Page 1 | c-support@stratasys.com Fortus 450mc ® 3D Production System User Guide Part No. 821357-0002 Rev. A...
Page 2 Stratasys, Inc. makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.
Page 3 About the FORTUS 450mc Printer Welcome to the Fortus 450mc™ 3D Production System which is referred to throughout this User Guide as the 450mc. This printer incorporates the latest in innovative technologies to provide you with precise prototypes from a CAD design. Stratasys’ Fused Deposition Modeling (FDM) technology provides prototype parts, including internal features, that can be used to field-test form, fit, and function.
Page 4 About This Guide This guide is your introduction to building prototypes and end-use parts using a Stratasys 3D production, rapid prototype system. It is designed as a learning and reference tool that explains system operation in an easy to understand, step-by-step, process.
Page 5: Table Of Contents
Table of Contents 1 Service and Support ..................1 Service..............................1 Software Support..........................1 Safety Instructions..........................2 Hazard Types ..............................2 Product Safety Signs............................. 2 Product Safety Label Locations........................3 Potential Safety Hazard Areas ........................6 Door Locks ..............................7 General Safety Practices ..........................8 Environmental Requirements ........................
Page 6 Platen ................................25 Tip Wipe Assembly ............................ 26 Canister Bay Enclosure Components....................27 Canister Bay..............................28 Canister Drives and Canister Release Knobs ..................... 28 Canister Status LED Indicators ........................29 Tip Wipe Height Adjustment Wheels......................29 Purge Bin ..............................30 Storage Area ...............................
Page 7 Canister Load Status ........................... 70 Material Load Controls..........................71 Tips Controls .............................. 74 Working with the Calibration Page....................79 Viewing Calibration Status......................... 80 Calibration Controls ........................... 80 XYZ Tip Offset Calibration........................81 Touchscreen Calibration..........................82 Find Z Home............................... 82 Find XY Home ............................82 Working with the Settings Page......................
Page 8 Information Available During a Build...................... 166 Build Warnings............................167 Pausing a Build ............................168 Aborting a Build ............................168 After a Build is Complete ......................... 170 Changing Printer Defaults....................... 172 Display Units ............................172 Job Storage..............................172 Oven Temperature Control ........................173 Part Build Location...........................
Page 9 8 Troubleshooting ....................236 Getting Help ............................ 236 Warnings and Errors ........................237 Warnings at Build Start ..........................237 Errors Preventing a Build from Starting....................239 Load Errors ............................... 241 Build Pause Warnings..........................243 Build Abort Warnings..........................245 Finding a Remedy ........................... 247...
Page 10: Service And Support
13). You may also need access to your Insight workstation to provide a diagnostic file from your hardware. Software Support If you have a software problem that is not covered in this guide, please contact Stratasys Customer Support: Region Phone...
Page 11: Safety Instructions
Stratasys equipment and are not to be considered as comprehensive on matters of safety. The Fortus 450mc printer is designed to be a safe and reliable rapid prototyping printer. Access to areas of the printer are potentially dangerous.
Page 12: Product Safety Label Locations
Hot Surface: The hot surface sign indicates the presence of devices with high temperatures. Always use extra care when working around heated components. Always wear the safety gloves provided in the Welcome Kit. Head temperatures in the printer can exceed 450° C (800° F). Gloves: The gloves sign indicates that if you enter the area specified by the symbol you must wear safety gloves (provided in the Welcome Kit) which have been approved for high temperatures.
Page 13 Figure 1-2: Oven safety label locations Figure 1-3: Z Stage safety label locations...
Page 14 Figure 1-4: Air system safety label locations Compressed Air System Vacuum System...
Page 15: Potential Safety Hazard Areas
Figure 1-5: Rear safety label locations Potential Safety Hazard Areas The following components and areas of the printer are highlighted as potential safety hazards that may cause system failure or reliability problems if proper safety procedures are not followed. Oven Warning: Always wear safety gloves and long sleeves when working inside the oven.
Page 16: Door Locks
Gantry Warning: Never wear a tie, loose clothing or dangling jewelry when working around moving components of the printer. Beneath the top cover of the printer is the gantry. This area houses the mechanical drive components of the X and Y axes. Use extreme caution whenever accessing this area of the printer.
Page 17: General Safety Practices
General Safety Practices Abide by these general safety practices when working with this printer. High Voltage: High voltage is present in the printer. Warning: Only use an OSHA or CE approved step stool when accessing the area under the top cover of the printer. Warning: Always wear safety gloves and long sleeves when working in the oven, with the head, or liquefier tips.
Page 18: Setup And Installation
Setup and Installation This chapter describes basic setup and installation of the 450mc. General Information Welcome Kit Contents The printer’s Welcome Kit contains the Welcome Insert document, software CDs, the common tools you will need to maintain the printer, and a variety of replacement parts. Use the following figures and tables to identify the contents of the Welcome Kit.
Page 19 Figure 2-2: Welcome Kit Contents - Tools Table 2-2: Key for Figure 2-2 Leather Printer components may be extremely hot. To prevent burns or other injuries, these gloves Safety should be worn any time you see the gloves safety sign throughout this document. See Gloves “Product Safety Signs”...
Page 20 Figure 2-3: Welcome Kit Contents - Spare Parts Table 2-3: Key for Figure 2-3 Oven Bulbs Periodically you may need to replace an oven bulb. Bulbs generally burn out in Replacement Kit pairs. The Welcome Kit contains oven bulb replacement kits, with 2 replacement Festoon bulbs per kit.
Page 21 Figure 2-4: Welcome Kit Contents - Cleaning Supplies Table 2-4: Key for Figure 2-4 Touchscreen From repeated use, the touchscreen may become dirty and occasionally need to Cleaning Kit be cleaned. Only use suitable LCD cleaning agents when cleaning the touchscreen.
Page 22: Prepare Your Facility For Installation
This tag also lists all patent numbers associated with the printer, some FCC compliance information, voltage warnings and the Stratasys web address. Both tags are located on the back side of the printer near the bottom, and are typically placed near the printer’s power connection.
Page 23: Basic Setup
Basic Setup Note: See Figure 2-6 for all rear connections. Making the Network Connection Processed job files are transferred to the 450mc through your facility’s Ethernet network. An RJ45 network connector is located on the right, rear corner of the printer (as viewed from the rear) for the network connection (see Figure 2-6).
Page 24: Configuring The Network
Figure 2-6: Rear Connections AC Circuit Breaker (OFF Position) Ethernet Network Connection (RJ45) Optional UPS Connection Power Cable Connection Configuring the Network This section is provided in case you need to change your network settings. The printer’s network address type can be set to DHCP (Dynamic) or Static. DHCP (Dynamic) address - a network server or PC will generate an IP address for the •...
Page 25 UPnP Configuration To configure your printer’s UPnP settings: Power ON the printer, see “Powering ON the Printer” on page 111. Press the Settings button within the Navigation Bar (see Table 4-5 on page 51). Locate the UPnP option within the Network portion of the Settings page (see “UPnP”...
Page 26 Figure 2-7: Enter Network Settings Dialog Backspace Exit (delete) (without saving) Checkmark (confirm) • Use the to enter address digits. number keys Use the key to delete entries digit by digit. • backspace Use the key to confirm entries and exit the dialog with saving. •...
Page 27: Setting The Printer's Date And Time
Setting the Printer’s Date and Time In order to ensure accurate build times, the printer’s clock must be set. This is done within the FDM Control Center application which was installed on your workstation PC as part of the installation process (see “FDM Control Center Software”...
Page 28: Licensing The Printer
The Change 450mc Date and Time dialog will be displayed. The date and time settings within this dialog are automatically configured based on the workstation PC’s date and time settings. Adjust the date and/or time setting if needed, then click OK to close the dialog. Your printer’s date and time settings will be configured and are displayed within the Information Bar portion of the User Interface (see “Information Bar”...
Page 29: System Components
System Components This chapter describes the components of the 450mc. Information regarding the materials and tips that can be used by the printer is also included in this chapter. Printer Overview Access Doors and Panels Warning: The right and left upper and lower side panels, as well as the upper and lower rear panels, should only be removed by an authorized service representative.
Page 30 Figure 3-2: Access Doors and Panels - Rear View Upper Rear Panel Lower Rear Panel Top Cover Allows access to the gantry and head assembly. Six fans are used to cool this area of the printer. The two fans on the left and the two fans on the right draw cool air into the gantry area, while the two fans on the rear draw warm air out of the gantry area.
Page 31: Touchscreen User Interface
Right & Left Side Panels Warning: The right and left upper and lower side panels should only be removed by an authorized service representative. Upper & Lower Rear Panels Warning: The upper and lower rear panels should only be removed by an authorized service representative.
Page 32: Oven Components
Oven Components The oven is comprised of the oven door and everything that you see through the oven door window, including the platen and the tip wipe assembly. The oven is where parts are built. Figure 3-3: Oven Components Tip Wipe Assembly Oven Door...
Page 33: Oven Lights
Oven Lights Hot Surface: Bulbs are hot. Never touch bulbs when the oven light is turned on. Bulbs should only be removed/replaced when the oven light is turned off. See “Replace an Oven Bulb” on page 232 for bulb replacement instructions. There are four Festoon bulbs (Figure 3-4) mounted on the front upper edge of the oven, two...
Page 34: Platen
Platen The steel platen provides the level surface on which parts are built. A build sheet is securely affixed to the platen by the vacuum source (see “On Board Vacuum System” on page 35 details). A checkerboard pattern is machined into the top surface of the platen which allows vacuum to be evenly distributed across the entire surface.
Page 35: Tip Wipe Assembly
Tip Wipe Assembly The tip wipe assembly is located on the front, right side of the oven. The assembly consists of two flicker/brush assemblies (one for each tip), two purge ledges (one for each tip), and a purge chute. The assembly is housed behind the purge chute access plate. The flicker/brush assemblies keep the printer’s tips and tip shields free of purged material debris and material buildup.
Page 36: Canister Bay Enclosure Components
Canister Bay Enclosure Components The model and support material canister bays are accessed by opening the canister bay doors on the front of the printer. The canister bay doors do not contain electromagnetic locks and can therefore be opened while the printer is building. Figure 3-7: Canister Bay Enclosure Components Tip Wipe Height...
Page 37: Canister Bay
Canister Bay The 450mc has four operating material canister bays - two model and two support. The two left-most bays (M1 & M2) hold model material while the two right-most bays (S1 & S2) hold support material. While building, one model and one support canister will be active. An active canister has material filament loaded to the head, as indicated by a steady green LED above the canister and a status of “Loaded”...
Page 38: Canister Status Led Indicators
Canister Status LED Indicators There is one colored status LED above each canister. This LED indicates the canister condition for each canister bay (Figure 3-7). LEDs states are as follows: Off: No canister detected, or a canister is present but filament has not been fed into •...
Page 39: Purge Bin
Purge Bin The canister bay enclosure contains a purge bin. This bin collects purged material debris passed down from the flicker/brush assemblies via the purge chute. The purge bin is equipped with its own door which is spring loaded. The purge bin door should be closed whenever the printer is building.
Page 40: Gantry
Gantry To access the gantry or the head, you must first open the top cover. The top cover utilizes an electromagnetic lock. The top cover remains locked while the printer is building and automatically unlocks when it is safe for you to access the components within this area of the printer;...
Page 41: Head Assembly
Head Assembly The head assembly has been designed for use with a wide range of modeling materials. The board inside the head provides direct heater. The head extrudes model material and support material with two identical liquefiers. The support liquefier moves up and down via a drive motor.
Page 42: Head Maintenance Bracket
Head Maintenance Bracket The 450mc is equipped with a head maintenance bracket which places the head in a convenient location for many head maintenance tasks, such as changing tips (see “Changing Tips within the Top Cover” on page 158). Placing Head into Maintenance Bracket When necessary, perform the following steps to place the head into the maintenance bracket: Ensure that the printer is stopped and not building.
Page 43 While firmly grasping the maintenance handle, lift the head and place it into the head maintenance bracket. Figure 3-15: Head in Maintenance Bracket Removing Head from Maintenance Bracket After performing any necessary head maintenance tasks, perform the following steps to remove the head from the head maintenance bracket and replace it within the gantry: While firmly grasping the maintenance handle, remove the head from the head maintenance bracket and return head to its initial position within the gantry.
Page 44: Vacuum And Air Dryer Systems
Vacuum and Air Dryer Systems On Board Vacuum System The vacuum pump generates the vacuum used to hold the build sheet to the platen. When sufficient vacuum is achieved, the build sheet automatically affixes to the platen and the red X over the top of the Vacuum Status Indicator (within the Information Bar) will disappear (see “Information Bar”...
Page 45: Modeling Materials And Tips
Modeling Materials and Tips Materials Used The 450mc can use a variety of material types: • High strength polycarbonate (PC) model material used with PC_S breakaway support or SR-100 soluble support. PC-ISO model material used with PC_S breakaway support. • •...
Page 46: Liquefier Tips
When initiating a build, the printer compares the material requirements (model and support) of the build file to the printer’s current materials configuration. If materials do not match, the User Interface prompts you to change materials to the appropriate type. Note: You can choose to continue the build with mis-matched material(s), but part build quality will be unpredictable.
Page 47 When changing tips, the printer will guide you through the process of resetting tip odometers using the Tip Change Wizard (see “Using the Tip Change Wizard” on page 125.) Table 3-1: Available Tips Model Material Model Tip Support Material Support Tip ABS-M30 T10, T12,T16, T20 SR-30...
Page 48 Table 3-3: Tip Life Model Tip Life Support Tip Life Model Model Support Material Canisters Canisters ABS-M30 10160 T12SR30 4420 ABS-M30i ABS-M30 12620 T12SR30 9010 ABS-M30i ABS-M30 15080 10.0 T12SR30 10550 ABS-M30i ABS-M30 15080 10.0 T12SR30 10550 ABS-M30i ABS-ESD7 12620 T12SR30 9010 ABS-ESD7...
Page 49 Tip Identification Figure 3-17: Tip Identification The Soluble Release support tip is shorter than standard tips. All unused model and support tips are interchangeable EXCEPT for Soluble Release support tips. Once a tip is used, it is committed to that material type and is no longer interchangeable.
Page 50: Software
The 450mc builds parts by processing the original STL job file into a Stratasys CMB file that is downloaded to the printer. To build a job, you must send the job file to the 450mc using the Insight application.
Page 51: Fdm Control Center Software
FDM Control Center is an application that connects with Insight software to send jobs to the printer to be built. Control Center is designed to be used with your network-based Stratasys printer. Insight performs the model processing to prepare a CMB file and Control Center connects to the printer to build the job and monitor the printer’s status.
Page 52: User Interface
User Interface This chapter provides an overview of the 450mc User Interface (UI). Specific printer operation information and procedures can be found in “5 Operating the Printer” on page 111. You must power ON the printer prior to using the touchscreen, see “Powering ON the Printer”...
Page 53: Information Bar
The Information Bar is docked at the top of the touchscreen display, and appears on every page of the User Interface. A variety of information is displayed within the Information Bar including the System Status Indicator (printer’s “heartbeat”), Stratasys logo, Vacuum Status Indicator, Network Status Indicator, high level system messages, and current date/time.
Page 54: Dashboard
Dashboard The Dashboard is docked just beneath the Information Bar and appears on every page of the User Interface. The Dashboard displays the printer’s build state (button), material statuses and canister volumes (model and support), tip statuses and odometer amounts (model and support tip), and oven light control (button).
Page 55 Pressing the Build State button will open a dialog indicating the reason(s) for the current build state (see “Warnings and Errors” on page 237 for explanations of warnings displayed on this page). Once all warnings have been corrected, press the checkmark button to exit the dialog.
Page 56 Materials/Tips Status The center section of the Dashboard contains 6 icons pertaining to the status of the printer's current materials and tips. Note: Icons are display only and are not buttons. The information displayed within these icons is meant to be used as a quick reference of the printer’s current configuration.
Page 57 Icon State Description Canister is empty - material name and empty volume displayed, user action required to remove empty canister. “Unloading Material from the Liquefier Tips” on page 119 for instructions. “Removing an empty canister” on page 121 Yellow (empty canister) Valid canister installed in canister bay, but material does not match the current material configuration of the printer and/or...
Page 58 Valid tip, tip size, and current odometer for this tip is displayed. Tip is below odometer limit for associated material and is currently in position to be used for building. While building, highlighting will switch between the model and Blue (white support icon to indicate which tip is currently active.
Page 59: Display Area
Display Area The buttons/icons and information shown within the Display Area of the touchscreen will vary depending on which main page of the User Interface is selected. When powered ON, a representation of the printer’s current state is displayed. • After pressing the Build State button within the Dashboard, the Display Area will •...
Page 60 The buttons in the Navigation Bar are mutually exclusive, meaning only one button may be selected at any given time. In some instances, all of the buttons in the Navigation Bar will be disabled. Buttons can appear as follows: Table 4-5: Navigation Bar - Button States Button Name Selected State...
Page 61: Working With The Build Page
Working with the Build Page The Build page is comprised of the four main areas of functionality that are necessary for selecting and building parts on the printer; these items are highlighted in Figure 4-6. Within the Build page you can select a job, see how a selected job matches the printer’s current configuration, view build time and materials usage estimates for the selected job, start, pause, and abort a job, and see status and estimated action points for the currently building job.
Page 62: Viewing Print Job Information
Viewing Print Job Information Information pertaining to a selected job is displayed at the top of the Build page within the Print Job Information Panel. This information is static and represents the details of the job as submitted to the printer from the Insight application on your workstation PC. Figure 4-7: Print Job Information Panel Information displayed within this panel for a selected job includes:...
Page 63: Print Job Status
A Print Job Selection button that is available for selection is indicated by a blue border with no white outline, as in the left button in Figure 4-8. When you select the left or right button, it will momentarily indicate the selection by showing a white outline, as in the right button in Figure 4-8.
Page 64 Build Status Display The upper portion of the Build Status Display shows the following build information: The build’s percentage of completion is displayed as a numerical percentage just • above the build’s layer completion information. • The number of completed layers as compared to the total number of layers in the build is displayed just below the build’s percentage of completion.
Page 65 Materials Status Display Materials related information is displayed within three areas of the Materials Status Display. Information pertaining to model material is displayed within the upper portion of the Materials Status Display. • The Available: field displays the total amount of model material loaded within the printer (in or cm depending on your printer’s configuration).
Page 66 Figure 4-14, there is sufficient material in the printer to complete the build if it were started. The model and support progress bars are shown in dark blue. Figure 4-14: Materials Status Display Details - Idle, Sufficient Materials Figure 4-15, there is not sufficient material in the printer to complete the build if it were started.
Page 67 When the printer is building an additional progress bar is displayed for both the model and support fields. This light blue bar indicates build progress and reflects the amount of material used so far during the build. Figure 4-16, the light blue progress bars indicate the amount of model and support material used so far.
Page 68: Print Job Controls
Print Job Controls Three buttons are displayed at the bottom of the Build page (just beneath the Print Job Status Display). These buttons are used to start, pause, and abort a build. Figure 4-18: Print Job Controls Build (play) Button The Build button, which resembles the “Play”...
Page 69 Pause Button The Pause button allows you to pause an active build. The Pause button can appear in the following states: Table 4-7: Print Job Controls - Pause Button States Button State Description Printer is actively building. Selecting the Pause button in this state will pause the build.
Page 70: Working With The Queue Page
Working with the Queue Page There are two, separate queues available on the 450mc: the Job Queue and the Sample Queue. From the Queue page you can view, edit, sort and select jobs from the Job Queue or Sample Queue. To access these queues, press the Queue button within the Navigation Bar; the Job Queue will be displayed by default.
Page 71: About The Job Queue
About the Job Queue The Job Queue contains the list of files (jobs) downloaded to the printer from the Control Center application on your workstation PC. By default, jobs are added to the Job Queue in the order they were submitted to the printer via Control Center. Individual jobs are listed in rows, with columns indicating job name (Job Name), estimated build time (Est.
Page 72 Job Queue Controls There are four buttons displayed directly below the Job Queue list which can be used to rearrange the print jobs listed in the queue. These buttons are disabled for the Sample Queue. Figure 4-22: Job Queue Controls These buttons have the following functionality: Table 4-9: Job Queue Control Buttons...
Page 73 Viewing Job Details To view additional details regarding a particular job in the Job Queue or Sample Queue, select the right arrow displayed for that job. Figure 4-23: View Job Details This will open the job’s Job Details page which displays additional information such as the name of the user who submitted the job, the number of layers in the job, the support material and support tip associated with the job, and the size of the job.
Page 74: About The Sample Queue
About the Sample Queue The 450mc comes with several sample job files permanently installed on the printer. These files are accessible via the Sample Queue only. This queue is comprised of a few sample part files as well as a variety of other files that are helpful for testing the printer. The majority of the files within the Sample Queue will be utilized only by authorized service representatives when performing maintenance on the printer.
Page 75: Working With The Tips Page
Working with the Tips Page The Tips page displays a detailed representation of the printer’s current materials and tips configuration. Two Tip Status Icons and four Material Status Icons (similar to the icons within the Dashboard) represent the tips and model/support materials loaded/installed within the printer.
Page 76: Tips/Materials Status
Tips/Materials Status The Tips page contains six icons pertaining to the status of the printer's current materials and tips. Two Tip Status Icons and four Material Status Icons (similar to the icons within the Dashboard) represent the tips and model/support materials loaded/installed within the printer.
Page 77 Icon State Description Valid tip, tip size, current odometer, and approximate tip life for this tip is displayed. Tip is within 10% of or has reached the odometer limit for the associated material (see for approximate tip Table 3-3 on page 39 life information).
Page 78 Icon State Description Valid canister loaded into bay, material name and current volume displayed. Material from canister is loaded to the head and canister is selected to be used for building. Blue (white highlighted border) - - indicates that a material canister is not loaded in the corresponding canister bay - user action required to insert canister.
Page 79: Canister Load Status
Canister Load Status A variety of canister load status messages are displayed directly beneath each Material Status Icon, indicating the current activity of each canister and/or the canister’s filament. Throughout the process of loading and unloading material these statues will update frequently, giving you an indication of the progress being made.
Page 80: Material Load Controls
Material Load Controls The Tips page contains Material Load Control buttons which are used to load and unload material to the liquefier tips within the head. A Load Material (up arrow) and Unload Material (down arrow) button is displayed for each material canister; however, the selectability of these buttons is dependent upon the canister’s load status.
Page 81 As materials are loaded and unloaded, the pathway between the material and tip status icons will become blue with a white highlighted border, and will fill in the direction that the canister’s filament is traveling. Figure 4-28 depicts the functionality displayed when a canister’s filament is being loaded to the head, while Figure 4-29 depicts the functionality...
Page 82 Material unload progress will display the same functionality regardless of whether a model or support canister is being unloaded. Once a canister’s material is unloaded from the head the pathway between the canister’s Material Status Icon and the corresponding Tip Status Icon will be solid black, and the canister’s load status will update to “Not Loaded”.
Page 83: Tips Controls
Tips Controls Three buttons are displayed at the bottom of the Tips page (just above the Navigation Bar). These buttons are used to initiate a variety of tip related functions. Figure 4-30: Tips Controls These buttons have the following functionality: Table 4-13: Tips Controls Buttons Icon...
Page 84: Tip Purge/Unplug
Note: The Navigation Bar is hidden within the Tip Change Wizard. A detailed walk through of the Tip Change Wizard can be found in “Using the Tip Change Wizard” on page 125. The example within this section outlines the necessary steps for changing material type (model and support) as well as changing tips.
Page 85 Unplug Pressing the Unplug button initiates an automated tip unplug routine. This button should be pressed if you encounter a paused build due to the “Model filament clogged in tip” or “Support filament clogged in tip” warning (see “Build Pause Warnings” on page 243).
Page 86 Tip Wipe Adjustment Pressing the Tip Wipe Adjustment button will open the Tip Wipe Adjust Wizard page. Within this page you can: • Instruct the printer to set to its standby or build temperature • Command the head to move to the purge position Initiate a tip wipe •...
Page 87 Go to Purge Position Pressing the Go to Purge Position button will instruct the head to move to the purge position (directly above the purge ledge). This button must be pressed before the Wipe Tips button will become selectable, as the head must be in the purge position before tips can be wiped. Wipe Tips After pressing the Go to Purge Position button the Wipe Tips button becomes selectable.
Page 88: Working With The Calibration Page
Working with the Calibration Page Note: This section provides an overview of the Calibration page and its features, but does not go into detail regarding calibration procedures. See “6 Calibration” on page 183 for detailed calibration procedure information and instructions. The Calibration page allows you to perform a variety of calibration procedures on the printer, including: XYZ Tip Offset Calibration...
Page 89: Viewing Calibration Status
Viewing Calibration Status Your printer’s calibration status is displayed within the upper portion of the page. The text displayed within the Calibration Status Pane reflects the overall calibration status of the printer. If your printer is calibrated (i.e. XYZ Tip Offset Calibration has been completed), information similar to what is shown in Figure 4-34 will be displayed.
Page 90: Xyz Tip Offset Calibration
XYZ Tip Offset Calibration Pressing the XYZ Tip Offset Calibration button will open a page which allows you to initiate an XYZ Tip Offset Calibration and/or build a calibration part. See “XYZ Tip Offset Calibration” on page 184 for detailed instructions. An XYZ Tip Offset Calibration must be performed each time the printer’s tips are changed.
Page 91: Touchscreen Calibration
Touchscreen Calibration Pressing the Touchscreen Calibration button will open a dialog allowing you to recalibrate the touchscreen display. See “Touchscreen Calibration” on page 201 for detailed instructions. Figure 4-37: Recalibrate Screen Confirmation Page Find Z Home Pressing the Z Home button instructs the printer to find its home location for the Z axis. Note: This button can also be found within the Gantry/Stage Details page.
Page 92: Working With The Settings Page
Working with the Settings Page The options within the Settings page are organized into groupings of related functionality. Within each grouping, printer information can be viewed and individual printer settings and preferences can be configured. Within this page you can turn a variety of printer settings on/ off (including UPnP, part placement, auto cooldown, etc.), select your printer’s address type (dynamic or static) and manually configure an IP address, network mask, and gateway address (if needed), and adjust the brightness of the touchscreen display.
Page 93: Settings Page Navigation
Settings Page Navigation To scroll up and down within the Settings page simply touch the screen and pull the list of options in the direction you’d like to scroll. A small scrollbar is displayed along the right- hand side of the page, indicating the direction in which you’re scrolling. The options within the Settings page are organized into 3 main categories: Printer, Network, and Service.
Page 94 Rows containing a slider graphic (see Figure 4-39) allow you to configure a particular setting, typically turning the setting Off and On, directly within the Settings page. Simply touch the slider on the screen and move it to the left or right to adjust its setting. Rows containing a right arrow graphic (see Figure 4-39) will open a new page allowing you...
Page 95: Printer Settings
Printer Settings Within the Printer category of the Settings page you can configure a variety of printer functionality preferences. Note: The printer’s date and time settings are not configured within the Settings page. Instead, this information is configured within the FDM Control Center application which was installed on your workstation PC as part of the initial installation and setup process.
Page 96 You can select the part’s build location by dragging and dropping the bounding box on the touchscreen; the bounding box cannot be placed outside the limits of the platen. Pressing the checkmark button will confirm your selected placement and start a build. “Ghost box”...
Page 97 Auto Cooldown The Auto Cooldown row displays the printer’s auto cooldown setting. Pressing the right arrow graphic within this row will open a page allowing you to adjust this setting. Figure 4-45: Auto Cooldown Oven modeling temperature is determined by the material type (model and support) loaded within the printer.
Page 98: Network Settings
Network Settings Within the Network Settings category of the Settings page you can configure your printer’s UPnP and network address information. Note: Your printer was configured for your network as a part of its initial installation and setup (see “Configuring the Network” on page 15).
Page 99 Static Configuration When the Address Type is set to Static you must enter an IP address, network mask, and gateway address for the printer (provided by the system administrator). Once entered, the address will not change. Note: See your system administrator if you do not know the IP address, Network mask, or Gateway address.
Page 100 Network Address Information The printer’s network address information is displayed directly below the Network row. The printer’s Address Type, IP Address, Netmask, and Gateway Address are displayed within the right side of the row. Any configuration changes made within the Network Settings Details page will be reflected within this row.
Page 101: Display Settings
Display Settings Adjust Brightness The Adjust Brightness slider graphic allows you to adjust the brightness of the touchscreen display. To configure this setting, use the slider graphic to adjust as needed; sliding to the right will increase brightness, while sliding to the left will dim brightness. Figure 4-52: Adjust Brightness Service Settings...
Page 102: Working With The Maintenance Page
Working with the Maintenance Page Note: This section provides an overview of the Maintenance page and its features, but does not go into detail regarding printer maintenance procedures. “7 Maintenance” on page 204 for detailed maintenance information. The options within the Maintenance page are organized into groupings of related functionality.
Page 103: Maintenance Page Navigation
Maintenance Page Navigation To scroll up and down within the Maintenance page simply touch the screen and pull the list of options in the direction you’d like to scroll. A small scrollbar is displayed along the right- hand side of the page, indicating the direction in which you’re scrolling. The options within the Maintenance page are organized into 5 main categories: Head, Bays, Gantry/Stage, Chamber, and System.
Page 104: Head Settings
Head Settings Active Tip The Active Tip row indicates which tip is currently active on the printer (i.e. extruding material to create a part). This setting updates automatically to coincide with the status of the printer’s tips while building and will match the selected tip icon indicated within the Dashboard.
Page 105: Bay Settings
Bay Settings Filament Present Each individual canister bay has a canister drive containing a filament present switch (see “Canister Drives and Canister Release Knobs” on page 28). This switch detects the presence of material within the canister drive. The Filament Present row displays status information pertaining to the filament loaded in a canister drive;...
Page 106 Canister S/N The Canister S/N row displays the serial number of each of the model and support canisters installed in the printer’s canister bays. The printer automatically reads this number off of the canister’s memory chip when it is inserted into a canister bay. If a canister bay is empty “- -” will be displayed in place of a serial number.
Page 107: Gantry/Stage Settings
Gantry/Stage Settings Pressing the right arrow graphic within the Gantry/Stage row will open your printer’s Gantry/Stage Details page ( Figure 4-63 on page 99). Within this page you can move the platen (Z) up or down and the head in the X and Y axis. Figure 4-62: Open Gantry/Stage Details Page The Z Home and XY Home buttons are displayed within the lower portion of the page (just...
Page 108 Pressing the Maintenance button in the upper-left corner of the page will close the Gantry/ Stage Details page (returning you to the Maintenance page). Figure 4-63 the X axis is selected; absolute movements can be made to the Left, Mid (middle) or Right of travel.
Page 109 Figure 4-64 the Y axis is selected; absolute movements can be made to the Back, Mid (middle) or Front of travel. Figure 4-64: Gantry/Stage Details Page - Y Axis Selected Y axis selected Figure 4-65 the Z axis is selected; absolute movements can be made to the Mid (middle) or Bottom of travel.
Page 110 X, Y, Z Position Position information for the X, Y and Z axes is displayed within the X, Y, Z Position row. This information is the same as what is displayed within the Gantry/Stage Details page. The position information displayed within this row will update to reflect changes made within the Gantry/Stage Details page.
Page 111: Chamber Settings
Chamber Settings Oven Temperature The Oven Temperature row displays the oven’s current temperature as compared to its set point temperature. Note: Small offsets (1-3C) between actual and set point temperatures are normal, particularly oven temperatures above 150C. Figure 4-68: Oven Temperature Vacuum Enable The Vacuum Enable row displays whether the printer’s vacuum capability is on or off.
Page 112 Vacuum Status The Vacuum Status row displays status information pertaining to the printer’s vacuum system. “Low” is displayed if vacuum pressure is below threshold. In this instance, a build sheet will not affix to the platen as sufficient pressure is not present to hold the build sheet to the platen’s surface.
Page 113 Door Lock The Door Lock row displays whether or not the printer’s door is locked. Whenever the oven door can be opened (i.e. the printer is not building and it is therefore safe for you to open the oven door) “Unlocked” will be displayed. Whenever the oven door’s lock is engaged and the door cannot be opened (i.e.
Page 114 Cover Status The Cover Status row displays the status of the printer’s top cover. “Open” will be displayed when the top cover is open, and “Closed” will be displayed when the top cover is closed. Figure 4-74: Cover Status...
Page 115: System Settings
System Settings Serial Number The Serial Number row displays the printer’s unique serial number. This number can also be found on the label on the exterior surface of the printer (see Figure 2-5 on page 13 for label placement). Figure 4-75: Serial Number Software Version The Software Version row displays the version of Controller Software installed on the...
Page 116 Figure 4-78: Update Software Page Figure 4-79: Upgrade Software Page...
Page 117 Materials The Materials row displays the printer’s materials configuration information (see Available Material Options for details). This information is based on the material license purchased for the printer. The printer’s material license determines the types of materials (model and support) that can be used to build parts on the printer. The printer is licensed as part of its initial installation and setup process (performed by your authorized service representative).
Page 118 If you find that the printer’s materials configuration no longer meets your needs, you can purchase a different material option and upgrade the printer’s material license. Pressing the Add License button within the Materials Details page puts the printer into License Upgrade Mode, and opens the Add Material License page.
Page 119 Restart Pressing the right arrow graphic within the Restart row will open a dialog allowing you to manually restart the printer. Figure 4-83: Restart Pressing the checkmark button within this dialog will cause the printer to restart automatically. Selecting the X (Cancel) button within this dialog will close the dialog. Figure 4-84: Restart...
Page 120: Operating The Printer
Open the canister bay doors. Within the canister bay area, flip the power switch to the ON (I) position. The printer will begin to boot. The touchscreen will turn on and the Stratasys logo followed by start-up code will be displayed for a brief period.
Page 121: Powering Off The Printer
Once the printer boots up “Initializing” will be displayed on the touchscreen, followed by “Starting”. The icons within the Dashboard will be blank until this process is complete. Figure 5-2: Initializing Start Up Screen After the initialization and start up process is complete, the printer will automatically perform an XY Home Calibration.
Page 122: Material, Canisters, And Liquefier Tips
Material, Canisters, and Liquefier Tips Loading Material to the Liquefier Tips Caution: Any time the printer’s material type is changed, tips must also be changed. The following information does not contain steps for changing the printer’s tips. Any time you are changing material type and tips you must follow the steps within “Changing Tips or Material Type”...
Page 123 Figure 5-3: Current Configuration - Load Material Observe the status information displayed below each of the model and support canister icons. The "Insert Canister" status indicates that a canister is not present in the material’s corresponding canister bay. Insert the canister you’d like to load into its appropriate canister bay. See “Canister Installation”...
Page 124 The printer automatically completes the process of pre-loading filament. The drive motor advances filament until it contacts the filament present sensor. Once • filament is detected, the drive motor stops and the canister status LED begins to flash green. A status of "Advance Filament" is displayed until filament is detected by the filament •...
Page 125 Canister Installation The process for installing a new, unopened canister varies slightly from the process for installing a previously used canister. The following instructions will guide you through the process of installing a canister, noting the steps which only apply to new (unopened) canisters.
Page 126 Figure 5-5: Canister Installation Table 5-1: Figure 5-5 Key to Item Description Item Description Foil Tape Plastic Plug (operating position) Anti-Rotation Plug Plastic Plug (storage position) Thumbwheel Door Foam Gasket (operating position) Canister Snout Foam Gasket (storage position) Filament Drop the canister drive down onto the canister by pulling out the canister release knob.
Page 127 Figure 5-6: Pre-loading Filament Filament Present Sensor Canister Release Knob Drive Wheels Filament Thumbwheel Filament Pre-load filament to the drive wheels Pre-loading filament to the drive wheels places a canister’s filament into position to be loaded to the liquefier tips within the head. To pre-load filament to the drive wheels: Open the thumbwheel door.
Page 128: Unloading Material From The Liquefier Tips
The printer automatically completes the process of pre-loading filament. The drive motor advances filament until it contacts the filament present sensor. Once • filament is detected, the drive motor stops and the canister status LED begins to flash green. A status of "Advance Filament" is displayed until filament is detected by the filament •...
Page 129 Figure 5-7: Current Configuration - Unload Material Observe the status information displayed below each of the model and support canister option icons. A "Loaded" status indicates currently loaded material. The Unload Material (down arrow) button should be selectable for all loaded materials.
Page 130: Removing Canisters
Material begins to unload from the liquefier. The material’s status is updated to "Unloading" and the canister status LED rapidly flashes green. The pathway displayed between the canister’s material icon and the corresponding tip icon becomes highlighted to indicate unload progress (see Figure 4-28 on page 72).
Page 131 Removing a partially used canister Note: Refer to Figure 5-5 for referenced item numbers. Unload filament from the liquefiers (see “Unloading Material from the Liquefier Tips” on page 119). Once the material’s status is displayed as "Remove Canister", open the canister thumbwheel door (item 3).
Page 132: Canister Auto Changeover
Canister Auto Changeover Auto changeover allows you to leave a long build unattended. When an active canister becomes empty: The printer is paused and the drive motor automatically withdraws residual material from the printer. The changeover canister is pre-loaded, and then material is loaded to the head. The job is automatically resumed.
Page 133: Handling/Storing Canisters
Like other thermoplastics, the filament within canisters can absorb moisture when exposed to ambient humidity. Stratasys canisters are designed to minimize moisture exposure while unopened and opened. When a canister's filament absorbs moisture a finished part's surface quality, seam quality and overall part aesthetics can be affected.
Page 134: Changing Tips Or Material Type
Changing Tips or Material Type The information within this section is meant to guide you through the process of changing materials and tips. The Tips page includes a Tip Change Wizard designed to streamline the process of changing the printer’s model and/or support materials and tips. The Using the Tip Change Wizard section contains a detailed example which will guide you through the...
Page 135 To access the Tip Change Wizard, press the Tip Change (Wizard) button within the Tips page. From the list of material options displayed, select the model material you'd like to switch to (ABS-M30 in this case). The newly selected model material will be indicated.
Page 136 From the list of tip options displayed, select the model tip you'd like to switch to (T16 (new) in this case). The newly selected model tip will be indicated. Press the Next button to proceed with the wizard. Note: When selecting the tip you’d like to switch to you are given a “current” (i.e.
Page 137 Based on the model material you selected in step 2, a list of support material options will be displayed. From the list of material options displayed, select the support material you'd like to switch to (SR-30 in this case). In this case, only one material option is displayed (and is selected by default) as only one support material is compatible with the model material selected previously.
Page 138 Based on the support material you selected in the previous step, a list of compatible support tip options will be displayed. From the list of support tip options displayed select the support tip you'd like to switch to (T12 in this case). In this case, only one support tip option (T12) is displayed, and is selected by default, as only one support tip is compatible with the support material selected previously (see...
Page 139 Verify that the material and tip selections displayed are correct. If you need to change your material and/or support tip selections, press the Previous button and make changes as needed. Ensure that a part is not on the platen and then press the Next button to proceed with the wizard.
Page 140 Once the platen moves to the oven cleaning location perform the steps displayed within the page. When finished, press the Next button to proceed with the wizard. Note: Please be aware of the warning(s) indicated within the page.
Page 141 The model and support material currently loaded in the printer (Ultem and Ult_S in this case) will start to unload (model material will unload first followed by support material). A two-part radial progress graphic displays the amount of time remaining until this process is complete (12 minutes in this case). Material unload percentage of completion is represented by radially filling in the outer progress ring of this graphic, in a clockwise direction.
Page 142 As material unload progress is made, the radial progress graphic will be updated. A green checkmark will be displayed indicating that material has been completely unloaded from the printer.
Page 143 Once the material unload process is complete, you will be prompted to remove unloaded canisters (as appropriate). Remove unloaded canisters (see “Removing Canisters” on page 121) and then press the Next button to proceed with the wizard.
Page 144 Caution: Discard material pulled from printer. Do not attempt to rewind material in canister. If filament is forced into canister, cross winding will most likely occur, making the entire canister unusable. Once canisters have been removed, the printer will clear the filament remaining within the filament tubes.
Page 145 Confirm that the material and tip selections displayed are correct and then press the Next button to proceed with the wizard. Note: Please be aware of the warnings associated with your selections. A tip and/or material type change will require calibration. If you proceed past this page of the wizard and exit the wizard without performing an XYZ Tip Offset Calibration, your printer will not be calibrated.
Page 146 A screen will be displayed momentarily indicating that the printer is preparing to have its tip(s) replaced. Perform the necessary steps to replace model and/or support tips. See “Changing Tips within the Top Cover” on page 158 for detailed instructions on changing tips. If a tip is removed that may be re-installed at a later time, be sure to record the tip’s odometer reading (item 4 in the image below) and store this reading with the removed tip.
Page 147 A default odometer value of 0.0 (in ) is automatically populated for the newly installed model and support tip; update tip odometer information as needed. If you are using brand new (unused) tips, no configuration is necessary. Simply • accept the default values, press the Next button, and then proceed to step •...
Page 148 Press the touchscreen anywhere within the Model field. When selected, the field will turn blue. Using the keypad, enter the odometer value corresponding to your model tip (150.6 in in this case). Use the delete key to erase a field’s default value. Repeat steps as needed to update the support tip's odometer information.
Page 149 Your materials and/or tip changes will be saved and the odometer values entered in the previous step will be displayed within the Tip Status Icons of the Dashboard.
Page 150 Perform the necessary steps to prepare for tip calibration. Install a build sheet - make sure the build sheet is as centered as possible when placed onto the platen. Verify vacuum - within about 5 minutes the printer should attain sufficient vacuum to secure the build sheet to the platen.
Page 151 Select the model and support canisters to be loaded during the calibration sequence (M2 and S2 in this case) by pressing the corresponding row on the touchscreen. When selected, the row will be blue. Selected canisters are indicated by a white outline encasing the canister's icon. Canisters with the lowest volume of material are selected by default.
Page 152 A screen will be displayed allowing you to select the calibration part’s location on the build sheet prior to starting the build. The screen contains a graphic representing your printer’s platen as well as a blue bounding box graphic (the imaginary box surrounding the part).
Page 153 The printer will begin the process of building a calibration part. This process includes allowing oven temperature to stabilize (see Table 5-3 for stabilization times), performing a Z tip-to-tip calibration, loading model material, loading support material, and then building the calibration part. The status of each task is indicated on the screen.
Page 154 Table 5-3: Oven Stabilization Times (in hours) Material Type Being Installed Ultem Current Oven ABS-M30 Temp. ABS-M30i ABS-ESD7 Nylon 12 PC-ISO 9085 Room temp. ABS-M30, ABS-M30i Auto Cool-Down ABS-ESD7 Nylon 12 PC/PC-ISO Ultem 9085 The screen will update as the printer: •...
Page 155 Loads model material, and then loads support material. •...
Page 156 In addition to the screen updating, the Information Bar and the Build State button will update to indicate when the printer is building the calibration part.
Page 157 Once the calibration part is complete you will be prompted to remove the part from the printer. Remove the completed part and then press the Next button to proceed with the wizard.
Page 158 The Adjust XYZ Calibration page will open; this page will vary slightly depending on the type of units that the printer is configured for (see “Units” on page 87 for details). The icons and buttons within this page will allow you to make XYZ tip offset adjustments based on an analysis of the calibration part.
Page 159 Determine where on each axis the support toolpath is most centered between the X-Y alignment indicators (see Figure 5-9 Figure 5-10 for English units, Figure 5-11 Figure 5-12 for Metric units). The numbers on the calibration part represent thousandths of an inch (e.g., 4 = 0.004 in. (0.1mm)). Figure 5-9: Calibration Part - No Adjustment Needed (English units) Magnified single side of a calibration part with a reading of 0.
Page 160 Figure 5-11: Calibration Part - No Adjustment Needed (Metric units) Magnified single side of a calibration part with a reading of 0. Calibration Part Most centered at 0 Support toolpath Alignment indicators Figure 5-12: Calibration Part - Adjustment Needed (Metric units) Support toolpath is most centered between the alignment indicators at the 4, indicating an adjustment of +X = 0.1 Calibration Part...
Page 161 Within the Adjust XYZ Calibration page, slide the scale icons on the screen to match where the support toolpath is most centered between the alignment indicators. The Delta X and Delta Y fields will reflect adjustments made. Note: Only one offset value can be selected for each axis, (i.e., an adjustment of +X = 2 (0.002 in.
Page 162 • If the support toolpath is not centered at 2 (0.05 mm) or less (as in Figure 5-10 Figure 5-12) an offset adjustment is needed. The following figure shows a +X adjustment of 4 or 0.004 in. (0.1 mm). The +X scale icon has been moved downward to the 4 (0.1) and the Delta X value reflects this adjustment (0.0040 in./ 0.100 mm).
Page 163 • The Build Calibration Part screen will be displayed (see step 17 B.) and the calibration part will begin building. A two-part radial progress graphic displays time remaining for the build as well as the build’s percentage of completion. Once the calibration part is complete you will be prompted to remove the part from the printer (see step 17...
Page 164 Refer to Table 5-4 and determine the slice height for the model tip installed in your printer. Table 5-4: Model Tip Slice Heights Model Tip Slice Height (in) Slice Height (mm) 0.005 0.127 0.007 0.178 0.010 0.254 0.013 0.330 If the value measured in step C is within ±0.0005 in.
Page 165 • Use the Up button to enter the value obtained in step C if this value is greater than the tip’s slice height. For example, if you measured an average of 0.012 in. (0.305 mm) for a tip with a slice height of 0.010 in. (0.254 mm), press the Up button until 0.0120 (0.305) is displayed within the Material Thickness field.
Page 166 • The Build Calibration Part screen will be displayed (see step 17 B.) and the calibration part will begin building. A two-part radial progress graphic displays time remaining for the build as well as the build’s percentage of completion. Once the calibration part is complete you will be prompted to remove the part from the printer (see step 17...
Page 167: Changing Tips Within The Top Cover
Changing Tips within the Top Cover Any time the printer’s material type is changed, tips must also be changed. If you are following the steps outlined within “Using the Tip Change Wizard”, complete the steps below to change tips, and then return to step 11 page 137 and proceed with the wizard.
Page 168 Using the 9/64 Hex Ball End Driver tip change tool (provided in the Welcome Kit), loosen the two (2) liquefier retaining screws which clamp the liquefier tip in place. Remove the desired tip from the head by gently grasping the tip’s tip shield and pulling the tip downward and out of the printer.
Page 169 Figure 5-20: Tip Installation Tip should be flush with bottom of heater block Repeat steps if an additional tip needs to be changed. Remove the head from the head maintenance bracket and return head to its initial position. Secure the head to the head mounting plate using the two (2) head mounting screws.
Page 170: Adjusting Tip Wipe Heights
Adjusting Tip Wipe Heights The tip wipe assembly contains two flicker/brush assemblies which are used to keep tips and tip shields free of purged material debris and buildup. The flicker cleans the tip’s opening, while the brush cleans the tip shield. After changing one or both tips, you must manually adjust tip wipe heights to ensure proper placement of the flicker/brush assemblies in relation to tips/tip shields.
Page 171 Note: As needed, press the Wipe Tips button again to initiate an additional 4 passes of the head. Once you believe you have achieved proper placement (as shown in Figure 5-22), press the Wipe Tips button and observe placement via the purge chute access plate window.
Page 172: Basic Job Build Tasks
Material residue on the sheet can adhere to the platen or interfere with the build sheet vacuum. Note: Using build sheets not provided by Stratasys may impact part quality and printer reliability. Note: ABS, ASA and PC parts use a clear build sheet.
Page 173: Selecting A Job To Build
Selecting a Job to Build Select the Queue button within the Navigation Bar. The Queue page will open, and the Job Queue tab will be selected by default (see Figure 4-19 on page 61). Within the Job Queue, select the job you wish to build by touching its entry in the list;...
Page 174 Figure 5-23: Part Placement Dialog “Heating Oven and Tips” is displayed within the Information Bar. The oven will begin to heat to a set point temperature determined by the material types specified for the job. Please be patient. After the oven and liquefier tips reach temperature “Finding Z Zero” is displayed within the Information Bar, and the printer performs a Z Zero Calibration.
Page 175: Information Available During A Build
Information Available During a Build During a build, information pertaining to that build is displayed within two areas of the Build page: The Print Job Information Panel displays the details of a job, as submitted to the printer from the workstation PC. This information is static and is for reference purposes only. See “Viewing Print Job Information”...
Page 176: Build Warnings
Build Warnings If the printer detects an issue that may affect a build, it will be indicated within the Dashboard. The Build State button will turn yellow or red depending on the severity of the warning. Pressing the Build State button will open a dialog indicating the reason(s) for the warning/error.
Page 177: Pausing A Build
Pausing a Build During a build the Pause button within the Build page becomes selectable (see “Pause Button” on page 60 for details). The printer can pause automatically, or be manually paused using this button: • An automatic pause occurs when a canister runs out of material, a failure is detected, etc.
Page 178 Figure 5-26: Abort Confirmation Dialog An abort command will be sent to the printer and the dialog will close. The Z stage will move to its end of travel and “Aborting” will be displayed within the Information Bar. Once the Z stage reaches its end of travel “Build Aborted - Remove Part” is displayed within the Information Bar prompting your to remove the aborted build.
Page 179: After A Build Is Complete
After a Build is Complete After the completion of a build, the printer performs the following actions: • The Z stage is lowered and the head is parked. • Depending on your printer’s auto cooldown configuration, the oven may or may not begin to cool (see “Auto Cooldown”...
Page 180 If the part does not peel easily, use a metal scraper to carefully pry the part from the build sheet. Remove supports from the completed part (material specific information and instructions can be found on the Stratasys Website and Customer Extranet). PC, PC-ISO and Ultem material use break-away supports, called BASS. This support •...
Page 181: Changing Printer Defaults
Changing Printer Defaults Factory presets can be changed via the Settings page. To access this page, press the Settings button within the Navigation Bar. Display Units By default the printer is configured to display English (imperial) units (inches). However, you can adjust this setting as needed to have the printer display metric units. The Units setting determines the type of units that the printer is configured for, English or Metric.
Page 182: Oven Temperature Control
Oven Temperature Control Oven modeling temperature is determined by the material type (model and support) loaded within the printer. It is controlled by the printer’s software and cannot be modified; however, you do have control of some oven temperature functions. The Auto Cooldown setting allows you to configure the printer’s auto cooldown function (see “Enable Part Placement”...
Page 183: Part Build Location
Part Build Location The Enable Part Placement setting determines whether or not you can select a job’s placement on a build sheet prior to starting the build (see “Network Settings” on page 89). By default this setting is set to Off and single part jobs are built in the center of a build sheet while packs are built according their selected placement within Control Center.
Page 184: Printer Status
Printer Status The various pages of the User Interface display each of the following: • Odometer status • Material status Temperature status • Software version • Other printer information • Tip Odometer Status The printer tracks and displays the total amount of material extruded through a liquefier tip since it was last replaced.
Page 185 Tip Life Status In addition to the odometer status information displayed, approximate tip life information can also be found within the Tips page. Tip life is the maximum amount of material that can be extruded through a tip. Approximate tip life information is displayed within the two tips icons, directly beneath the tip’s current odometer value (e.g 920 in /15,080 cm ).
Page 186: Materials Status
Materials Status You can find the current status of each of the canisters installed/inserted in the printer via two methods: The Dashboard contains four Material Status Icons, two corresponding to the printer’s model canisters (M1 & M2) and two corresponding to the printer’s support canisters (S1 &...
Page 187 Regardless of whether you are viewing these icons within the Dashboard or the Tips page, icons will take on a variety of colors, depending on their status (see Table 4-2 on page 47 for detailed status explanations): Blue - an icon with blue coloring indicates that a valid canister is inserted into the •...
Page 188: Temperature Status
Temperature Status Current and set point temperature information for the oven and liquefier tips can be found within the Tips and Maintenance pages. Oven Temperature To view the oven’s temperature information within the Maintenance page: Press the Maintenance button within the Navigation Bar; the Maintenance page will be displayed.
Page 189 Tip Temperature To view temperature information pertaining to the model and support tips within the Maintenance page: Press the Maintenance button within the Navigation Bar; the Maintenance page will be displayed. Locate the Head section of the page. The Model Temperature row displays temperature information for the model tip while the Support Temperature row displays temperature information for the support tip.
Page 190 Tip temperature information can also be found within the Tip Maintenance page: To open this page, press the Tip Purge/Unplug button within the Tips page. The page is divided into two groupings, one for the model tip and one for the support tip.
Page 191: Software Version
Software Version Version information for the software used to control the printer (Controller Software) can be accessed via the Maintenance page: Note: Controller Software is installed on the printer’s hard drive and should not be confused with Insight software, which is installed on the workstation PC. To access the Maintenance page, press the Maintenance button within the Navigation Bar.
Page 192: Calibration
Calibration This chapter describes basic calibration procedure for the 450mc. The buttons/pages described within this chapter are accessible via the Calibration page (see “Working with the Calibration Page” on page 79). To open the Calibration page, press the Calibration button within the Navigation Bar; a screen similar to the one in Figure 6-1 will be displayed.
Page 193: Xyz Tip Offset Calibration
XYZ Tip Offset Calibration Tip offset values are the distance between the model and support tips in the X, Y and Z directions. Accurate tip offset values ensure that support toolpaths are accurately located in reference to model toolpaths. Inaccurate tip offset values can cause part quality issues such as support material embedded in a part or improperly supported parts.
Page 194 The Tip to Tip Calibration page will be displayed. Within this page you have the option of performing a Z Tip-to-Tip Calibration and/or building a calibration part; the checkbox for each option is selected by default. Touching a checkbox on the screen will allow you select and deselect options as needed.
Page 195 Perform the necessary steps to prepare for tip calibration and then press the Next button to proceed with the wizard. Install a build sheet - make sure the build sheet is as centered as possible when placed onto the platen. Verify vacuum - within about 5 minutes the printer should attain sufficient vacuum to secure the build sheet to the platen.
Page 196 A screen will be displayed allowing you to select the calibration part’s location on the build sheet prior to starting the build. The screen contains a graphic representing your printer’s platen as well as a blue bounding box graphic (the imaginary box surrounding the part).
Page 197 The printer will begin the process of building a calibration part. Since both options were selected in step 3, this process includes performing a Z tip-to-tip calibration and then building the calibration part. The status of each task is indicated on the screen. A green checkmark will be displayed once a task is completed and the page’s header will update to reflect the task currently in process.
Page 198 In addition to the screen updating, the Information Bar and the Build State button will update to indicate when the printer is building the calibration part. Figure 6-7: Build Calibration Part Page...
Page 199 Once the calibration part is complete you will be prompted to remove the part from the printer. Remove the build sheet from the platen and allow it to cool and then press the Next button to proceed with the wizard. Figure 6-8: Remove Calibration Part Page...
Page 200 The Adjust XYZ Calibration page will open. The buttons within this page will allow you to make XYZ tip offset adjustments based on an analysis of the calibration part. The Material Thickness field displays the slice height for the model tip installed in the printer (see Table 6-2 for slice height information).
Page 201 Determine where on each axis the support toolpath is most centered between the X-Y alignment indicators (see Figure 6-10 Figure 6-11 for English units, Figure 6-12 Figure 6-13 for Metric units). The numbers on the calibration part represent thousandths of an inch (e.g., 4 = 0.004 in.). Figure 6-10: Calibration Part - No Adjustment Needed (English units) Magnified single side of a calibration part with a reading of 0.
Page 202 Figure 6-12: Calibration Part - No Adjustment Needed (Metric units) Magnified single side of a calibration part with a reading of 0. Calibration Part Most centered at 0 Support toolpath Alignment indicators Figure 6-13: Calibration Part - Adjustment Needed (Metric units) Support toolpath is most centered between the alignment indicators at .1, indicating an adjustment of +X = 0.1 Calibration Part...
Page 203 Within the Adjust XYZ Calibration page, slide the scale icons on the screen to match where the support toolpath is most centered between the alignment indicators. The Delta X and Delta Y fields will reflect adjustments made. Note: Only one offset value can be selected for each axis, (i.e., an adjustment of +X = 2 (0.002 in.
Page 204 • If the support toolpath is not centered at 2 (0.05mm) or less (as in Figure 6-11 Figure 6-13) an offset adjustment is needed. The following figure shows a +X adjustment of 4 or 0.004 in. (0.1 mm). The +X scale icon has been moved downward to the 4 (0.1) and the Delta X value reflects this adjustment (0.0040 in./ 0.100mm).
Page 205 • The Prepare for Calibration page will be displayed (Figure 6-4). Perform the steps indicated on the screen, making sure to install a build sheet, and then press the Next button. Within the Select Calibration Part Location page (Figure 6-5) select the calibration •...
Page 206 Figure 6-16: Remove and Measure Support Layer Measure support layer here (on all 4 sides) Peel support layer here Refer to Table 6-2 and determine the slice height for the model tip installed in your printer. Table 6-2: Model Tip Slice Heights Model Tip Slice Height (in) Slice Height (mm) 0.005...
Page 207 Figure 6-17: Z Offset Adjustment English units Metric units Down button for adjusting Z offset • Use the Up button to enter the value obtained in step C if this value is greater than the tip’s slice height. For example, if you measured an average of 0.012 in. (0.305 mm) for a tip with a slice height of 0.010 in.
Page 208 If a Z offset adjustment is required you will need to rebuild the calibration part. To do so: • After entering your Z offset adjustment press the Next button within the Adjust XYZ Calibration page. Your Z offset adjustment will be saved. The Finish Calibration page will be displayed (see Figure 6-19);...
Page 209 The Finish Calibration page will be displayed. Press the checkmark button within the Finish Calibration page to exit the wizard. You will be returned to the Calibration page, and “System is calibrated” should be displayed within the Calibration Status Pane (Figure 4-34).
Page 210: Touchscreen Calibration
Touchscreen Calibration Caution: A stylus pen should be used when performing this calibration to ensure precise calibration. Do not use your fingertip to perform this calibration. If a stylus pen is not available, a pencil eraser may be used. You have the option of recalibrating the printer’s touchscreen display. Extreme care must be taken when performing this calibration as an improperly calibrated touchscreen can lead to button accuracy issues.
Page 211 A dialog is displayed with instructions for recalibrating the touchscreen. Using a stylus, touch the screen in the center of the calibration point displayed. Repeat this process for the remaining calibration points (1 point for each of the 4 corners of the screen).
Page 212: Xy Home Calibration
XY Home Calibration The printer is designed to automatically perform an XY Home Calibration as part of its initialization and startup process. Each time the printer is powered on, it will automatically perform this calibration. The XY Home Calibration is responsible for finding the home position for the X and Y axes.
Page 213: Maintenance
Maintenance This chapter describes various maintenance tasks that will routinely need to be performed on the 450mc. Add Printer to Control Center Control Center software is packaged together with Insight software (see “Software” on page 41), and is installed on your workstation PC as part of the initial installation and setup process (performed by your authorized service representative).
Page 214 From the workstation's Start Menu, navigate to All Programs > Insight (installed version) > Control Center (installed version) or double-click the Control Center shortcut (if available). Figure 7-3: Open Control Center Within Control Center, select the Services tab and then click the Manage FDM Systems button.
Page 215 2 into the IP Address: field. • Select Fortus 450mc from the Type: drop-down menu. • Click the Add System button when finished. A dialog will be displayed informing you that Control Center is verifying the connection to the printer as well as the printer type.
Page 216: Install/Update Material License
Install/Update Material License The printer’s material license determines the types of materials (model and support) that can be used to build parts on the printer (see Available Material Options for material option details). The printer should have been licensed as part of its initial installation and setup process (performed by your authorized service representative).
Page 217 The Add Material License page will open. A radial progress graphic is displayed within the lower portion of the page, indicating that the printer is in License Upgrade Mode and waiting to receive the material license upgrade. The text displayed within this section of the page will update as license upgrade progress is made.
Page 218 Within Control Center, select the Services tab. Ensure that your 450mc printer is selected from the drop-down menu and then click the Update License button. (See “Add Printer to Control Center” on page 204 if you cannot select your printer from the drop-down menu.) Figure 7-8: Update License Button Location Control Center will begin establishing a connection with the printer.
Page 219 The following dialog will be displayed on the touchscreen once the license update is received. Press the checkmark button to finish installing the new material license; “Installing license” will be displayed on the touchscreen. Figure 7-10: Complete License Install Dialog Once the license install is complete you will be returned to the Materials Details page (Figure...
Page 220: Controller Software
Controller Software Controller Software can be updated using either of the methods described below; however, the Web Method is the preferred update method: Note: Updating Controller Software will erase all job files from the Job Queue (files within the Sample Queue are retained). After completing the software update, you will need to resend jobs to the printer.
Page 221 The Update Software page lists a variety of version information. The Controller Version field lists the version of Controller Software currently installed on the printer. Press the Upgrade System Software button; this will open a new page and automatically put the printer into Software Upgrade Mode, allowing it to accept the software update.
Page 222 The following is displayed on the touchscreen while the printer is in Software Upgrade Mode. A radial progress graphic is displayed within the lower portion of the page, indicating that the printer is in Software Upgrade Mode and waiting to receive the software upgrade. The text displayed within this section of the page will update as upgrade progress is made.
Page 223 From the workstation's Start Menu, navigate to All Programs > Insight (installed version) > Control Center (installed version) or double-click the Control Center shortcut (if available). See Figure 7-3 on page 205. Within Control Center, select the Services tab. Ensure that your 450mc printer is selected from the drop-down menu then click the Check for System Updates button.
Page 224 The Stratasys Update Manager application will open and will automatically check to see if your Controller Software version is current. If an update is available, it will be indicated on the screen. Click the Update button to apply the software update.
Page 225 The following dialog will be displayed on the touchscreen once the software update is received. Press the checkmark button to install the software update and reboot the printer. Figure 7-17: Upgrade Confirmation Dialog...
Page 226 Controller Software will begin to boot on the printer. The following will be displayed on the touchscreen while the software update is booting on the printer. Note: This process may take up to 15 minutes, please be patient. Figure 7-18: Printer Upgrading Once The printer reboots it will conduct its regular startup process and automatically perform an XY Home Calibration (see...
Page 227: Updating Controller Software - Cd Method
Updating Controller Software - CD Method If the printer has a weak network connection or does not allow for automatic updates, you can manually download Controller Software updates by performing the following steps: Open the Maintenance page by pressing the Maintenance button within the Navigation Bar (see Figure 7-11 on page 211).
Page 228 Note: All recent calibration data (i.e. tip offset values), printer settings/ configurations and material license information are automatically retained during the software update process. Files sent to the Job Queue are not retained. Insert the Controller Software Update CD into the workstation PC and then transfer the .upg file to a known location on the workstation's hard drive.
Page 229 Browse to the location of the .upg software update file that was transferred in step Select the .upg file to be downloaded and then click Open. Control Center will begin sending software to the printer. Progress is indicated within the bottom of the Control Center window.
Page 230 The following dialog will be displayed on the touchscreen once the software update is received. Press the checkmark button to install the software update and reboot the printer. Figure 7-23: Upgrade Confirmation Dialog...
Page 231 Controller Software will begin to boot on the printer. The following will be displayed on the touchscreen while the software update is booting on the printer. Note: This process may take up to 15 minutes, please be patient. Figure 7-24: Printer Upgrading Once The printer reboots it will conduct its regular startup process and automatically perform an XY Home Calibration (see...
Page 232: Maintenance Schedule
Welcome Kit (see Table 2-3 on page 11). Once replacements are depleted, you will need to order additional replacement items from Stratasys or your regional Stratasys office. Use the part numbers listed in this table when ordering replacement parts Table 7-1:...
Page 233: Daily Maintenance
Note: Do not attempt to remove the vacuum port screen. It is not a customer replaceable item. Contact Stratasys Customer Support or your regional Stratasys office (see “Service”...
Page 234: Empty The Purge Bin
Empty the Purge Bin The purge bin is located inside the canister bay. It catches the material that has been purged or wiped from the liquefiers and liquefier tips. The purge bin should be emptied daily, to do Open the canister bay doors. Open the purge bin door.
Page 235: Weekly Maintenance
Weekly Maintenance Vacuum the Build Envelope The purge chute is designed to catch purged material debris and pass debris into the purge bin for disposal. However, some excess material debris may fall into the bottom of the build envelope. Do not allow excess material debris to accumulate in the build envelope as this could cause damage to the printer.
Page 236 Figure 7-26: Purge Chute Access Plate Removal Remove the model side purge ledge by lifting it upward until it clears it locating pin. Repeat step 5 to remove and the support side purge ledge. Figure 7-27: Purge Ledge Removal...
Page 237 Remove the model side flicker/brush assembly by lifting it upward until it clears it locating pins. Repeat step 7 to remove the support side flicker/brush assembly. Note: If the head is positioned above the purge area it may impede your ability to remove the flicker/brush assemblies.
Page 238 Inspect the flicker portion of the flicker/brush assemblies. The top edge of the flicker should be straight and must not contain excessive notching/wear. A small amount of wear is acceptable (see Figure 7-29). Figure 7-29: Flicker with Unacceptable Wear Inspect the brush portion of the flicker/brush assemblies. Brush bristles must not show evidence of wear (i.e.
Page 239 Reinstall the support side flicker/brush assembly by placing the assembly onto its locating pins and sliding the assembly downward. Repeat step 14 to reinstall the model side flicker/brush assembly. Reinstall the support side purge ledge by placing the purge ledge onto its locating pin and sliding the purge ledge downward.
Page 240: Quarterly Maintenance
Quarterly Maintenance Clean the Tip Sensor Plunger Hot Surface: Components can be hot; never touch the tip sensor plunger with your bare hands. It is recommended that you remove/replace the tip sensor plunger when the printer is powered OFF or has been allowed to cool thoroughly. Material debris can occasionally accumulate on the top of the tip sensor plunger.
Page 241: As Needed Maintenance
As Needed Maintenance Replace an Oven Bulb Hot Surface: Bulbs are hot; never touch bulbs with your bare hands. Always wear safety gloves (provided in the Welcome Kit) when changing bulbs. It is recommended that bulbs be removed/replaced when the printer is powered OFF.
Page 242: Clean The Printer
Clean the Printer Cleaning the Exterior Surface of the Printer The printer’s exterior surfaces (doors and panels) may accumulate dust and periodically require cleaning. Exterior doors and panels, with the exception of the oven window and touchscreen display, can be cleaned using a slightly damp microfiber cloth (supplied in the Welcome Kit).
Page 243 Figure 7-33: Removing Oven Window Gently clean the exterior surface of the tempered glass pane using a slightly soapy warm water solution, and a microfiber cloth (supplied in the Welcome Kit). Open the oven door and repeat step 5 to clean the interior surface of the tempered glass pane.
Page 244 Cleaning the Touchscreen Display CAUTION: Using a cleaner which contains ammonia and/or alcohol can damage the touchscreen. Only a suitable LCD cleaning solution and microfiber cloth (included in the Welcome Kit) should be used to clean the touchscreen display. As needed, to remove smudge marks and buildup, clean the touchscreen display using the LCD cleaner and microfiber cloth provided in the Welcome Kit.
Page 245: Troubleshooting
East, & Africa (9:00 AM - 5:00 PM) If needed, you can write to Customer Support North America at: Stratasys, Inc. Customer Support 7665 Commerce Way Eden Prairie, MN 55344 USA Before calling for service or supplies, always have the following information ready: Your printer’s software version (see...
Page 246: Warnings And Errors
Warnings and Errors If the printer detects an issue that may affect a build, it will be indicated within the Dashboard. The Build State button will turn yellow or red depending on the severity of the warning/error. Pressing the Build State button will open a dialog indicating the reason(s) for the warning/error.
Page 247 Support material does not match selected job The type of support material loaded in the printer does not match the support • material required to build the selected job. • Correct condition - change the support material loaded in the printer to the type of support material required to build the job.
Page 248: Errors Preventing A Build From Starting
Errors Preventing a Build from Starting Close the door • Indicates that the oven door is open. • Correct condition - close the oven door. Close the cover • Indicates that the top cover is open. • Correct condition - close the top cover. Load model material •...
Page 249 Ensure that the platen is free of material debris and then reposition the build sheet on the platen. Wait for the printer to achieve sufficient vacuum. If you are still unable to achieve sufficient vacuum, install a new build sheet. Contact Stratasys Customer Support or your regional Stratasys office if after performing these steps you are still unable to achieve sufficient vacuum (see “Getting Help”...
Page 250: Load Errors
“Removing Canisters” on page 121) and • reload the canister (see “Loading Material to the Liquefier Tips” on page 113). If the error persists, contact Stratasys Customer Support or your regional Stratasys office (see “Getting Help” on page 236 for contact information).
Page 251 “Removing Canisters” on page 121). Reload the canister (see “Loading Material to the Liquefier Tips” on page 113). If the error persists, contact Stratasys Customer Support or your regional Stratasys office (see “Getting Help” on page 236 for contact information).
Page 252: Build Pause Warnings
• Material to the Liquefier Tips” on page 113 for instructions). Contact Stratasys Customer Support or your regional Stratasys office if canister load fails again (see “Service” on page 1 for contact information). If material cannot move freely, contact Stratasys Customer Support or your •...
Page 253 Status Indicator (within the Information Bar) will disappear once sufficient vacuum is achieved. If you are still unable to achieve sufficient vacuum, install a new build sheet. Contact Stratasys Customer Support or your regional Stratasys office if after performing these steps you are still unable to achieve sufficient vacuum (see “Getting...
Page 254: Build Abort Warnings
41). If you encounter the same error when rebuilding with the reprocessed file, attempt to build a different file to see if the error occurs again. If so, contact Stratasys Customer Support or your regional Stratasys office (see “Getting Help” on page 236 for contact information).
Page 255 Dryer pressure lost Printer unexpectedly lost dryer pressure. • • Correct condition - contact Stratasys Customer Support or your regional Stratasys office (see “Getting Help” on page 236 for contact information). Unknown abort An unexpected error occurred in which the printer was unable to map the cause of •...
Page 256: Finding A Remedy
(load time-out canister (see “Removing Canisters” on page 121 reached) “Loading Material to the Liquefier Tips” on 113). If the error persists, contact page Customer Support or your regional Stratasys office (see “Getting Help” on page 236 contact information).
Page 257 224.) A small piece of material Contact Customer Support or your regional may have been sucked into Stratasys office (see “Getting Help” on page 236 the vacuum line. for contact information). The vacuum port’s debris Clean the debris screen (see “Clean the Platen”...
Page 258 Check oven door seal and verify that it is securely affixed to oven door frame and does not exhibit cuts/tears. If excessive wear is visible, Contact Customer Support or your regional Stratasys office (see for contact “Getting Help” on page 236 information).

Stratasys Fortus 450mc User Manual

1 Service and Support

2 Setup and Installation

3 System Components

4 User Interface

5 Operating the Printer

6 Calibration

7 Maintenance

8 Troubleshooting

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