate File), or download the G-code file (Download). You can also rename or delete the file, as well as manually edit the G-code.
  • Page 42 Emergence PRO™ 3D Printer Manual 2. Select Test Prints (Figure 52). Figure 52: Test Print Files 3. The test prints loaded onto Card 0, which is part of the Printer Control Screen, will be listed. Select a test print for the filament loaded and hot end installed.

  • Page 43: Run G-Codes

    Emergence PRO™ 3D Printer Manual 4. Press Print. Figure 54: Print Test Print 3.2.6 Run G-Codes To run other G-codes preloaded on your printer, follow the steps below. 1. Load the appropriate hot end and filament used to print the selected test print.

  • Page 44: Monitoring The Print Process

    2. To resume printing, select Print and then press Resume. The Emergence PRO™ also includes a door sensor that will pause an active print when opening the front door. This function acts as an added layer of protection for the printer and operators.

  • Page 45: Helpful Recommendations

    Emergence PRO™ 3D Printer Manual 4. Helpful Recommendations 4.1 Best Practices In order to increase your familiarity and comfort with the Emergence PRO™, we have included a few best practices. 4.1.1 Filament Storage and Drying Moisture content in filament can cause a multitude of problems including inconsistent extrusion, poor surface quality, and ultimately, it will deliver a printed part with weak mechanical properties due to poor layer adhesion.

  • Page 46: Hot End

    Most G-codes received from PVA will already contain a command to run a bed probe before beginning a print. For materials certified by PVA Med (see Figure 55: Recommended Drying Times), there should be no need to prepare the bed with blue tape or spray adhesive before starting a print.

  • Page 47: Standby Temperature Tool

    Emergence PRO™ 3D Printer Manual 4.1.8 Standby Temperature Tool Standby temperatures can be used to keep the nozzle and print bed at or near normal operating temperature to reduce the time required for the printer to get to operating temperature between prints.
  • Page 48 Emergence PRO™ 3D Printer Manual Figure 59: Standby Temperature in Yellow 4. Repeat the same steps for the bed temperature. 5. Wait until both the bed and nozzle temperature reach their set temperature as displayed by the Current Temperature status.

  • Page 49: Installing Nozzle And Melt Zone Extender

    Emergence PRO™ 3D Printer Manual 4.1.9 Installing Nozzle and Melt Zone Extender 1. Unload any filament and heat the Hot End to 265°C. 2. Ensure the Melt Zone Extender hexagonal plane is smooth and free of any residue. 3. Tighten the nozzle and Melt Zone Extender together with the cylindrical side of the Melt Zone Extender facing the outlet of the nozzle.

  • Page 50: Cleaning And Maintenance

    To clean the inside of the nozzle, the Cold Pull Method is recommended. 4.2.2 Bed Maintenance PVA recommends cleaning the print surface after every 2-3 prints. The print surface should be cleaned with isopropyl alcohol or soap and water to remove any oils or residue left behind when removing prints.

  • Page 51: Rail Maintenance

    Emergence PRO™ 3D Printer Manual 4.2.4 Rail Maintenance The Emergence PRO™ uses linear guide rails for all axes. Maintaining these rails takes a small amount of synthetic lubricant applied once per month. In the printer kit is a small bottle of synthetic lubricant. To lubricate the rails: •...
  • Page 52 Emergence PRO™ 3D Printer Manual Figure 64: Right Rail Figure 65: Left Rail Page 52 of 70 Revision F July 2023...

  • Page 53: Belt Maintenance

    Emergence PRO™ 3D Printer Manual 4.2.5 Belt Maintenance The Emergence PRO™ uses a single belt for moving along the X-/Y-axis. While testing is performed on the Emergence PRO™ before shipping, it is recommended that the belt be examined before use in case of looseness developed during shipping. In addition, it is recommended that the belt be checked weekly for the first few weeks as the printer is used more frequently.

  • Page 54: Check For Quality

    Emergence PRO™ 3D Printer Manual 4.3 Check for Quality Many print quality issues associated with 3D printing are a result of incorrect slicer settings or variance in filament from manufacturer to manufacturer. However, if you continue to experience the same issues with different slicer settings, there may be a mechanical issue.
  • Page 55 Emergence PRO™ 3D Printer Manual Inconsistent texture: Inconsistent texture can be a sign of moist filament, under extrusion, and poor layer adhesion. If the filament finish is not as expected, moisture within the filament is likely the reason. Overheating: This can cause drooping, poor layer adhesion, and gaps in the print. To solve this, first check if the fans are on.

  • Page 56: Quick Tips

    Emergence PRO™ 3D Printer Manual 4.4 Quick Tips As you gain more experience, you will be able to judge how to best address issues with prints. To get you started, here are some tips. • Printing slower (5% to 10%) will help with print quality.

  • Page 57: Frequently Asked Questions

    Emergence PRO™ 3D Printer Manual 4.5 Frequently Asked Questions 4.5.1 Under Extrusion Refer to Section 4.3.1 for more information regarding under extrusion. If there is little to no filament coming out from the hot end, follow the steps below. 1. Loosen or tighten the tension screw on the extruder.

  • Page 58: Print Sagging Or Drooping

    WalkStrong filament is 50°. 4.5.5 Print Appears Cloudy If the print appears cloudy, the filament is not dry. For ClearFit™, PVA recommends drying the filament for 4-6 hours at 65°C. Refer to Figure 55: Recommended Drying Times for PVA’s recommendations on other filament or consult the filament manufacturer for the...

  • Page 59: Clogged Nozzle

    Emergence PRO™ 3D Printer Manual 4.5.7 Clogged Nozzle 1. Perform the Cold Pull method on the nozzle to remove any old material. • Remove the filament feeder tube from the extruder head. • Heat up the hot end to the printing temperature of your chosen cold pull filament, preferably the material most recently used in the hot end, while removing the old filament.

  • Page 60: Materials Errors

    Emergence PRO™ 3D Printer Manual 4.5.8 Materials Errors Refer to the filament manufacturer’s recommendations or contact us with questions. 4.5.9 Printer Warning Messages and Remedies Error Message Possible Cause Corrective Action Warning: Vin Under-Voltage Input voltage to control is Ensure Emergency Stop...

  • Page 61: Printing Terminology

    Emergence PRO™ 3D Printer Manual 5. APPENDIX A 5.1 Printing Terminology 3D Model Any digital shape occupying three dimensions. Extruder Allows for filament to be extruded; includes the hot end. Feed Rate The speed at which the extruder moves filament.

  • Page 62: Printer Dimensions And Parts

    Emergence PRO™ 3D Printer Manual 6. APPENDIX B 6.1 Printer Dimensions and Parts Figure 71: Printer Dimensions Page 62 of 70 Revision F July 2023...

  • Page 63: Y-Assembly

    Emergence PRO™ 3D Printer Manual 6.1.1 X-/Y-Assembly A breakdown of the X-/Y-assembly. Page 63 of 70 Revision F July 2023...

  • Page 64: Z Assembly

    Emergence PRO™ 3D Printer Manual 6.1.2 Z Assembly Page 64 of 70 Revision F July 2023...

  • Page 65: Print Head

    Emergence PRO™ 3D Printer Manual 6.1.3 Print Head Figure 72: Print Head Page 65 of 70 Revision F July 2023...

  • Page 66: Technical Specifications And Warnings

    Emergence PRO™ 3D Printer Manual 6.2 Technical Specifications and Warnings Build Volume 480 mm X 330 mm X 635 mm (19 in x 13 in x 25 in) Volts: 120/220V (Refer to machine serial tag) Power Requirements Amps: 10A Frequency: 50/60Hz Hot End Temperature Limit Up to 300°C (572°F)

  • Page 67: Recommended Maintenance Schedule

    Emergence PRO™ 3D Printer Manual 7. APPENDIX C Recommended Maintenance Schedule Task Frequency Date Last Performed Recharge Dehumidifier Once per Week Check Belt Tension Once per Month Clean Hot End Every 5 prints Lubricate Rails Once per Month Every 3 to 6...

  • Page 68: Table Of Figures

    Emergence PRO™ 3D Printer Manual Table of Figures Figure 1: Remove Plastic Wrapping ..................... 10 Figure 2: Remove Metal Plates ......................10 Figure 3: Secure Metal Ramp to Wooden Pallet and Move Printer ..........11 Figure 4: Raise and Lower Feet ......................11 Figure 5: Remove Exhaust Flange Cover ...................
  • Page 69 Figure 43: MicroSD Screen ........................37 Figure 44: Select G-code ........................38 Figure 45: Print ............................38 Figure 46: Emergence PRO™ Web Interface Home Screen ............39 Figure 47: Select G-code and Open ....................39 Figure 48: Upload Complete ........................ 40 Figure 49: G-code Files .........................

  • Page 70: Warranty

    Unauthorized repair or modification of the enclosed product, and/or the use of spare parts not directly obtained from PVA (or from factory authorized dealers) will void all warranties.

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