1. Manuals
  2. Brands
  3. Z Corporation Manuals
  4. 3D Printers
  5. Z 406
  6. User manual

Z Corporation 406 User Manual

3d color printer
Hide thumbs Also See for 406:
Table of Contents

Advertisement

Quick Links

Download this manual
Z406 System User Manual
September 2004
®
Z
406 3D Color Printer User Manual
Z Corporation
Type II
Revision D
© 2003-2004 Z Corporation
Part Number 09520

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 406 and is the answer not in the manual?

Questions and answers

Related Manuals for Z Corporation 406

Summary of Contents for Z Corporation 406

  • Page 1 Z406 System User Manual September 2004 ® 406 3D Color Printer User Manual Z Corporation Type II Revision D © 2003-2004 Z Corporation Part Number 09520...

  • Page 2: Table Of Contents

    PART CONTAINING AN OPENING OR HOLLOW AREA .........30 3.2.2 PART CONTAINING OVERHANGS ................30 CHECKING BUILD SETTINGS ................31 3.3.1 POWDER SETTINGS ....................32 PRINTING THE BUILD ..................33 POST PROCESSING THE PART................34 REMOVING THE FINISHED PART..............34 Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 3 Z406 System User Manual Z Corporation DEPOWDERING THE PART ................35 4.2.1 ZD4I DEPOWDERER DETAIL...................36 4.2.2 ZD4 DEPOWDERER DETAIL..................39 4.2.3 USING THE EXTERNAL VACUUM BAG LINER ............42 DRYING THE PART.....................45 4.3.1 STARCH AND PLASTER PARTS................45 4.3.2 ZCAST PARTS ......................45 4.3.3 POST PROCESSING TOOLS ...................46 INFILTRATING THE PART ..................49...
  • Page 4 11 Z406 SYSTEM DETAILS ..................110 11.1 DESCRIPTION OF REAR I/O PANEL............... 110 12 SYMBOLS USED..................... 111 12.1 SYSTEM SPECIFICATIONS ................112 12.2 MATERIAL STORAGE PRECAUTIONS ............113 12.3 ERROR CODES ....................113 13 INDEX........................117 Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 5 Z406 System User Manual Z Corporation APPENDIX I ZCast 501 Design Guide....…………………………………………………..119 www.zcorp-users.com...
  • Page 6 Figure 3: Illustration of Z406 System Print Orientations ............11 Figure 4: The Z406 3D Printer ....................12 Figure 5: Gantry and Printer Assembly................... 13 Figure 6: Z406 System Components ..................14 Figure 7: Z406 Control Panel....................18 Figure 8: Service Station Detail ..................... 24 Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 7 You agree to indemnify, defend and hold Z Corporation and its officers, directors and employees harmless from and against any and all claims, losses, damages, costs and expenses resulting from any use of the Equipment other than for the production of early-stage appearance models and prototypes.

  • Page 8: Your Z406 System

    8. Changing Material Systems. This section will guide you through changing binder and powder systems. 9. Troubleshooting. This section offers some troubleshooting tips. 10. Z406 System Details. This section contains system specifications about the Z406 3D Printer. 11. Index. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 9: How It Works

    Z406 System User Manual Z Corporation 1.1.2 HOW IT WORKS The Z406 System is based on the Massachusetts Institute of Technology’s patented 3DP™ (3D Printing) technology. The software first converts a three-dimensional design built using 3D CAD into cross-sections or slices that can be between 0.003”...

  • Page 10: Figure 2: The Z406 3D Printer Shelling And Infrastructure Features

    “slow” axis (the gantry direction of travel) and laminated layers along the z-axis. (See figure 3). This discussion only applies to untreated parts; once parts are infiltrated, they uniformly take on the strength characteristics of the infiltrating material. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 11: Figure 3: Illustration Of Z406 System Print Orientations

    Z406 System User Manual Z Corporation z-axis Less Strong x-axis Most Strong Strong y-axis Figure 3: Illustration of Z406 System Print Orientations Accuracy. The accuracy of the system depends on the materials you choose. You can employ the anisotropic scaling feature in the software to adjust for expected shrinkage and bring your parts into true scale.

  • Page 12: The Parts Of The Z406 3D Printer

    1.2 THE PARTS OF THE Z406 3D PRINTER Fast Axis Rail Scraper Blade Service Station Top Cover Carriage Feed Box Build Box Control Panel Waste Fluid Clear Binder Solution Wash Fluid Powder Overflow Bin Color Binder Solution Figure 4: The Z406 3D Printer Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 13: The Parts On The Printer Assembly And Gantry

    Z406 System User Manual Z Corporation 1.3 THE PARTS ON THE PRINTER ASSEMBLY AND GANTRY Grease Fittings Carriage Cover Scraper Cover Snowplows Scraper Print Heads Figure 5: Gantry and Printer Assembly www.zcorp-users.com...

  • Page 14: Z406 System Components

    Z Corporation Z406 System User Manual 1.4 Z406 SYSTEM COMPONENTS ZD4i Depowdering Station Z406 3D Printer Figure 6: Z406 System Components Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 15: Printing A Part Overview

    Z406 System User Manual Z Corporation 1.5 PRINTING A PART OVERVIEW Printing a part using the Z406 3D Printer is fast, easy, clean and fully compatible with an office environment. This manual will show tips on how to print the most challenging parts, but for most purposes, printing a part is as simple as 1-2-3.

  • Page 16: Part Infiltration

    By seeing how quickly it wicks into the part you will be able to judge where and how quickly to move the Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 17 Z406 System User Manual Z Corporation tip of the bottle while applying the CA, being sure not to apply the CA to the same place more than once. 1.6.2.2 When Using a Z-Max and Z-Snap Epoxy • If the part has delicate features, infiltrate them last as the feature will be less strong after being infiltrated until the epoxy begins to cure.

  • Page 18: Preparing The Z406 3D Printer

    Moving the gantry from left communication. to right allows you to spread powder over the build box. Holding down this button will result in continuous spreading of powder. Figure 7: Z406 Control Panel Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 19: Preparing The 3D Printer

    Z406 System User Manual Z Corporation 2.2 PREPARING THE 3D PRINTER If the printer is off, switch it on by pressing and releasing the power ON/OFF switch. The gantry will move slowly as it orients itself. We recommend that you leave the printer on at all times—in sleep mode the printer will exercise the print heads during periods of inactivity to prevent clogging.

  • Page 20: Filling The Feed Box With Powder

    Use the tamper to level the powder but do not apply any pressure. WARNING: Use only powder supplied by Z Corporation. Use of any other material may impact the performance and/or safety of your Z406 System and will void warranty of equipment.
  • Page 21 Z406 System User Manual Z Corporation 5. Vacuum up any powder spilled on the top deck. 6. Move the gantry so that it is above the feed piston. Press and hold the feed up button until the surface of the powder in the feed piston is even with the top deck.
  • Page 22 4. Spread powder over the build plate as you normally would over the build piston. 5. Select the ‘Fill Bed’ option under the 406Service menu in the software to spread powder automatically over the build box. 6. Vacuum up the powder on the top deck. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 23 Z406 System User Manual Z Corporation Technical Tip - Keep powder containers closed when not in use to keep powder dry. Scoop powder carefully to minimize airborne powder. Make sure that you carefully vacuum up excess powder. It only takes a minute, and the tidier the machine is, the less often it will need maintenance! Carefully read the Material Safety Data Sheet for powder before use.

  • Page 24: Cleaning The Service Station

    The service station cleans the array of the print heads during printing. The service station should be cleaned before every build. This will remove any deposits of powder. Make sure parking caps are dry before beginning the build. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 25 Z406 System User Manual Z Corporation To clean the service station: 1. Move the gantry to the left of the top deck by pressing the ‘Spread’ button. 2. Lift the top cover. 3. Manually lift up the metal plate covering the service station.

  • Page 26: Checking Fluid Levels

    If the binder bottles and wash fluid are less then half full, refill them. Empty the waste bottle before each build. Waste should be treated in accordance with local regulations. Wash Fluid Binder Solution Waste Fluid Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 27: Checking Powder Overflow Bin

    Z406 System User Manual Z Corporation 3. Unscrew the lid covering the binder or wash fluid bottle. 4. Fill the bottle up with binder or wash fluid. Replace the lid. 5. Close front cabinet doors. WARNING: Do not recycle waste solution.

  • Page 28: Putting The Machine Online

    CHECK FLUID LEVELS! Make sure you have enough fluid to complete the build. Make sure the waste bottle is empty. Keep your Z406 3D Printer as clean as possible. The cleaner it is, the better it will function. Carefully read the Material Safety Data Sheet for binder and wash fluid before use. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 29: Using Zprint Software

    Z406 System User Manual Z Corporation USING ZPRINT SOFTWARE This chapter will briefly explain how to set up the build, check the settings, and print. For more information about the features in the ZPrint Software, please refer to the ZPrint Software User Manual.

  • Page 30: Orienting The Part

    Cylindrical features will be more accurate when their axis is parallel z-axis. example, if you were to print a bottle, the bottle would best be printed standing up, with the mouth of the bottle facing the top of the printer. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 31: Checking Build Settings

    Z406 System User Manual Z Corporation CHECKING BUILD SETTINGS ALWAYS check build settings before printing: 1. Choose the ‘3D Print Setup’ option from the File menu (or toolbar). 2. Check that selected printer, powder type, powder settings for the build are correct.

  • Page 32: Powder Settings

    3. ZCast Material System The ZCast material system has been found to remain dimensionally accurate during printing and thus, the recommended anisotropic scaling values are one (1) in all axes. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 33: Printing The Build

    Z406 System User Manual Z Corporation 3.3.1.2 Saturation Values The saturation values determine how much binder is placed on the powder to print the part. The part is made up of two areas, the shell and the core, as described in Section 1.1.2, How It Works. Thus, there are two saturation values, one for the shell and another for core.

  • Page 34: Post Processing The Part

    WARNING: When performing any vacuuming operation, use the vacuum provided as part of the Z406 System. Vacuuming powder can generate static electricity, and use of a non-grounded vacuum will create static charges, which may affect the operation of the Z406 System and harm the operator. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 35: Depowdering The Part

    Z406 System User Manual Z Corporation 4.2 DEPOWDERING THE PART 1. Place parts inside depowdering unit. 2. Attach and turn on the vacuum cleaner. 3. Using compressed system included depowdering station, remove excess powder that remains concave surfaces. Technical Tip - The air pressure on your depowdering station is adjustable.

  • Page 36: Zd4I Depowderer Detail

    Z Corporation Z406 System User Manual 4.2.1 ZD4I DEPOWDERER DETAIL Vacuum Nozzles Air Gun External Compressor Vacuum 1. Turn on air compressor. ON/OFF Switch Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 37 Z406 System User Manual Z Corporation 2. Turn external vacuum on. ON/OFF Switch 3. Open the top cover, place part(s) in depowderer and close top cover. www.zcorp-users.com...
  • Page 38 Z Corporation Z406 System User Manual 4. Place hands in depowdering unit. Check air pressure and adjust on the air compressor. 5. Depowder your part(s). Press down on airgun knob to release air. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 39: Zd4 Depowderer Detail

    Z406 System User Manual Z Corporation 4.2.2 ZD4 DEPOWDERER DETAIL Vacuum Handles to Lift Nozzles Top Cover Air Pressure Control ON/OFF Switch Vacuum Suction Compressor Control External Vacuum www.zcorp-users.com...
  • Page 40 Vacuum Suction Control 2. Lift top cover, place parts in depowderer and close top cover. 3. Place hands in depowdering unit. Test air pressure of the air gun. Adjust air pressure if needed. Air Pressure Control Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 41 Z406 System User Manual Z Corporation 4. Depowder your part(s). Press down on airgun knob to release air. www.zcorp-users.com...

  • Page 42: Using The External Vacuum Bag Liner

    4.2.3 USING THE EXTERNAL VACUUM BAG LINER Z Corporation has developed an accessory to the vacuum cleaner to assist the user with the removal of the vacuum bag from the canister. The vacuum cleaner liner is easy to use and will prevent ripping and tearing of the blue vacuum bag once it is full of powder.
  • Page 43 Z406 System User Manual Z Corporation 3. Install the vacuum bag inside the vacuum cleaner liner. 4. Fold the handles of the vacuum cleaner liner up onto the top of the empty vacuum bag. 5. Install the vacuum filter. www.zcorp-users.com...
  • Page 44 7. Once the vacuum bag is full, remove the motor and filter. Remove the vacuum bag from the canister by lifting the vacuum cleaner liner handles straight up. 8. Rotate the vacuum canister, in the direction of the inlet, from under the vacuum bag. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 45: Drying The Part

    Z406 System User Manual Z Corporation 9. Once the vacuum cleaner inlet tube is disengaged from the vacuum bag, you can lift and remove the bag and liner. 4.3 DRYING THE PART 4.3.1 STARCH AND PLASTER PARTS To infiltrate starch or plaster parts with wax, the parts must be hot and dry. Preheat part at 165 C) in the Automated Waxer or in a drying oven, remembering that drying time and part wall thickness are directly related.

  • Page 46: Post Processing Tools

    There are six tools included in the accessories kit that are used to assist the user with gross depowdering and cleaning of the part. 1. Wide Blade Utility Scraper: This part is extremely useful in moving powder from the build chamber or deck surface back into the feed chamber. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 47 Z406 System User Manual Z Corporation 2. Polypropylene Scraper: When gross depowdering a bulky part, such as the engine block, the user may choose to carve powder away from the part instead of moving it away with either the vacuum or their hands.
  • Page 48 Z Corporation Z406 System User Manual 6. Soft Acid Brush: This part can also be used to remove caked powder from hard to reach areas and the soft bristles make this brush perfect for delicate features. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 49: Infiltrating The Part

    For additional information on how Z Corp. customers are utilizing our line of infiltration products, call us at Z Corporation, or visit our user group website at www.zcorp- users.com.
  • Page 50 The resin will cure at room temperature after 24 hours. For more information on the uses of Z-Max epoxy, please refer to the technical data sheet that can be found on the User Group Website at www.zcorp-users.com. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 51: Using Z-Bond Cyanoacrylate

    Z406 System User Manual Z Corporation 5.1.2 USING Z-BOND CYANOACRYLATE Z-Bond cyanoacrylate is an extremely fast setting, low viscosity, general-purpose infiltration resin. This resin is designed to rapidly strengthen parts. Z-Bond is a one part, user friendly, no-odor, non- blooming resin that may eliminate the need for special ventilation. This resin is easily sanded and enhances the vibrancy of color parts.

  • Page 52: Using Z-Snap Epoxy

    Clean up of the spraying apparatus is simple with solvents found at a local hardware store such as acetone or denatured alcohol. For more information on the uses of Z-Snap epoxy, please refer to the technical data sheet that can be found on the User Group Website at www.zcorp-users.com. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 53: Using Paraplast X-Tra Wax

    Z406 System User Manual Z Corporation 5.1.4 USING PARAPLAST X-TRA WAX Paraplast X-Tra is a low viscosity, general purpose, infiltration wax formulated to melt at very low temperatures (122°F or 50°C) and strengthen both starch and plaster parts. This material cures rapidly and enhances the vibrancy of color parts.

  • Page 54: Applications

    Z Corporation Z406 System User Manual 6 APPLICATIONS In this section, you will learn various ways to maximize the versatility of your Z Corporation 3D Printer through the implementation of advanced part processing techniques. Please visit the User Group Website at www.zcorp-users.com...

  • Page 55: Gluing Multi-Piece Parts

    Z406 System User Manual Z Corporation 6.1 GLUING MULTI-PIECE PARTS Instructions: 1. Remove, depowder, and dry parts out of printer as described in Section 4, Post Processing the Part. 2. Sand seams prior to gluing and check fit of any assemblies. Sanding small parts or parts with curved surfaces can be made easier with a small, air-powered glass air etching/sanding kit.

  • Page 56: Painting Parts

    5. Apply 10 light coats of Sher-wood sanding sealer by spraying. 6. Apply laquer primer by spraying. A hand-held, air sprayer will be necessary for the highest quality surface finish. 7. Apply colored lacquer gloss paint to achieve the shiny, plastic-like finish. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 57: Polyester Resin

    (HVAC) of the interior space. Prototype ducting produced on the Z Corporation 3D Printer can be used for form and fit testing, as well as air-flow testing across a range of temperatures and humidity. The parts...

  • Page 58: Electroplating

    Contacts If you would like to have a part plated, we recommend contacting Jason Channell at Associated Electroplaters, Inc. Phone Number (248) 547-5520. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 59: Water Transfer Printing

    The process is also referred to as: Dip Printing, Immersion Printing, 3D Printing, or Cubic Printing. Process Description Part preparation: Print the chosen part using any Z Corporation plaster series powder. The part should be infiltrated with cyanoacrylate or epoxy resin. Sand the part prior to dip printing. For an improved finish, the part can be sprayed with a spray-filler (such as Plasti-kote Sandable Primer or Spraila AutoK) and sanded again.
  • Page 60 Top Coating: The parts are clear coated or varnished to protect the printed surface. A varying degree of gloss can be achieved by using different top coats. Polishing completes the process. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 61 Z406 System User Manual Z Corporation Presenting: The finished parts can now be used. The surface can be very durable and scratch resistant – depending on the top coat used, so the finish will stand up to many functional applications.

  • Page 62: Investment Casting

    The ZW4 or ZW3 Waxer and hand application methods have both been successfully used on Z Corporation parts. Some users briefly blast their parts with a consumer hairdryer or heat gun to quickly heat and re-cool the wax to improve surface finish.
  • Page 63 Z406 System User Manual Z Corporation 2. When using wax patterns assembled on wax runners, the tree assembly should go though an autoclave process for 10 minutes before being put in the firing oven. The autoclave should be F (193 C) and 130 psi (9 bars).

  • Page 64: Flexible Parts

    5. Excess material can be removed with a paper towel. 6. Let the parts sit on wax paper to cure. Make sure excess material is not dripping into a puddle on the wax paper. This will be difficult to remove after it cures. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 65: Thermoforming

    PVC, polystyrenes, polyesters, acrylics etc. in this process. Making light gauge (plastic less than 0.060”) thermoforming molds for prototype parts is an ideal use for Z Corporation 3D Printers and plaster powder. For more information regarding the process and the industry, check out SPI’s website: www.plasticsindustry.org/index.htm...
  • Page 66 Z Corporation Z406 System User Manual The instructions below are specific to molds produced on Z Corporation Printers. It is assumed that the user currently owns a thermoforming system and is familiar with using molds created from other techniques for creating thermoformed parts.

  • Page 67: Rtv Molding

    Master patterns are classically sanded and polished regardless of the method of their production. This makes parts printed using Z Corporation technology a perfect fit due to the ease in which their surface finish can be enhanced.
  • Page 68 Instructions: 1. Remove, post-process and infiltrate the printed part from the Z Corporation 3D Printer. Infiltration with cyanoacrylate or epoxy is recommended. The use of wax is not recommended because the part will not accept a primer later in the finishing process and is not easily sanded.
  • Page 69 Z406 System User Manual Z Corporation 4. Sand the filler with 220-grit sand paper. The finish at this point should be completely smooth with no surface defects. 5. Prime the part with a sprayable / sandable primer. Z ® Corporation recommends Plasti-kote Sandable Primer for ®...
  • Page 70 5 Inhibition – The failure of silicone to cure within the recommended cure time. Surfaces of the mold will typically remain gummy, uncured or stick to the master pattern. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 71 Z406 System User Manual Z Corporation Preparing and Pouring the Silicone Mold Preparing the silicone is relatively easy but must be performed properly to ensure a good mold. Pay close attention to the mix ratio of the two components of the silicones. Be sure to prepare a large enough volume to completely encase the pattern.
  • Page 72 Printer, which will reduce the overall time it takes to get your final cast part. Whether a Z Corp. 3D Printer is your complete prototyping solution or just a piece of it, there is no tool more valuable at saving the things most valuable, your time and money. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 73: Maintenance

    Z406 System User Manual Z Corporation 7 MAINTENANCE Maintenance Action: Frequency: 1. Change Print Heads Every 30 Billion Pixels (each print head in monochrome mode), 15 Billion Pixels (each print head in color mode), or when needed 2. Flush Binder If not used regularly 3.

  • Page 74: Changing The Print Heads

    3. Wait for the printer to finish moving and the front panel lights to change to slowly blinking. This indicates that it is safe to remove the print heads from the carriage. 4. Lift the carriage cover. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 75 Z406 System User Manual Z Corporation 5. To remove the print head, lift the blue handle and pull up gently. Repeat for all four print heads. PLEASE NOTE: All print heads should be changed at the same time to ensure proper print head alignment.

  • Page 76: Aligning The Print Heads

    3. Close the top cover and put the printer online. 4. Select the ‘Alignment’ option under the 406Service menu. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 77 Z406 System User Manual Z Corporation 5. Click on ‘Print Test Pattern’ in the alignment dialog box. It will take a minute to initialize the printer, send the pattern, and print. 6. For each print head to be aligned, there are two numbers to be chosen. To do this, look at the alignment pattern and decide which pattern looks best.
  • Page 78 The three short lines are interleaved with the long lines. Examples of problem reticules: Slow axis too low Good slow axis reticule. Slow axis too high The three short lines are interleaved with the long lines. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 79 Z406 System User Manual Z Corporation 7. Choose ‘Edit Alignment’ alignment dialog box. Technical Tips – If you have printed problem reticules, and are not able to choose the best aligned pattern, choose ‘Set Defaults’ under the Edit Alignment option and continue alignment procedure.
  • Page 80 If you need to work in another dialogue box, click the close window button (X located on the upper right-hand corner), NOT THE DONE OR CANCEL button. You may continue purging. Complete the procedure by pressing the ‘Online’ button on the printer when complete. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 81 Z406 System User Manual Z Corporation 14. Unpark the gantry to expose the service station. 15. Clean the service station of any HP ink residue as described in Section 2.2.2, Cleaning the Service Station. Clean the deck and fast axis rails. Oil the fast axis rails.

  • Page 82: Color Alignment

    2. Spread powder onto the build piston. 3. Choose ‘Color Alignment’ under the 406Service menu. 4. Choose to print the ‘Pattern’ to print two layers. 5. The pattern shown on the left will print. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 83 Z406 System User Manual Z Corporation Look at the left and right edges of the squares. Look for the least color fringing on the sides. For each color choose the corresponding square in the dialog box. In this case, the ‘0’...

  • Page 84: Flushing The Binder

    For instructions on how to assemble the grease gun, please refer to the manufacturer’s instructions on the packaging. The software will alert you as to when to grease the fast axis if the Maintenance Reminders feature is enabled. Grease Fittings Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 85: Greasing The Slow Axis

    Z406 System User Manual Z Corporation 7.6 GREASING THE SLOW AXIS Apply grease (supplied in the tool kit) to the two grease fittings located on the slow axis rails located in the back of the printer. For instructions on how to assemble the grease gun, please refer to the manufacturer’s instructions on the packaging.

  • Page 86: Oiling The Snowplows

    2. Put printer offline and lower build piston. 3. Put printer online. 4. Unpark the carriage so that the gantry can be manually moved. 5. Clean bottom surface with moist paper towel and dry. Move gantry manually if needed. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 87: Greasing The Piston Screws

    Z406 System User Manual Z Corporation 6. Press ‘OK’ on the software dialog box to repark. 7.9 GREASING THE PISTON SCREWS 1. Lower both the feed and build pistons all the way down. 2. Turn off and unplug the printer.

  • Page 88: Replacing The Scraper Blade

    To replace, follow the instructions outlined below. 1. Remove the scraper cover. 2. Unscrew the scraper blade holder using an Allen wrench sized 3/32. 3. Remove the scraper blade holder. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 89 Z406 System User Manual Z Corporation 4. Loosen the scraper blade by pushing the blade so that it no longer adheres to the side of the scraper blade holder. 5. Remove the scraper blade. 6. Remove adhesive cover from the new scraper blade.
  • Page 90 Z Corporation Z406 System User Manual 8. Using the Allen wrench tool, push scraper blade against the wall to ensure adhesion to wall. 9. Replace and reattach the scraper. 10. Replace the scraper cover. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 91: Changing The Binder Supply

    Z406 System User Manual Z Corporation CHANGING THE BINDER SUPPLY Changing the binder supply allows you to change between monochrome and color mode. To change binder supplies, choose the ‘Change Binder Supply’ option under the 406Service Menu. The software will inform you when the printer is finished changing binder supplies.

  • Page 92: Changing Material System

    1. Remove all powder from the feed and build envelopes. Place powder in a sealed container prevent absorption moisture into powder. 2. To prevent material contamination vacuum off any remaining powder from the feed and build plates, and the top deck. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 93 Z406 System User Manual Z Corporation 3. Remove the powder from the overflow bin and empty into a sealed container. 4. To prevent any material contamination, vacuum any remaining powder in the overflow bin. 5. Change binder solution (color and clear binder) if necessary.
  • Page 94 Section 2.2.1, Filling the Feed Box with Powder. Change Powder Type 7. Open or import your file into the ZPrint Software using version 6.0 or higher. 8. Open up the 3D Print Setup dialog box. 9. Change powder type in ZPrint Software. Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 95 Z406 System User Manual Z Corporation Recommended Saturation Values 10. Override or approve all powder parameters. 11. Then proceed to printing your part. www.zcorp-users.com...
  • Page 96 15. For ZCast Powder users, remove scraper assembly if you are changing over to ZCast powder. Or reattach scraper assembly if using plaster or starch material. Use the 3/32 Allen wrench tool that accompanied the Z406 ZCast Kit. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 97: Using Zcast Powder

    Please review the guide along with safety issues before continuing with this product. Upon review, contact Z Corporation Applications Team for information about a free online training session by sending an email entitled “ZCAST ONLINE TRAINING SEMINAR”...
  • Page 98 Use a straight edge to view the clearance between the build plate and the top deck. Adjust the build up and down arrows on the control panel so that the clearance is approximately 1/16 in (1.6 mm) below the top deck. Build Plate Deck adjustment with straight edge Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 99: Loading Zcast Into The Z406 3D Printer

    9.1.4 SETTING UP ZCAST BUILDS Follow best practices for setting up a build in Z Corporation 3D Printers found in the ZPrint Software User Manual. Take into consideration part orientation verses strength tradeoffs and use fixtures when applicable to control the reduced effects of ‘squash’. For more information, please refer to the ZCast Direct Metal Casting –...

  • Page 100: Recycling

    Dispose of ZCast powder according to local and state regulations. 9.1.10 QUESTIONS AND SUPPORT If you have any questions regarding this product, contact the Z Corporation Applications Team for technical support at (781) 852-5005 or via email at applications@zcorp.com.

  • Page 101: Software Setup

    To check the version of ZPrint Software currently installed select “About Z Corporation Software” from the Help Menu. If ZPrint version 6.2 or higher is not installed contact the Z Corporation Service Department for an upgrade at service@zcorp.com.
  • Page 102 To create a fixture that completely cradles the entire part, raise the part in the z-axis at least 0.5” (12.7 mm) from the bottom of the build plate in the ZPrint Software. If the part is not raised it will not be fully support by the fixture after depowdering. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 103: Part Removal And Post Processing

    Z406 System User Manual Z Corporation • Go to the “3D Print Setup” window under the File Menu and select zp250 powder as the powder type. 9.2.3 PART REMOVAL AND POST PROCESSING 1. When printing parts that can be manually handled, allow the part and fixture to dry in the build bed for at least 2 hours before removing.
  • Page 104 6. Apply Z-Snap or Z-Max epoxy to the rest of the part. Do not apply excess epoxy as pooling will occur. Several thin coats are better than one thick coat. Use a paper towel or tissue paper to remove excess epoxy that may have pooled on the surface of the part. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 105: Infiltration Addendum

    Z406 System User Manual Z Corporation 6. Let the part sit for 30 minutes at room temperature to allow excess Z-Snap epoxy to drain or wick into the fixture. Z-Max parts should sit at ambient for 1 hour prior to the oven cure.

  • Page 106: Troubleshooting

    If the error and power light come on but nothing happens after that, shut the machine off and turn it back on again. The machine should come online. But if it does not, please contact the Z Corp. Service Department. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 107: My Starch-Based Parts Are Unusually "Cakey

    Z406 System User Manual Z Corporation 10.5 MY STARCH-BASED PARTS ARE UNUSUALLY “CAKEY” • Is the saturation too high? If your parts (especially bulky parts) are unusually difficult to depowder, too much moisture has moved from the part into the immediately surrounding powder. The first is that you may have the saturation levels set too high for this type of part.

  • Page 108: Air Entered The Fluid Lines

    2. Insert the syringe into the septum and let the syringe fill until there are no more air bubbles. Syringe Septum 3. Remove syringe and place on a paper towel to prevent binder from dripping. 4. Empty the syringe. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 109: Communication Errors Between Print Head And Printer

    Head ROM errors) or when it is dirty. To clean the pogo pins, follow the instructions below: 1. Use the alcohol swabs which can be ordered from Z Corporation (part number 12073). 2. Remove the alcohol swab from the packaging.

  • Page 110: Z406 System Details

    The keyboard connection is PS/2 style compatible. Ethernet Connector – The Ethernet connector allows the printer to be network compatible. For more information contact the Z Corporation Service Department at (781)852-5050 or via email at service@zcorp.com. Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 111: Symbols Used

    Z406 System User Manual Z Corporation 12 SYMBOLS USED The following symbols are used on the Z406 3D Printer: This is the international symbol for ‘standby power’. It is used on the Z406 3D Printer power switch. The Z406 3D Printer is partially powered as soon as you plug it in.

  • Page 112: System Specifications

    The expected lifetime of the battery is in excess of five years. Replacement will be handled by your Z Corporation customer service representative. FCC Notice: Note: this equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules.

  • Page 113: Material Storage Precautions

    Z406 System User Manual Z Corporation 12.2 MATERIAL STORAGE PRECAUTIONS Carefully read the Material Safety Data Sheets (MSDS) before using any Z Corporation materials. Material Storage Usage Powder Store powder on pallets in a cool, dry, Use of powder in...
  • Page 114 MOVER: axis %d destination out of range – Rezero problem Obstructed or sticky axis. Clean and lubricate the indicated axis - 0 = slow; 1 = fast (Error 2303-2305) 2303 MOVER: axis %d excessive position error Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 115 Z406 System User Manual Z Corporation 2304 MOVER: axis %d timed out completing move 2305 MOVER: axis %d didn't settle 2400 REZERO: axis %d can't find end of travel 2501 SHAKER: bad layer number 2600 HEAD: bad ROM format 2700...
  • Page 116 BINDER: weak pressure from pump %d – Leak, bad pump, or out of binder with indicated fluid line – 0 = clear; 1 = yellow; 2 = 4700 magenta; 3 = cyan. 4702 BINDER: invalid plumbing type %d Z Corporation Service (781)852-5050/(877)88-ZCORP...

  • Page 117: Index

    Z406 System User Manual Z Corporation 13 INDEX Color Alignment, 82 Control Panel, 18 3D Print, 33 Depowdering Parts, 35 Drying Parts, 45 Aligning the Print Heads. See Alignment Alignment, 76 Color, 82 Edit, 79 Electroplating, 58 Alignment Plate, 76...
  • Page 118 Printing the Build, 33 ZD4i Depowerer, 36 ZPrint Software, 29 Collision Detection, 31 Removing finished parts, 34 Install, 29 RTV Molding, 67 Part Orientation, 30 Printing, 33 Setting Up, 29 Z-Snap Epoxy, 52 Saturation Values, 33 Z Corporation Service (781)852-5050/(877)88-ZCORP...
  • Page 119 Appendix I ® ZCast 501 Direct Metal Casting DESIGN GUIDE September 2004 ® 09521 ZCast Design Guide Rev E...
  • Page 120 Appendix I Table of Contents Introduction ................. 4 General Safety................5 Safety Precautions ......................5 Safety Symbols ......................... 5 Safety Instructions......................6 ZCast Advantages ..............10 The Material ........................10 Design Freedom......................10 Locating a Foundry ..............12 Foundry Trial Parts......................12 Designing with ZCast –...
  • Page 121 Appendix I Seal – ............................31 Clamp............................32 Pour............................32 Pouring Metal................33 Metal Types........................33 Material Handling..............34 Storage..........................34 Disposal........................... 34 Powder Recycling ......................34 10 Finishing ................... 35 10.1 De-molding ........................35 10.2 Secondary Operations....................35 10.3 Ovens ..........................

  • Page 122: Introduction

    ZCast. But it also covers some of the basics of sand casting to help familiarize those with less casting experience. Z Corporation is dedicated to your successful application and usage of this product. Please contact Z Corporation directly to schedule a free online training session at (781)852-5005. Ask for the ZCast applications engineer or email the applications team at applications@zcorp.com.

  • Page 123: General Safety

    Appendix I 2 General Safety This manual has safety information and instructions to help users reduce or eliminate the risk of accidents and personal injuries. This section briefly explains hazards associated with fabrication of metal parts using the ZCast process. 2.1 Safety Precautions The making of molds and casting of metal parts using the ZCast process involves steps, such as mold baking and handling molten metal, that have particular safety hazards.

  • Page 124: Safety Instructions

    Appendix I 2.3 Safety Instructions Read and follow this safety information to reduce or eliminate the risk of accidents and personal injuries. GENERAL SAFETY Do not allow untrained individuals to design or handle ZCast molds during manufacturing. Only trained individuals with WARNING sand casting design and foundry experience should design and handle the ZCast molds.
  • Page 125 Appendix I Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten metal causing personal injury during metal casting. Venting paths WARNING in the mold must be arranged and directed away from the metal path to avoid entrapment of gases.
  • Page 126 Appendix I PREPARING AND BAKING MOLDS Bake ZCast molds until all moisture is removed before metal casting. Residual moisture in the mold can cause the mold WARNING to unexpectedly fail, releasing entrapped gases and molten metal and causing serious personal injury. Do not bake ZCast molds in unvented ovens.
  • Page 127 Appendix I FINISHING Breaking molds with a hammer or high-pressure water jet releases airborne objects and may cause personal injury. CAUTION Wear eye, face and hand protection while breaking molds. Drill, cutting or grinding cast parts releases airborne objects and dusts and may cause personal injury. Wear eye and CAUTION face protection while performing these tasks.

  • Page 128: Zcast Advantages

    Appendix I 3 ZCast Advantages Today, metal casting molds are commonly created by first producing a machined pattern (or pattern set) that is then used to create the molds. Instead of utilizing this costly and often time consuming process, the ZCast process utilizes 3D printing to create the molds and mold inserts directly from CAD data.
  • Page 129 Either the sand mold can be created with machined patterns, or to keep the time of casting to a minimum, the patterns can be ® printed on a Z Corporation 3D Printer using zp 100 series materials. ZCast Design Guide - 11...

  • Page 130: Locating A Foundry

    Appendix I 4 Locating a Foundry Whether you are an experienced mold designer with a foundry in-house, or a design engineer who has never designed a mold, the first step in the ZCast process is to run a trial with your foundry.

  • Page 131: Designing With Zcast - Mold Design

    Appendix I 5 Designing with ZCast – Mold Design ZCast powder offers flexibility and simplicity in mold design. Because of its simplicity, the engineer or designer can spend more time focusing on the design of the part rather than on the design of the mold.

  • Page 132: Selecting A Design Method

    Appendix I 5.2 Selecting a Design Method This first step in designing a mold is to decide which design method best suits the desired casting. These are the three basic methods. Direct Pour 5.2.1 A mold designed by this method incorporates the cavity of the casting and the entire gating system, including risers and vents.

  • Page 133: Combination Method

    Appendix I Figure 4: Shell Method – ZCast components of a shell mold (left). Assembled mold with ZCast components packed in foundry sand. Note that the risers, runners and sprue have been formed in the foundry sand (right). Combination Method 5.2.3 Combining ZCast with the traditional sand casting techniques can keep the cost per prototype down to a minimum.

  • Page 134: Designing Molds In Your Cad System

    Appendix I Figure 5: Combination Method – a) zp102 patterns infiltrated and backed with epoxy; b) ZCast 501 core; c) traditional foundry sand mold half with ZCast core; d) and e) finished casting. 5.3 Designing Molds in your CAD System Regardless of the method you select, it is likely that some CAD work will be required.

  • Page 135: Shell Method

    Appendix I 9. Add mating features to help align the mold components. These can be simple holes pegged with dowel pins, or mating positive and negative features built into the model. 10. Add venting to the mold cavity and to the cores. 11.

  • Page 136: Combination Method

    Appendix I 5.3.3 Combination Method The combination method is slightly more process oriented and is not represented in the context of this document. Users familiar with the conventional sand casting process that incorporates the use of a pattern will find this technique to be desirable using ZCast.

  • Page 137: Design Techniques With Zcast Patterns

    Appendix I 6 Design Techniques with ZCast Patterns 6.1 Direct Gating Conventional methods of runner design are based on having a flat pattern that must be drawn out of a sand mold. This forces the runners and gates out sideways resulting in a mold that covers a larger area.

  • Page 138: Stiffening Ribs

    Appendix I 6.4 Stiffening Ribs Increase the strength of your mold with the addition of stiffening ribs. You can use the Make Fixture functionality in the ZPrint software, or you can create a rib lattice in your CAD system of choice.

  • Page 139: Venting Cores

    Appendix I into the metal. When gas passes through the metal as it cools, it can be trapped, forming pockets called porosity. To avoid this, the cores can be hollowed with the hollow sections vented through the core print to the outside of the mold. It is important to keep the venting path away from the metal path.

  • Page 140: Venting The Mold

    Appendix I 6.5.2 Venting the Mold Vented molds facilitate the safe passage of gas generated as a result of molten metal coming into direct contact with the ZCast material. The design and adequacy of the mold vents is a contributing factor that strongly influences whether quality castings are made or the mold possibly fails releasing molten metal.
  • Page 141 Appendix I Suggested Solutions: • For the majority of the molds, there should be least a 0.5 in (13 mm) wall thickness between the metal and the outside of the mold. Mold wall thicknesses of less than 0.5 inches (13 mm) may allow molten metal to leak from the mold unexpectedly and cause CAUTION personal injury.
  • Page 142 Appendix I Make sure that geometries are properly shelled. Almost all molds are capable of having ‘sacrificial’ outer surfaces that can be removed to allow for even baking and proper gas dispersion during the pouring process (see below). Make certain that if the mold has a core that the core is properly vented to the atmosphere to allow unimpeded release of gas.

  • Page 143: Parting Lines

    Appendix I Creating a runner bar, for example, across the heat sink fins would help to facilitate proper filling; however mold vents must still be provided for adequate exhausting of any gas. 6.6 Parting Lines The process for creating a mold in CAD software typically involves taking an object (the casting) and subtracting it from a larger, encompassing object (the mold).

  • Page 144: Depowderability - Fixed Vs. Removable Cores

    Appendix I Parting lines near core vents may leak molten metal into the CAUTION vents. The vents may not function properly and cause the unexpected release of molten metal and personal injury. 6.7 Depowderability – Fixed vs. Removable Cores Part depowdering refers to the removal of loose, unprinted powder from the mold cavities following the printing process.

  • Page 145: Geometry Guidelines

    Appendix I radius to the bottom edges of core prints where they sit in the cope or drag; this provides space for loose powder to collect safely away from metal flow. A foundry will typically seal parting surfaces with core paste. A bead of this material is placed around the outer edges of the mating surfaces of the mold and across the core prints to prevent leakage.

  • Page 146: Pouring Sleeves & Risers

    Appendix I 6.11 Pouring Sleeves & Risers A pouring sleeve is a tapered cylinder made of a refractory material with a ceramic filter at the base. The filter is removable, so the pouring cup can be used as a riser as well. There is no requirement to use sleeves, but the convenience is an advantage.

  • Page 147: Machine Settings

    Appendix I • For mating parts (such as a cope and drag of the same mold), try to always print them in the same orientation in the build. 6.13.1 Machine Settings ® Use the following optimized print settings for printing ZCast 501 powder with zb 56 binder: Saturation Settings Shell...
  • Page 148 Appendix I Figure 13: a,b,c: Horizontal filter orientation – Metal rises up through filters (maximum are achieved with horizontal placement. d,e,f: Vertical filter orientation ZCast Design Guide - 30...

  • Page 149: Mold Preparation

    Appendix I 7 Mold Preparation After the mold is designed and printed in a Z Corp. 3D Printer, there are only a few necessary steps before you are ready to pour metal: Mold Wash – Mold wash is used in traditional sand casting to improve the surface finish of the castings.

  • Page 150: Clamp

    Appendix I Clamp – Carefully close the mold with the cores in place. Clamp with C – clamps or similar and orient in the proper direction for pouring. Attach pouring cups and risers if necessary (use core paste to glue in place). Attachment of risers and cups without core paste may result in the unexpected release of molten metal and personal CAUTION...

  • Page 151: Pouring Metal

    1400°F – 1500°F Flammable Magnesium WARNING: NO ATTEMPT SHOULD BE MADE TO POUR FERROUS METALS IN ZCAST 501 MOLDS ASM metals handbook, 4 edition Heine & Rosenthal Foseco foundryman’s handbook Consult Z Corporation prior to pouring ZCast Design Guide - 33...

  • Page 152: Material Handling

    Appendix I 9 Material Handling 9.1 Storage Though ZCast powder has no special storage requirements; it should be stored in a cool, dry environment. See container labels for additional information. 9.2 Disposal ZCast powder is a non-toxic substance. Please consult the Material Data Safety Sheet for product details.

  • Page 153: Finishing

    Wear eye and face protection while performing these tasks. 10.3 Ovens You can bake your parts in one of the ovens offered through Z Corporation, or any other oven º that will reach temperatures up to 400 F.

  • Page 154: Foundry Consumables

    Appendix I 11 Foundry Consumables You can purchase foundry consumables through a wide offering of vendors. This includes items such as core wash, pouring sleeves, filters, core paste, etc. Prominent foundry consumables that are commonly used are: Ceramic filters – These disposable items are inserted into either the pouring sleeve, or they are often placed in the drag in a cavity in line with the runner channel.

  • Page 155: Sand Casting Glossary

    Appendix I 11.1 Sand Casting Glossary Cope 11.1.1 Cope and Drag Molds are typically made up of two halves encapsulating the outer surfaces of the casting. The two parts are called the cope and drag; the cope being the “top” section and the drag being the “bottom.”...

  • Page 156: Pouring Cup

    Appendix I Core prints (light areas) 11.1.4 Pouring Cup The pouring cup, as the name implies, is where the molten metal is poured into the mold. The pouring cup can take many different forms, each to optimize the feeding of metal into the mold and minimize the amount of turbulence produced in the metal stream.

  • Page 157: Ingates

    Appendix I 11.1.8 Ingates The metal enters the mold cavity through the ingates. Ingates typically feed thicker sections of the casting, which subsequently, feed thinner Runners sections. Thick sections, where the metal will be slowest to cool, should be Ingates allowed to feed thin sections that cool more quickly and may freeze off before the entire casting is filled.

Table of Contents