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Z810T3 User Manual Rev B

1. The printer will restart Run a test build SLOW_HEAD_OFFSET1 280 SLOW HEAD OFFSET 566 to see if the short spreading problem has been SLOW HEAD OFFSET3 852 solved If not change the line to SLOW_HEAD_OFFSET4 1136 oLa HEAD_OFFSET5 1416 SLOW HEAD START 0 SLOW HEAD STARTS 0 ai SLOW HEAD START4 0 It is important to start at a value of 1 and to SLOW HEAD STARTS 0 increment by 1 Under almost all circumstances FAST_HEAD_OFFSET1 373 i FAST HEAD OFFSET 7491 a value of 1 will solve the problem Large FAST HEAD OFFSETS 1111 values will reduce the depth of build that can FAST_HEAD_OFFSET4 1481 i FAST HEAD OFFSETS 1853 be completed successfully because there is COLOR STRIPE LINES 136 only a limited amount of powder in the feeder REMOTE_NATTER 1 c FARK_SECONDOS 0 A large value may also cause a 50103 USE NETWORK POWDER Overflow Full error PRIMTER_NAME ENGLAB_Z2K GATEWAY ADDRESS 0 0 0 0 DNS ADDRESS 0 0 0 0 CARWASH TWEAK SLOW 0 000737 Values larger than 5 will be treated by the CARWASH TWEAK FAST O firmware as a value of 5 If you later experiences an Overflow Full error you can edit the INI file and reduce the value of EXTRA_POCKETS Z Corporation Service 781 852 5050 887 88 ZCORP 103 Z Corporation Z810 System User Manual 13 MAINTENANCE Maintenance Action Frequency Z810 3D Printer 1 Refill zc10 Wash Fluid 2 Flush Binder with Distilled Water When not in use for two or more weeks 10 Bleed
2. e 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 A CAUTION molten metal to leak from the mold unexpectedly and cause personal injury Design molds to ensure at least 0 5 inches 13 mm mold wall thickness e Around areas of the casting where low porosity is important or near thick sections in the casting there should be vents for gases to escape Insufficient venting of thick mold sections can result in the unexpected release of molten metal and personal injury during WARNING metal casting Design molds with adequate venting capacity and proper location e Vents should be approximately 0 125 in 3 2 mm in diameter and open to the atmosphere The lower limit of vent diameter is 2 3 mm determined by depowderability e Vents DO NOT need to break through to the casting surface If they pass to within 0 1 in to 0 2 in 2 5 to 5 mm from the casting surface the gas generated inside should permeate through except in extreme cases Vents not located in the core vents too close to parting lines or vents that break through to the casting surface may leak molten A CAUTION metal and cause personal injury Locate vents in the core away from the casting surface and as far as possible from parting lines e Insert vents vertically where possible opening in the cope Bringing the vents
3. 887 88 ZCORP 91 Z Corporation Current binder supply le color Change to color Lancel Flush Binder O Fress Start to begin flushing binder When the binder ts flushed press Done Start Done www zcorp users com Z810 System User Manual Change binder supply if necessary If you are using starch powder use zb 51 binder If using plaster zp250 powder or ZCast powder use zb56 binder Change binder supply mode if necessary using the Change Binder Supply function under the 810Service menu in the ZPrint Software Flush binder for two minutes if you have changed binder supply by choosing the Flush Binder option under the Service menu Purge the print heads by selecting the Purge Print heads option under the 810Service menu IF USING ZCAST POWDER remove scraper blade assembly by unscrewing the thumb nuts IF USING STARCH OR PLASTER POWDER make sure scraper assembly is attached PLEASE NOTE Failure to remove scraper assembly when using ZCast powder will result in damage to the scraper blade 92 Z810 System User Manual Z Corporation 8 Change ZF8 Powder Feeders with the desired powder system 9 Fill ZF8 Feeder with desired powder if necessary xl 10 Use the Fil Bed option under to 810Service menu to spread powder Press Start to initiate a build When the process is complete press Done 11 Set up build in ZPrint Software and print
4. Always spray in a vented hood While wearing all protective equipment insert the spray trigger nozzle into bottle Use cardboard or wax paper to protect the spraying area from overspray Spray Z Bond 100 only onto parts that have been oven dried and are free from moisture this ensures deepest available penetration and decreases smoking from reaction with water Keeping the tip of the spray bottle 4 6 inches 10 15 cm away from the top of the part begin squeezing the trigger Adjust the tip of the sprayer until the desired spray pattern is reached Apply the Z Bond 100 to all upward facing surfaces and sides of the part Be sure not to spray the base of the part as it will stick to the surface it is sitting on Wait for the top of the part to cure or speed up the process by using an approved Z Bond 100 accelerator Turn your part over and apply to any uninfiltrated surfaces CURING INFORMATION The part should be placed on a non stick material wax paper Teflon etc to prevent it from adhering to the surface it is sitting on while curing Wear gloves when handling the parts to avoid contact with uncured resin Parts will attain full strength in two minutes For more information on the uses of Z Bond resin 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 887 88 ZCORP 59 Z Corporation Z810 System User Manual 8 3 USI
5. 9 3 POLYESTER RESIN Many types of transportation equipment require the use of geometrically complex ducting for heating ventilation and air conditioning 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 can be prepared to have sufficient toughness and resiliency to survive bench testing and functional testing in an automobile The basic parts are produced in zp15e starch powder It is recommended to print a sample part first to practice all the process steps if you are a new user This step is worthwhile especially when dealing with large parts because it will help to minimize waste and to increase efficiency Infiltration Details This application requires use of a marine grade thixotropic low viscosity polyester resin This resin is widely available at hardware stores and industrial supply centers Some common manufacturers are Evercoat Fibre Glast and or FiberLay Materials Required Polyester resin and catalyst Plastic container for resin Disposable brushes Fiberglass mat optional Kevlar E S glass mat CA or equivalent glue for joining assemblies Personal Protective Equipment Gloves Eye protection Apron Application Time Highly dependent on part 5 30 minutes Application Technique Applied by brush Working Life 15 Minutes Set Time 4 hours min
6. Z Corporation Service 781 852 5050 887 88 ZCORP 35 Z Corporation Z810 System User Manual 4 3 FILL BED 1 Press the Fill Bed button on the control panel This will prompt the powder feeder and gantry to deposit and spread powder over the build pallet It will continue spreading until the build pallet is covered 2 To cancel the operation press Online on the control panel PLEASE NOTE The powder should spread evenly throughout the build pallet If it does not spread evenly manually spread powder over the build pallet by pressing Spread on the control panel 44 REMOVE POWDER FROM OVERFLOW CHUTE 1 Place one end of the vacuum hose into the overflow chute vacuum receptacle 2 Place the other end of the vacuum hose into the powder feeder vacuum receptacle 3 From the software select the Empty Overflow option under the 810Service menu The vacuum and vibrator located on the overflow chute will operate automatically 4 The vacuum and vibrator will stop when the overflow chute is empty To reduce airborne powder particles turn on the vacuum and remove the vacuum hose from both the overflow chute vacuum receptacle and feeder vacuum receptacle Then turn off the vacuum PLEASE NOTE The airflow from the powder feeder may stall for a minute while cleaning the filter The vacuum and the vibrator in the printer will remain on After cleaning the powder feeder will resume emp
7. button on the control panel _ raise the build pallet 2 Vacuum off any surrounding powder WwWw zcorp users com Z810 System User Manual Z Corporation 3 Place the tracks on each side of build pallet 4 Secure the tracks to the top deck by interlocking the j shaped slots with the track pegs Peg for Side Track 5 Place ZD8 Cart in front of printer and attach tracks from cart to top deck Z Corporation Service 781 852 5050 887 88 ZCORP 49 Z Corporation 6 Press Online on the control panel to lower build pallet 7 Push or pull pallet onto cart Remove tracks and replace in storage position on cart 8 Lift ZD8 Window 9 Move cart in front of ZD8 Depowdering Station 10 Orient the ZD8 turntable so that the track pegs are towards the front of the depowdering unit 11 Attach the tracks 12 Push build pallet into depowdering unit 13 Detach tracks from turntable and move cart to a convenient storage location www zcorp users com _ Track on ZD8 i Depowdering Unit Z810 System User Manual Track on Cart 90 Z810 System User Manual Z Corporation 14 Turn depowdering unit on and leave parts to dry for 45 60 minutes The circulating air will allow the parts to dry before depowdering the part PLEASE NOTE If the depowdering unit is on and the warning lamp is illuminated turn the machine off This will allow the depowdering unit to
8. powder may be piled up behind the access panel 2 Use the external vacuum to remove any debris 3 Replace powder screen cover 13 13 EMPTY POWDER DRAWER ON THE ZD8 DEPOWDERING UNIT The Powder Drawer in the ZD8 Depowdering Unit collects the excess powder removed during the depowdering process The powder drawer should be emptied weekly If you are a heavy user or if your part geometry encapsulates large volumes of powder the powder drawer may need to be emptied more frequently 1 Release powder drawer by moving the control switch to the left Z Corporation Service 781 852 5050 887 88 ZCORP 115 Z Corporation Z810 System User Manual 2 Slide the powder drawer out There are two handles available One handle option extends out to allow you tow push and maneuver the powder drawer to and from an emptying location The other handle option allows you to pull and push the powder drawer at the base 3 Remove powder If you are using two different material systems use the external vacuum or scoop to remove powder If you are using one material system and would like to recycle use the powder feeder vacuum to remove powder for reuse 4 Slide back powder drawer and replace handle 5 Return control panel to Stand By mode www zcorp users com 116 Z810 System User Manual Z Corporation 14 Z810 SYSTEM DETAILS 14 1 SYMBOLS USED The following symbols are used on the Z810 3D Printer This is the
9. 3005 3006 3007 3008 3009 3010 3011 3012 3013 3100 3101 3102 3103 3104 3105 3106 3200 3201 3202 3300 BMOCO BMOCO MOVER MOVER MOVER MOVER MOVER MOVER MOVER MOVER MOVER MOVER Z810 System User Manual LM629 does not respond can t reset motor d bad axis axis d destination out of range axis d move intersects no fly zone axis d excessive position error axis d timed out completing move axis d didn t settle axis d can t change acceleration axis d can t set filter axis d excessive speed axis d safety handler not installed REZERO axis d can t find end of travel REZERO axis d already over sensor REZERO axis d timed out looking for sensor REZERO axis d couldn t find sensor SHAKER can t read layer info SHAKER bad layer number HEAD bad ROM format DRAWSPAN bad bit number DRAWSPAN bad print mode TIGERCOM serial write timeout TIGERCOM serial read timeout TIGER bad head index SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER SEQUENCER PRINTER PRINTER PRINTER PRINTER PRINTER PRINTER PRINTER bad FIFO size d entries can t create event can t create thread can t set priority bad interrupt number can t save interrupt vector can t set interrupt vector not enough data overrun while waiting for HF stalled while waiting for HF sequence didn t finish
10. 7 DEPOWDERING THE PART 7 1 CHANGING AIR NOZZLES You may choose to use different air nozzles for different stages of depowdering For rough depowdering use the large nozzle Use the fine point nozzle for depowdering detailed areas 1 To remove nozzle slide the outer sleeve of the socket towards the nozzle 2 To connect a nozzle press the plug end of the nozzle into the quick disconnect socket until it clicks 3 Turn air gun on by opening the 1 4 turn valve at the end of the coiled blow off hose The valve is open when the thumb lever is in alignment with the valve body and closed when the thumb lever is perpendicular to the valve body Valve parallel with valve body Air flow is on in this position 4 Adjust airflow by using the control valve Slide the red ring down to lock the settings PLEASE NOTE When depowdering thin walled or fine detailed areas use lower air pressure www zcorp users com 94 Z810 System User Manual 5 Depowder the part beginning from the top surface area and working downwards Rotate turntable as needed Remove as much powder from part as possible For plaster parts do not remove the supporting powder For starch parts remove supporting powder For ZCast parts remove all loose powder Leave part in the depowdering unit and let it sit for 15 minutes with the depowderer on 6 You will need to lift the starch part up to depowder the bottom surface o
11. 84 Anisotropic Scaling Values 42 Plaster 42 Starch 42 ZCast Powder 42 Apollo 5005 57 Applications 62 Electroplating 66 Flexible Parts 72 Investment Casting 70 Multi pieced Parts 63 Painting 64 Polyester Resin 65 RTV Molding 75 Thermoforming 73 Water Transfer Printing 67 B Binder Containers Disconnect 105 Bleed Air 112 Build Pallet Replacing 34 Build Settings 41 3D Print Setup 41 Override 41 Carriage Unpark 34 Changing Material System 91 Collision Detection 42 Contacts 82 D Depowderer See ZD8 Depowdering Unit Depowdering 31 54 Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation Disconnect Binder Containers 105 Drying Time Plaster Powder 55 Starch Powder 55 ZCast Powder 55 E Electroplating 66 Empty Overflow Chute 36 Empty Powder Drawer 115 Error Codes 118 Extra Pockets 102 Fan Filter 110 Fast Axis 9 108 Fast Axis Pulley 113 Feeder See ZF8 Powder Feeder File Import 40 Open 40 Fill Bed 36 Cancel 36 Fill Binder Containers See Refill Binder Fill ZD8 Powder Feeder See Refill Powder Filter Cleaning Pausing 23 ZD8 Depowdering Unit 23 Flexible Parts 72 Fluid Levels 38 Empty Waste Container 39 Refill Binder Containers 38 Flush Binder 105 G Grease Fast Axis 108 Slow Axis 109 Gross Depowdering 46 Import File 40 Infiltrants 57 Wax 61 Z Bond 100 59 Z Max Epoxy 57 Z Snap Epoxy 60 123 Z Corporati
12. Pouring cup sprue and well It is typically a conical shape tapering in as it extends The well is typically where the filter through the cope and into the drag The sprue with the would be placed pouring cup at its top should be the tallest component of the mold The height is what produces the pressure needed to fill the mold with metal The sprue should be at least 4 in 102 mm higher than the casting The base of the sprue is often used as a choke to control the flow rate of metal into the mold The diameter of this point can be derived from the geometry of the casting and the subsequent gating design 11 1 6 Well Just beyond the choke at the bottom of the sprue the metal path opens up to the well The well is typically a cylindrical opening with a diameter about 2 5 times bigger then the choke It directs the metal to the runner system The well often serves the dual purpose of housing a filter Filters are usually ceramic webs or open cell sponges used to help remove some of the dross metal oxides and dirt from the molten metal 11 1 7 Runners Runners are the paths that feed metal around the mold to regions farthest from the pouring cup Runners are usually designed to minimize the turbulence of the metal as it travels through them Typically they are rectangular in cross section and again like many other components of the gating system the runner dimensions can be determined from the cast parts geometry Runners also serve as
13. These documents as well as other instructions will accompany the mold The goal of this exercise is to make your foundry comfortable with the ZCast process You would like them to be as well informed about the materials and the process as you are If you have trouble finding a foundry in your area contact your Z Corp sales representative to help you locate an experienced foundry ZCast Design Guide 12 Appendix 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 This simplicity does away with undercuts and draft which are critical when using other methods ZCast s unprecedented flexibility allows the designer to choose the technique that is the most proper for the application at hand metal and personal injury during the metal casting steps Improper design of molds can result in the release of molten A CAUTION Only trained or supervised individuals should design molds 5 1 Sources of Mold Design Information The subtleties of casting design are beyond the scope of this document The designer may wish to gain as much information as possible on designing sand molds before attempting to use the ZCast process The more knowledge one possesses about good mold design the more successful you will be at designing complex and challenging p
14. Vents not located in the cope may unexpectedly release CAUTION molten metal and cause personal injury 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 Loose powder left in molds may create pockets voids or block vents during metal casting resulting in the unexpected release of molten metal Ensure that all loose powder is removed before casting CAUTION gt PPP PP gt DP gt ZCast Design Guide 7 Appendix PREPARING AND BAKING MOLDS Bake ZCast molds until all moisture is removed before metal casting Residual moisture in the mold can cause the mold A WARNING to unexpectedly fail releasing entrapped gases and molten metal and causing serious personal injury Do not bake ZCast molds in unvented ovens Irritating and toxic fumes are formed at elevated temperatures during WARNING Oven baking Ovens must be vented to the outside Refer to the ZCast 501 powder MSDS for more information on the irritating and toxic fumes Depowdering with compressed air will generate airborne particles Only trained or supervised individuals should CAUTION depowder a mold Use hood ventilation and safety goggles or faceshield to protect the eyes and face Refer to the ZCast 501 powder MSDS for more information Pouring sleeves attached to the ZCast mold with core paste may shift while pouring m
15. careful consideration is placed on their overall design capacity placement and number Here are the more common vent design issues a mold designer must consider Large Surface Area To Volume Ratios As depicted in the example below closely spaced thin walled mold geometries can lead to gas entrapment because there is a large area of interaction between the molten metal and the resins in the ZCast powder In some situations such geometric conditions can impede proper ventilation Mold geometries with thin walls such as those used to cast heat sinks illustrate this issue well They require careful design and placement of vents to prevent unexpected mold failure and yield quality castings Excessive mold wall thickness can prevent adequate curing of the binder resins during the mold baking process Inadequately baked molds when in contact with molten metal will create excessive quantities of gas and an increased possibility of unexpected mold failure during casting Poor ventilation can cause the entrapment of gas during the pouring process resulting in the unexpected release of molten metal through the gating system Gas entrapment within the mold cavity walls will result in an infiltration of gas in the molten metal This entrapment will show up in the solidified casting resulting in porosity a quality control issue Heat sink fins require a thin wall mold ZCast Design Guide 22 Appendix Suggested Solutions
16. early stage design tool it may not be necessary to infiltrate the parts at all However the true versatility of the 2810 System is derived from the spectrum of material properties that can be achieved by applying one of our infiltration materials to parts that will be exposed to a variety of product testing environments 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 You will also find other ways to finish your part in the next chapter Applications 8 1 USING Z MAX EPOXY SAFETY PRECAUTIONS e Wear lab coat gloves we recommend PVC Examination Gloves face shield or goggles Face shield is required if spraying Apply in ventilated hood e Use specialized containers recommended for dispensing and application A system for avoiding spills includes Catch pan waxed paper or plastic drop cloth e Label disposal materials e Wear dust mask when sanding finished parts e Read the Material Safety Data Sheet for Z Max epoxy prior to the use of this material MIXING INSTRUCTIONS e When using the 250 gm Z Max kit simply pour the entire contents of the Z Max Hardener container into the Z Max Resin container and mix the two parts thoroughly for two minutes prior to application If less than 250 grams is desired follow the instructions for mixing by weight or volume e Mix 100 parts Z Max Resin to 37 parts Z
17. flags x error in DPC flags x spurious interrupt flags x timed out finishing swath flags x Spurious read event bad dispatch type d unknown message d message queue overrun need service call error d can t create event SendMessage deadlock MONITOR can t create waitable timer MONITOR can t set waitable timer MONITOR thread took too long TIMER unknown time unit www zcorp users com 120 Z810 System User Manual Z Corporation 3400 3900 3901 3902 3903 3600 3601 3602 3603 3700 3701 3 02 3800 3801 3802 3803 3900 3901 4000 4001 4002 4003 4004 4005 4006 4007 4008 4009 4010 4011 4012 4013 4014 4100 4101 4102 4103 4104 4200 4201 4300 4301 4302 4400 4401 4402 4500 4501 4502 SWITCHES switch d is undefined KEYPAD object already exists KEYPAD can t create event KEYPAD object not initialized KEYPAD object has too many users BLINK object already exists BLINK object not initialized BLINK object has too many users BLINK undefined sequence LCD object already exists LCD object not initialized LCD object has too many users LOWLEVEL can t find PCI card LOWLEVEL error opening FPGA file LOWLEVEL invalid FPGA load LOWLEVEL bad IRQ number SOCKETS can t initialize WinSock interface SOCKETS WinSock 1 1 not supported TCP can t create event TCP can t launch thread TCP thread refuses to die TCP error d creating socket TCP error d setting socket opti
18. 1 0 12 7 25 4 mm Distance Between Wall by Y 0 5 1 0 12 7 25 4 mm High ate to avoid a between Accuracy Coefficient the part and the fixture To change the default values in the Make Fixture window select Preferences from the ZPrint Edit Menu and select the Fixtures tab Enter the new values and click OK Edit Transform wiew 3D vie EES General Rendering impos E spon Futures Shrew Layers Ernad Zut Chrl x Az Copy Ctrl C i az Paste Cbr Top Sudace Thickness 5 E Delete Del Wall Therese 1 ip Select All cH 4 Distance beiren wae by as ni Empty clipboard Distance botencn vada br 05 a Normals Accuracy coefficient x Colors m Make Label Undo Label Make Solid Make Fixture 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 Print AU AER e 5 E O pe ik poem yew DO Ve window Grke Jlibevie Ledo ajo jej lele l e olej oft selel Fitis iso ayer 0 Height 0 000 inches Z Corporation Service 781 852 5050 887 88 ZCORP 97 Z Corporation Z810 System User Manual e Go to the 3D Print Setup window under the File Menu and select zp250 powder as the powder type 3D Print Setup Printer ZPrinter 310 Offline Se
19. 11 1 4 POST PROCESSING ZCAST PARTS Remove and depowder the part as described in Chapter 6 Removing the Part Unlike other Z Corp parts ZCast parts requires no infiltration However ZCast molds must be thoroughly baked in a vented oven at sufficient temperatures to burn out the organic materials Additionally the user may apply a core wash solution to improve the surface finish of the casting See the ZCast Direct Metal Casting Design Guide for bake temperatures times and additional information 11 1 5 MATERIAL ORDERING You can order ZCast consumables either directly from Z Corp or through your local reseller The item list for ZCast is as follows rene etter sri 06091 ZCast 501 Powder 15 kg pail 500 in 06376 ZCast 501 Powder 90 kg pail 3000 in 06312 zb56 Clear Binder 1 gallon Z Corporation Service 781 852 5050 887 88 ZCORP 95 Z Corporation Z810 System User Manual 11 1 6 RECYCLING Similar to plaster and starch ZCast powder can be recycled Recycle only powder that is unprinted and free of moisture as bonded or printed material will degrade printing performance 11 1 7 STORAGE Though ZCast powder has no special storage requirements however it should be stored in a cool dry environment See container labels for additional information 11 1 8 DISPOSAL ZCast powder is a non toxic substance Please consult the Material Safety Data Sheet for product details Dispose of ZCast powder according to local
20. 15 20 psi When finished remove the disposable liner and clean sprayer with ethyl alcohol or acetone Remove the tip and thoroughly clean by hand to avoid resin build up Cleanup takes approximately 15 minutes CURING INFORMATION Allow the part to cure for 1 hour at ambient temperature to avoid outgasing of part which can result in bubbling on the top surface of the part The resin can be cured at an accelerated rate in an oven The oven must be vented Ventilation designs need to meet each customer s respective governmental health and safety requirements A reference frequently used by U S firms to comply with OSHA regulations is the American Conference of Governmental Industrial Hygienists Industrial Ventilation Manual At 160 F 71 C your part will reach full strength in 2 hours The part should be placed on a non stick material wax paper Teflon etc to prevent it from adhering to the surface it is sitting on while curing Wear gloves when handling the parts when they are still at an elevated temperature Parts will attain full strength and be safe to handle once they cool to room temperature 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 www zcorp users com 98 Z810 System User Manual Z Corporation 8 2 USING Z BOND CYANOACRYLATE Z Bond cyano
21. 3D Printer Connector Panel www zcorp users com Z810 System User Manual 2 1 1 4 Z810 Printer Control Panel power a erore Z Corporation Spread Button This button moves the gantry from left to right allowing the user to spread powder over the build piston LCD Panel Displays the current status of the Z810 3D Printer Load Unload Lifts build piston to allow for pallet placement and removal e ahline spread aay e Abod Online Button Fill Bed Enables and disables Prepares build printer communication area for printing by Z Corporation Service 781 852 5050 887 88 ZCORP spreading powder over the build area Build Up Down Buttons Allows the user to raise or lower the build piston Briefly pressing this button raises or lowers one layer thickness holding down the button for five seconds causes the build piston to move all the way down 17 Z Corporation 2 1 2 ZF8 POWDER FEEDER Site Requirements Power Voltage 100VAC 50 60Hz 20A 115VAC 50 60Hz 17A 230VAC 50 60Hz 10A Compressed Air Clean dry air dew point 40 F 4 C or below Z810 System User Manual Air Fitting 1 4 Industrial quick disconnect or other quick disconnect with 1 4 inch NPTM pipe thread Dimensions 31 inches 0 79 meters deep x 32 inches 0 81 meters wide x 78 inches 1 98 meters tall V
22. Air If you run out of binder or air enters the fluid system 11 Clean Fast Axis Pulley After every print head change TI E ZF8 Powder Feeder 1 Clean Powder Screen Once a week or after vacuuming up small parts 2 Clean the Metering System AAA ZD8 Depowdering Unit 1 Empty Powder Drawer Once a week or as needed 13 1 ADD ZC10 WASH FLUID The zc10 wash fluid will need to be refilled when the zc10 wash fluid container is empty 1 Unpark the gantry by selecting the Unpark option under the 810Service menu in the ZPrint Software 2 Open the service station cleaning station 3 Fill the container with a full bottle of zc10 wash fluid 4 Replace cover close top cover and repark the gantry www zcorp users com 104 Z810 System User Manual Z Corporation 13 2 FLUSH SYSTEM WITH DISTILLED WATER If the printer will not be in use for more than two weeks it is strongly recommended that it be flushed with distilled water This will prevent the binder from coagulating in the fluid lines Make sure waste bottle is empty prior to flusing your fluid system This will prevent overfilling the waste bottle PLEASE NOTE If the printer is in color mode and will only be used in monochrome mode for more than two weeks only place distilled water in the color binder containers and flush in color mode Then change to monochrome mode 1 Open cabinet door 2 Remove primary color binder fluid lines using the quick disc
23. Castings can be produced in as few as one or two days for a fraction of the cost of traditional tooling 3 1 The Material ZCast 501 powder is a plaster ceramic composite suitable for casting low temperature metals aluminum magnesium and zinc Tests conducted by Z Corp and it s foundry partner Griffin Industries have shown results that mimic traditional sand casting finishes and tolerances Many successful castings have been made in 356 390 and 319 aluminum as well as zinc bronze and magnesium The ZCast material set can be used on the Z810 Large Format 3D Printer the Z406 3D Printer and the ZPrinter 3D Printer Do not use ZCast 501 molds with molten ferrous metals or other metals with pouring temperatures above 1100 C A WARNING 2000 F The molds can suddenly fail unexpectedly releasing entrapped gases and molten metal causing serious personal injury 3 2 Design Freedom In addition to reducing the time and cost to create a prototype casting the ZCast process also provides the freedom to produce complex castings that previously were difficult or impossible to produce using conventional tooling methods One of the powerful features of the ZCast process is the freedom to incorporate undercuts and channels in the molds Runners and vents can be formed inside the mold that are otherwise impossible to machine cores can be integrated into the mold minimizing the number of parts and simplifying setup For prototype parts thi
24. Environmental Setting Please read the Material Safety Data sheets for these products carefully This operation should be conducted in a well ventilated area with protective eyewear Instructions 1 Depowder and air dry parts for a minimum of four hours 2 Apply the resin by brush to individual parts per the material s directions and allow them to cure 3 Sand as needed and check any critical dimensions Finally use cyanoacylate resin to construct any multi part assemblies as required 4 Apply polyurethane resin Z Corporation Service 781 852 5050 887 88 ZCORP 65 Z Corporation Z810 System User Manual 9 4 ELECTROPLATING Parts printed on the 3D printer on either starch or plaster can be easily prepared and electroplated for the look and feel of a metal part Preparation Preparation is the most important step in producing a good electroplated surface 1 Both starch and plaster based powder parts can be used as the base parts for electroplating Parts should be well infiltrated with cyanoacrylate resin or epoxy and sanded with 220 grit sandpaper Do not wax the parts 2 Spray parts with a sandable primer such as Rust Oleum Auto Primer let dry and sand again In order to create a smooth metal finish the part must be sanded as smooth as possible 3 Once sanded to satisfaction clean the part with a damp paper towel 4 To aid in the spraying process and make it easier to get a good contact when plating
25. Feeder Feeder the ZD8 Depowdering Unit Depowderer and the optional oven 3 Quick Start Guide This section will give you a quick breakdown of steps needed to print your part 4 Preparing the Z810 3D Printer This section will guide you through the steps for preparing the Z810 3D Printer It includes checking the powder and fluid levels as well as maintenance procedures such as cleaning the service station 5 Using ZPrint Software This section takes you through a few basics of how to set up your build in ZPrint Software also referred to as software For more details on the features available in the Software please refer to the ZPrint Software User Manual 6 Removing the Part This section will guide you through removing your part from the Printer and transferring it to the ZD8 Depowdering Unit 7 Depowdering the Part This section will guide you through using the ZD8 Depowdering Unit 8 Infiltrants This section offers some recommendations on which infiltrants to use and how to apply them to your part 9 Applications This section will teach you various ways to maximize the versatility of your printer through the implementation of advanced part processing techniques 10 Changing and Aligning Print Heads This section contains detailed instructions on how to change and align the HP Print Heads in the Z810 3D Printer 11 Changing Material Systems This section contains detailed instructions on how to use spe
26. Figure 14 ZD8 Powder Collection Drawer 2 2 4 ZD8 CART e The ZD8 Cart allows for easy transport of parts using the track system For information on how to use the ZD8 Cart and Track System see Section 6 3 Transferring the Parts to the Depowdering Station Also refer to Section 7 Depowdering the Part for instructions on how to depowder your part www zcorp users com Z810 System User Manual All of the discarded powder from the depowdering process is deposited in the Powder Collection Drawer at the base of the ZD8 Depowdering Unit During normal operation the drawer is actively sealed to the underside of the machine When the main control switch is in Powder Drawer Release mode the seal is disengaged from the drawer allowing the user to pull the drawer out from under the machine for emptying The extending tow handle stores underneath the powder drawer To deploy the handle slide it all the way forward until it reaches the stop on the track Then lift the handle to a comfortable walking height Once the handle is deployed is can be used to tow push and maneuver the Powder Drawer to and from the emptying location The handle is returned to its stored position by pivoting the handle down to the floor and then sliding it back under the Powder Drawer For information on how to remove powder from Powder Collection Drawer please see Section 13 13 Empty Powder Drawer from the ZD8 Depowdering Unit Figure 15 ZD
27. Manual 9 7 FLEXIBLE PARTS Material e Por A Mold 2030 Preparation e Read and understand the Material Safety Data Sheet as well as any directions e zp15e parts should be used e Be sure the parts are completely dry e Wear impervious rubber gloves glasses and a lab coat e Use adequate ventilation when mixing and applying the material 1 Material should be mixed well at an exact 1 1 ratio parts can be dipped be best infiltrated but is not required 5 Excess material can be removed with a paper towel remove after it cures www zcorp users com 2 Apply generously For thin parts use a brush or syringe Thicker 3 If the material soaks completely into the part within a minute apply another coat Multiple thin coats of elastomer will enable the part to 4 A vacuum chamber will help the material to soak deeper into the part 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 Z810 System User Manual Z Corporation 9 8 THERMOFORMING This process consists of heating a thermoplastic sheet to a formable plastic state and then applying air pressure and or mechanical assists to shape it to the contours of a mold In this process the air pressure may range from almost zero to several hundred psi Vacuum forming is the term given when a pressure differential of up to approximately 14 psi atmospheric pressure is
28. Max Epoxy 57 Zp 250 Powder 96 ZPrint Software Collision Detection 42 Installing 40 Open File 40 Part Orientation 40 Printing 44 Setting Up 40 Z Snap Epoxy 60 125 Appendix ZCast 501 Direct Metal Casting DESIGN GUIDE September 2004 Z CORPORATION ZCAST 09521 ZCast Design Guide Rev E Appendix Table of Contents HERO CIC TO A EEA EEEE EAE 4 2 General Salserin 5 2 Sale Pre Canos iia 5 2 SAS OY MOS ios 5 A A 6 Or 22ST AV Ma Sn 10 Sal ImeMatenal sado iodo 10 22 DesioiiFiecoo Masia tibio li 10 4 EOC AUING a FOUNO tia o i 12 41 Foundiy Malal Sida iia li a ile 12 5 Designing with ZCast Mold DesiQN oocccooccccnnnccocccnonnnnoncnno 13 5 1 Sources of Mold Design Informati0N ccccoccnnncnonnccncncnnoncnnncnonononncnnnnnnnnnnonnnnnnnnnnononans 13 5 2 Selecting a Design Method osista a a a ei 14 5 2 1 A A e ai 14 522 A A A 14 523 COMBINATION MEA o 15 5 3 Designing Molds in your CAD SySteM oooccncccncnccnnccccnonconnnonnancnnnonnnncnnononannnnnononnnnennnnnnnos 16 9 3 1 Direct Pour Metho0d ooccccccccnccccoconcccncnncononcnnnonanonnnnannnnononnnnononnnnonannnnononnnnennannnconaness 16 5 3 2 SMelMeinOd cuiden iii d s 17 5 3 3 Combination Method ooccccnnccccccccnnnccnncccnnnonncnnnnnnnnononnnnnnnnnnnonnnnnnnnnnnnnnnnnannnnnnnnnnnnnnan 18 5 4 Printing Your MoOdel oocccccconncnncccccccconcccconnconcnonnnncnnnnnnncnnnonnnnnnnnnnnnnnnrnnnnnnnnnrnnrnnnn
29. Max Hardener by weight or 100 parts Z Max Resin to 41 parts Z Max Hardener by volume Mix the two parts thoroughly for two minutes before application The material has a working time of 35 minutes in a 425 gram mass Please be aware of the gel time while preparing quantities of material as the gel time decreases as the quantity of material increases It is recommended not to mix quantities over 425 grams Z Corporation Service 781 852 5050 887 88 ZCORP 57 Z Corporation Z810 System User Manual GENERAL APPLICATION NOTES Material can be brushed or sprayed Material will penetrate between 0 079 0 28 inches 2 7 mm Material will pool off the part during curing if it is over applied Better penetration depth is achieved by applying several light coats of material Allow all mixed materials to cure prior to disposal SPRAYING INSTRUCTIONS Use Gravity Feed High Volume Low Pressure Sprayer Z Corp Part 14206 We recommend Devilbiss Sprayer with 14 18 mm tip Other sprayers are compatible however the use of a HVLP sprayer will minimize the amount of overspray generated The Devilbiss Sprayer is available with disposable canister liners Z Corp Part 14207 and will minimize the amount of cleanup Have the sprayer parts and materials ready before mixing the resin Mix resin and pour into the disposable liner in the canister Always spray in a vented hood Use of a respirator is also recommended Spray resin between
30. UNIT 0 ccceeeceeeeceececeeeeceeeeceeecaececaeeeaes 30 3 4 IDEPOWDERING THE PART enana dass 31 39 TRANSFER TO OVEN aer e a a 32 a A A e 32 A A RO SEE 32 3 7 1 Set up ANA Post processing cooocccccccccoccnncnccnonnonnononononnnnnnonanonnnnnanonnnnnonannnnnnnnnaninnnns 32 3 7 1 1 Part Setup Orientation and Print SettingS oocccccccnnncoconcncnconnnnononnnconanonoos 32 3 7 1 2 Gross and Fine DepowderingQ ccccccoocccnnccccnnconocnnoncnnnnononncnnnnonnnnnnnnnonnrnnnonnnanennnnss 33 SF lied Oven DN THO Pad a 33 3 7 2 PACTAN A IN IN A 33 3 7 2 1 When Using Z Bond Resin ceccccessecesescesessesecesseceeesvacessesecesveseevaseeeevnertaveteess 33 3 7 2 2 When Using a Z Snap or Z Max Y EpoXxy cccccesssescseseseseesecssessevecseereevacseereeees 33 4 PREPARING THE Z810 3D PRINTER ccsccceecceecceeccneccneceecceeeceescenseceecenseenseenseeeseenseness 34 4 1 REPLACING THE BUILD PALLET cccscccececececececececeeecaeecaeecasecucecueecaeecueecaeecaeesaeenaeesaeeaueees 34 4 2 CLEANING THE SERVICE STATION e 34 A 36 4 4 REMOVE POWDER FROM OVERFLOW CHUTE ceeceeceeceecceeceececceeceececcueceeeeeseeseeeeeeueeeeeaeenss 36 AS GHECKING POWDER LEVELS tecnnrsitos orton ootatunss 37 AG CHECK FLUID REV BS ce reese dich a aE lirio locali older ci 38 4 6 1 Binder Containers ei sci Pains 23202 sae rob beg Sony on daimans baed Soin aedoseoubbdad Bows bask sad pel baal BhaiGeevociatandocs 38 4 6 2 CHECK
31. Waste CONAN aos atada deta aA 39 5 USING ZPRINT SOFTWARE csccsccescsecsecceccecceccecesccsecsaesacsaceaseseeseesaesaceaneaneceseeseesaeees 40 5 1 OPEN OR IMPORT THE PIE o a e e o E E ae 40 5 2 VORIENTING THE PART wai e tl eee e at elt 40 5 2 1 Part Containing an Opening or Hollow Are a cccooooonncccnnncccoccconoconnnncnnnanononnnnnnnnnos 40 522 Fan Containing OverhangS A A 41 So CHECKING BUILD TING O o et a 41 Oost sPOWOE CNI E ceased ae eed eae 42 20 1 1 ANISOWODIC Scaling Values iii ao oo eaidios 42 www zcorp users com 2 7810 System User Manual Z Corporation 0 k2 Saturation VW OS cor ioe aon epica aah iicio 43 54A PRINTING PAE BUD e tapas 44 6 REMOVING THE PAR Tiana A A AAA AA EA AA 45 6 1 SET TIMES cat eee ae eee ee ee eee 45 62 ROSS DEPOWDERINGu tdt 46 6 3 TRANSFERING THE PARTS TO THE DEPOWDERING STATION c0cccceeeceececeececeececeeecaeeecaeeeees 48 64 POSTPROCESSING 1 COOLS Sia la iaa 52 7 DEPOWDERING THE PAR Tio Girtadaluieceneucdenuietiaeaanecinwtarveneannisias 54 7 1 CHANGING AIR NOZZLES eo de e e ead 54 Ss INE UTE TBR INS wcrc tia 57 Sm WWG ZMA EN bo 57 8 2 USING Z BonD CYANOACRYLATE ccsccsccsscoscssssscsccsscssecseccsecsecsaccssecsscsacsascsscsaccsscsecsesensesee 59 Dr SUOI PECUARIA eds 59 8 2 2 General Application Noles essri riaa aa aaa a a a a a a 59 g2 3 SOlAVINO INS TUCUONS 2 AAA AE 59 9 24 CUAD WMOMMAUON ossee E O A E E eae 59 8 3 USING Z SNAaP EPOXY coco
32. ZCast shells This method is conceived for larger molds than those used in the Direct Pour method and when the gating system would require very large ZCast components If the size of the mold exceeds the working volume of the printer the Shell Method is recommended These molds are more complicated to design than Direct Pour molds and require the designer to be familiar with tool design for conventional sand casting The designer must allow for the ZCast pieces to mount to a pattern board which aligns them with respect to the rest of the mold The ZCast shells must provide connections to the gating system vents and risers and they must have features that anchor them to the backing of foundry sand Finally the ZCast shells must be structurally sound by themselves so they can be handled and baked individually metal and personal injury during the metal casting steps Improper design of molds can result in the release of molten A CAUTION Only trained or supervised individuals should design molds The printed mold pieces consist of cores and a uniform shell at least 0 5 in or 13 mm that surrounds the mold cavity A flange of similar thickness extends out on the parting line The flange contains vent holes core prints and alignment pins The mold pieces can be built in sections and aligned together on a blocking board usually a plywood construction The blocking board assembly is placed in a mold box Standard gating forms can be positione
33. a small solid piece underneath overhanging surfaces would reduce the movement of the overhang Cylindrical features will be more accurate when their axis is parallel to the z axis For 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 5 3 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 the selected printer powder type and powder settings for the build are The ZPrint Software settings are correct the recommended values 3 If the settings need to be changed select Override Press OK to confirm For more information on how to change the settings please refer to the ZPrint Software Manual Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation Lap 10 Meighan H der xi Printer 2810 Offline Save Printer as Default Powder zP1 02 y Use Default Powder Save Powder as Defaut Powder Parameters Layer Thickness 0 004 in Saturation Shell Core Anisotropic BinderVolume Ratio 315 157 Saturation Level 100 100 2 x Bleed Compensation 7 On ts in Saturation 1 8 0 9 3 Z 0 007 in Override Use Default Save as Default Reset Factory Settings 41 Z Corporation Z810 System User Manual It is also
34. additional filters They will often run out to a dead end beyond the last ingate Itis in this dead end that dirt debris and dross collect while good clean metal enters the mold ZCast Design Guide 38 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 sections Thick sections where the metal will be slowest to cool should be allowed to feed thin sections that cool more quickly and may freeze off before the entire casting is filled Sometimes it is difficult to design a mold this way and for this reason among others risers are sometimes placed between the runner and the ingate 11 1 9 Risers A riser helps to feed the casting before the whole thing solidifies but it also helps to minimize the shrinkage in the casting by serving as a reservoir of molten metal which can continue to feed the casting as it begins to shrink The riser is typically cylindrical and MUST stand as tall as the pouring cup Failure to do so will result in a significant loss of material as the level in the pouring cup reaches equilibrium with the level at the risers Aluminum alloys require extensive use of risers Often more than one half of the casting mass is in the risers For more on riser design see Basic Principles of Gating and Risering AFS Cast Metals Institute Appendix Figure 20 Runners lead out from the well I
35. close to the casting surface runs the risk that the metal will break through so limiting their openings to the upper surface of the cope limits the risk of leaking metal metal and cause personal injury A CAUTION Vents not located in the cope may unexpectedly leak molten e Mold vents may be designed into the mold and printed or they may be drilled in after printing Modifications like these and the tooling to perform them are commonplace in traditional sand casting foundries lt may be the choice of an experienced foundryman to vent a mold in this manner ZCast Design Guide 23 Appendix 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 Mold Cavity Section View of Mold Make certain that if the mold has a core that the core is properly vented to the atmosphere to allow unimpeded release of gas For situations where large surface area to volume ratio geometries are present i e thin wall mold geometries skillfully design vents so that gas can readily escape from the large surface area It is worth noting that these molds are the most challenging geometries for ZCast because the user must ensure adequate mold ventilation while also ensuring mold strength with thin wall geometry Thin mold geometries can prevent proper mold ve
36. complete the filter cleaning cycle before you begin depowdering Z Corporation Service 781 852 5050 887 88 ZCORP 51 Z Corporation Z810 System User Manual 6 4 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 tool is used in ZPrinter 310 and Z406 3D Printers only 2 Polypropylene Scraper This tool is used in ZPrinter 310 and Z406 3D Printers only www zcorp users com 92 Z810 System User Manual Z Corporation 3 Soft Horsehair Brush This brush has very soft bristles and assists the user with the gross depowdering process Brushing powder away from a delicate part to expose the area may be useful prior to vacuuming 4 Stiff Detailing Brush This brush has very stiff bristles which are useful for scrubbing caked powder out of tight areas of a part The brush is also very helpful when removing fringing from color part surfaces 5 Stiff Handle Brush This tool serves the same purpose as the Stiff Detailing Brush but is slightly larger and is more useful when working with a larger surface area 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 887 88 ZCORP 53 Z Corporation Z810 System User Manual
37. components into sections suitable enough to print in your Z Corp 3D Printer Typically Shell method only Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten metal A WARNING causing personal injury during metal casting Venting paths in the mold must be arranged and directed away from the metal path to avoid entrapment of gases 5 3 2 Shell Method If you plan to use the Shell method you will need to Begin with steps one through five from the Direct Pour method Divide out the core geometry if a core or cores exist in your design and add core prints Isolate the casting surfaces of your part to be cast and divide it into desired number of sections Shell each of the resulting open surface sections Design gating system on a separate conventional pattern Incorporate alignment features into shell and patterns Incorporate locking features so that shells are firmly held into place by foundry sand PES ee a ZCast Design Guide 17 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 The primary advantage of the Combination method is that a significant number of components can be manufactured using this technique A tutorial can be provid
38. cups and risers if necessary use core paste to glue in place in the unexpected release of molten metal and personal injury Always use core paste or adhesive for attachments Additional clamps or securing wires may also be needed Attachment of risers and cups without core paste may result AY CAUTION Pour The mold is now ready for metal ZCast Design Guide 32 Appendix 8 Pouring Metal 8 1 Metal Types The current product offering is ZCast 501 powder and is designed for low temperature non ferrous metals MAX TEMP 1100 C 2000 F The higher temperature metals will cause more gassing on contact with the mold Use of molten metals with pouring temperatures above the maximum temperature recommended for the ZCast molds can cause the mold to fail possibly explode and release entrapped gases and molten metal Do not attempt to pour molten ferrous metals into ZCast 501 molds Do not use ZCast 501 molds with molten ferrous metals or other metals with pouring temperatures above 1100 C A WARNING 2000 F The molds can suddenly fail unexpectedly releasing entrapped gases and molten metal causing serious personal injury Do not handle molten metal without heat resistant A WARNING faceshield gloves and apron and tools suitable for handling molten metal in foundry operations Do not handle molten metal without adequate local exhaust WARNING ventilation Hot gases emitted during the casting process can burn
39. cycle that can be accelerated with heat and have virtually no shrinkage however they have a higher durometer Patterns used to create molds with higher durometers may need draft and must have an excellent surface finish to de mold cast parts It is also recommended that the novice mold maker use a translucent mold material so the pattern is visible within the mold making it easier to direct where the parting line is located Manufacturers of Molding Silicone Hapco www hapcoweb com Dow Corning www dowcorning com General Electric www gesilicones com Innovative Polymers www innovative polymers com US Composites www shopmaninc com moldmaking html Ebalta www ebalta de Building the Mold Box The purpose of a mold box is to contain the silicone rubber after it is poured over and around a master pattern until the silicone turns to a solid A mold box does not have to be a complex structure depending on the size and configuration of your part often a can small plywood box pan or plastic bucket will get the job done For ease and convenience plywood Plexi glass plastic or sheet metal work extremely well Be sure not to use a material that will inhibit the curing of the silicone Consult your silicone vendor for a list of these substrates The box must have four sides all of which must stand higher than the master pattern when mounted to the gate The box can be screwed or nailed together but clamps are used in mos
40. depowdered need to have their saturation values manually set These parts should be printed with a very low core saturation value and the highest shell saturation possible without affecting depowderability cakiness a Flop ipo tte il Di te pE presei p pi prar A ij owa E a i tera Y Unsupported Volume 18 ligii 0 000 laches Z Corporation Service 781 852 5050 887 88 ZCORP 43 Z Corporation Z810 System User Manual 5 4 PRINTING THE BUILD It is strongly recommended that the build settings be confirmed before Printing Calead Colorl 4 plp on ALEXEY1 printing To check build settings ti ishTime 59 PM Starting Time 1 43 PM choose 3D Print Setup under the File mated Ti ir Elapsed Time menu or click on the icon located on the taskbar After all build settings have been confirmed 1 Choose 3D Print under the File menu 2 A dialog box will appear asking that powder and fluid levels be checked Figure 16 Printing Status Dialogue Box 3 Press OK to confirm that these have been checked to begin the build Once the build has begun a dialog box will appear reporting the status of the build www zcorp users com 44 Z810 System User Manual Z Corporation 6 REMOVING THE PART 6 1 SET TIMES Once the build has completed let the part sit in the printer to set This will allow the part to dry while being supported by surrounding powder Recommended Set Times Mater
41. e E E da e dd 110 13 7 GLEAN GPREADER ROLLER a dd a lees 111 13 8 CLEAN SQUEEGEE SCRAPER Conan iia 111 13 9 CLEAN SQUEEGEEWIPERS tania di id 112 13 10 BLEED AIR FROM THE FLUID SYSTEM cccceccececcececcececcececcccucececuecececueuecueaeeeeaeseeacsecaees 112 13 11 lt GUEBANSFAST AXIS PULLEYS cacian das 113 13 12 CLEAN POWDER SCREEN ON THE ZF8 POWDER FEEDER eccececcececeececeececceucecaeeeceees 115 13 13 EMPTY POWDER DRAWER ON THE ZD8 DEPOWDERING UNIT ceceececeecececcececcececeees 115 14 Z810 SYSTEM DETAILS veces casi e ee ands 117 14 1 SYMBOLS USED st ride ita toca cds 117 14 2 SYSTEM SPECIFICATIONS cceccececececcccececcccccececueecececscuuceacaetecscauausecstseauaenerseauaunenscaeass 117 14 3 MATERIAL STORAGE PRECAUTIONS ccsceccececcececcececcecuccecuecccucaecucceaucueuceucaeaecueaeceuaecass 118 PAA ROR IDODES iaa a otitis 118 15 INDEX a a o det ol dd oem 123 APPENDIX I ZCAST DESIGN GUIDE cc ccccceeeecceceenscceceeenaesceeeuaseeeeeeuaneeeeueanneeess 126 www zcorp users com 4 7810 System User Manual Z Corporation TABLE OF FIGURES FIGURE TE THE PRINTING PROCESS e o o en de Ud 8 FIGURE 2 THE SHELLING AND INFRASTRUCTURE FEATURES 2 0cceeceeceeeceeceeceeceececceccucceeeuseuseueeaeeaes 9 FIGURE 3 ILLUSTRATION OF Z CORP SYSTEM PRINT ORIENTATIONS 0cceccecceceececcecceceececcesaeeaeeees 10 FIGURE 4 Z810 3D PRINTER FRONT VIEW aaa diia 12 FIGURE 922610 3D PRINTER TOP VIEW
42. facility for priming and clear coating varnishing the parts protective clothing such as breathing masks and gloves Suppliers Service Bureaus There are a limited number of companies that provide this service Below is a list of websites for several service bureaus and manufacturers around the world Many of these companies were found with an Internet search they have not all been qualified Dips n Pieces Located in Germany They manufacture and sell water transfer printing equipment and also operate a service bureau They have worked with Z Corp parts before Website www dips n pieces de Alsa Corp Located in the United States They are a service provider capable of prototype to production quantities They also offer other finishing services and equipment Website www alsacorp com Deco Tech Located in the United States They are strictly a service provider capable of prototype to production quantities They have worked with Z Corp parts before Website www xfinishes com Yuan Heng Tai Water Transfer Printing Located in Taiwan They manufacture and sell water transfer printing equipment and provide finishing service Website www yht com tw Z Corporation Service 781 852 5050 887 88 ZCORP 69 Z Corporation Z810 System User Manual Master Approach Sdn Bhd Located in Malaysia They offer dip printing as a service Website www maproach com Dorchase Industrial Ltd Located in Hong Kong They p
43. foundry sands Vents can be small holes usually at high points in the casting extending through the cope to the atmosphere These are often small enough 0 125 in or 3 mm is recommended to freeze off before the metal reaches the exterior of the mold Vents also must be used in cores Figure 9 When molten metal comes in contact with ZCast compounds out gassing occurs If the cores are solid the gas would have nowhere to go but For more detail attend online ZCast Design Guide seminar or refer to the ZPrint software help section ZCast Design Guide 20 Appendix 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 Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten metal A WARNING Causing personal injury during metal casting Venting paths in the mold must be arranged and directed away from the metal path to avoid entrapment of gases Do not handle molten metal without adequate local exhaust A WARNING ventilation Hot gases emitted by during the casting process can burn skin and are irritating and toxic Refer to the ZCast 501 powder MSDS for more information 6 5 1 Venting Cores Follow these guidelines to obtain bes
44. in the burnout oven Note this process has been omitted by some users to their satisfaction Patterns infiltrated with resin should skip the autoclave process and go directly to the burnout oven Z Corporation patterns should be burned out at 1750 1800 F 954 982 C in an oxygen rich environment Burnout time will depend on the part volume and air circulation If the part is an inch thick or less it should burn out completely in two hours For larger parts a longer burnout time should be expected The patterns will burn out completely if they are left in the oven for a sufficient amount of time Low temperature furnaces with air treatment devices using ionized air have also been utilized successfully to burn out Z Corporation patterns Refer to the furnace manufacturer for guidelines for this process After burn out allow the shell to return to room temperature In some cases a small amount of residual ash may remain less than 1 This can typically be washed or blown out of the mold Wash the shell out with water Allow the shell to dry and thoroughly pre heat shell before pouring metal to entirely eliminate any water vapor that may remain Results 2 shrinkage should be expected when going from the Z Corp pattern to a cast part The surface finish will depend on the surface of the original pattern but can be expected to be around 3 5 mils Z Corporation Service 781 852 5050 887 88 ZCORP 71 Z Corporation Z810 System User
45. international symbol for standby power It is used on the Z810 3D Printer power switch The Z8103D Printer is partially powered as soon as you C plug it in The power switch is momentary contact and toggles the machine from idle mode to full power on mode This is the international symbol for warning or caution When it appears on the exterior of the equipment it indicates the need to consult your manual for further information 14 2 SYSTEM SPECIFICATIONS Operating Conditions 68 to 85 F 20 to 60 Relative Humidity non condensing Lithium Battery Internal to the Z810 3D Printer is a lithium coin cell type battery This may be any one of the following Type CR2032 either Maxell Panasonic Renata Sanyo or Sony PLEASE NOTE This battery is not in a user accessible area and is not user replaceable 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 These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interferan
46. it is a good idea to attach wire before painting the parts Wire can be attached to any non visible surface with cyanoacrylate resin 5 After the wire is securely attached spray the entire part including the wire with a conductive paint There are a variety of conductive paints on the market such as Agri Systems Non Stick Graphite Paint or Dalmar Easyplate Copper Conductive Paint 6 The conductive coating is critical to good plating Spray all parts well and evenly Do not leave any surface un coated Be especially careful of where the part is held while you spray it Do a second coating to cover these spots Plating e While any electroplating shop should be able to plate the parts at this point it is a good idea to find a shop that has experience with plating nonconductors when possible During the plating process the first bath will be a copper strike This bath will use a relatively low current The paint you use may come with directions for the current and voltage that should be used for this coating If not a good guideline is to start at 1 to 2 amps square foot and increase that amount as the part starts to plate Once this first layer has been plated the following coats can be plated as normal If the surface is not leveling it can be sanded in between baths to help get a shiny finish Contacts If you would like to have a part plated we recommend contacting Associated Electroplaters Inc at 248 547 5520 ww
47. layer thickness The roller then spreads a new layer of powder and repeats the process until the entire part is printed printheads distribute colored binder BUILD PROCESS 1 Spread thin layer of powder layer of freshly build area 2 Deposit binder on area to be bonded roller spreads powder i ia bound powder 3 Lower build piston one layer 4 Repeat steps 1 3 until build is complete 5 Remove finished part printhead cleaning area appearance prototype build piston Figure 1 The Printing Process www zcorp users com 8 7810 System User Manual Z Corporation The Z Corp Printer System employ several techniques to quickly build parts First binder solution is applied in a higher concentration around the edges of the part creating a strong shell around the exterior of the part Within parts the Z Corp 3D Printer builds an infrastructure by printing strong scaffolding within part walls with a higher concentration of binder solution The remaining interior areas are printed with a lower saturation which gives them stability but prevents over saturation which can lead to distortion of the part Other interior areas printed at lower saturation Interior infrastructure printed at a higher saturation 4 Exterior walls printed at higher saturation Figure 2 The Shelling and Infrastructure Features After printing the part is removed from the powder bed dried and depowdered The part can then be
48. removed before metal casting Residual moisture in the mold can cause the mold CAUTION to unexpectedly fail releasing entrapped gases and molten A metal and causing serious personal injury Do not bake ZCast molds in unvented ovens Irritating and toxic fumes are formed at elevated temperatures during CAUTION oven baking Ovens must be vented to the outside Refer to the ZCast 501 powder MSDS for more information on the irritating and toxic fumes Final Depowder Immediately prior to pouring gently rub the mold surface to knock off any loose material and blow dust away with compressed air Depowdering with compressed air will generate airborne particles Only trained or supervised individuals should A CAUTION depowder a mold Use hood ventilation and safety goggles or faceshield to protect the eyes and face Refer to the ZCast 501 powder MSDS for more information Seal Run a bead of core paste around the parting surfaces to prevent metal from leaking out of the mold during pouring Use caution not to block vents Do not cast metal parts in molds with multiple sections A CAUTION without core paste or adhesive Molten metal may leak from the mold seams and cause personal injury Avoid blocking vents with paste or adhesive ZCast Design Guide 31 Appendix 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
49. safety recommendations regarding handling storage venting and personal protection equipment when using these kinds of materials This information can be found on the Material Safety Data Sheet of each material Z Corporation Service 781 852 5050 887 88 ZCORP 63 Z Corporation Z810 System User Manual 9 2 PAINTING PARTS This procedure reduces the amount of sanding needed to produce a nice smooth surface on Z Corporation parts 1 Depowder and dry the part 2 Hand sand the part with 230 grit sand paper lightly 3 Mix BCC Proto Kast BC8163 Proto Kast White urethane Proto Kast is a 2 part urethane Mix with a third of lacquer thinner This thins the mixture and retards the hardening process For example if you were to make 150 grams of the mixture take 50 grams of part A 50 grams of part B and 50 grams of lacquer thinner BCC products can be found at http www bccproducts com p3 html 4 Infiltrate with one coat of BCC Proto Kast urethane E mixture by dipping dripping or brushing si 5 Apply 10 light coats of Sher Wood sanding sealer by spraying l E A e o ae A We a de BUS fat B 6 Apply lacquer primer by spraying A hand held air sprayer will be necessary for the highest quality surface finish po em ly A rl 7 Apply colored lacquer gloss paint to achieve the shiny plastic like finish www zcorp users com 64 Z810 System User Manual Z Corporation
50. tarada 13 FIGURE 6 Z810 3D PRINTER CARRIAGE ASSEMBLY 2cceceececcecceceeceececceceecueceeceeaeceeaeceecessesaeeneeneaess 14 FIGURE 7 Z810 3D PRINTER SERVICE STATION co o ede ee ae 15 FIGURE 8 Z810 3D PRINTER CONNECTOR PANEL 2 ecceceeceeceececeeceeceeceeaeceecueceeecesaeceecusaeeaeeneeneaess 16 FIGURE 9 ZF8 POWDER FEEDER FRONT VIEW 0sccccccesseceecceeeeecececaeeeceeeseueceeeseeeeeeeeeeaeeeeeeeeas 18 FIGURE 10 ZF8 POWDER FEEDER REAR CONNECTOR PANE L esceeceececceceecceeceeeeeeeceeeneeaeceeeneeaees 19 FIGURE 11 ZD8 DEPOWDERING UNIT cccccecceceececeececeeeeceeeecueeeceeeeaecueaeceeeseeeeaeseeaeseeaesesaeaesneaeenees 21 FIGURE 12 ZD8 AIR CURTAIN SELECTOR LEVER 2 ceccecceeceeceeeeeeceeceeceecuecuecueceeaueceecuecuecueseeeuseueeaees 22 FIGURE 13 ZOO CONTROL ANE elise erases nectar nn nether ados celo oben ll Rai 23 FIGURE 14 ZD8 POWDER COLLECTION DRAWER 2 cecceceeceececcecceceececceeaececeesecuecesaeceecessesaeeneeneaess 24 FIGURES 208 GAR emer Sea neers E ene E ge ee er ee A rta 24 FIGURE 16 PRINTING STATUS DIALOGUE BOX curia aida 44 Z Corporation Service 781 852 5050 887 88 ZCORP 5 Z Corporation 7810 System User Manual Use of Equipment The Equipment was manufactured under patents licensed to Z Corp to be used for the fabrication of appearance models and prototypes Other uses may be restricted contact Z Corporation for further information The Equipment is designed to be
51. the plate carefully If you would like to save the sheet remove the top edge of the paper adhere it to a blank sheet of paper and pull the blank sheet of paper slowly 12 Repeat steps 2 12 on a clean sheet of alignment pad until all alignment reticles line up at 0 Z Corporation 13 Look at target drawings to confirm alignment of print heads f l All targets are evenly centered at 0 in the U and 5 axes 14 Purge print heads after alignment process with binder This will clear print heads of black ink and fill them will clear binder The process should take about 10 minutes The LCD will display Online when the printer has completed the purge process Technical Tip CAOT ETTET Mi DI All bull s eyes are centered Nutini Purge Print Heads fea Purge Print Heads fea Heads Press Start to begin purging the print heads When the print heads are purged press Done Start Done 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 887 88 ZCORP 89 Z Corporation 15 Unpark the gantry to expose the service st
52. the rest of the part This will add time to post processing the part but it ensures that you have a good strong part without any fractures Z Corporation Service 781 852 5050 887 88 ZCORP 33 Z Corporation Z810 System User Manual 4 PREPARING THE Z810 3D PRINTER 4 1 REPLACING THE BUILD PALLET Put the printer offline If there is no pallet in the printer replace the pallet by pressing Load Unload on the control panel to move the build piston up Once the build piston is in the unload position place the pallet on the build piston by lining up the pallet holes with the pegs Press the Online button to return build piston to printing position 4 2 CLEANING THE SERVICE STATION 1 Put the Printer online Unpark the carriage using the software by choosing the Unpark option under the 810Service menu Open the top cover Once the service station is exposed wipe the squeegees with a dry paper towel You may also wipe the other areas of the service station such as the parking cap and the spit station www zcorp users com 34 Z Corporation Z810 System User Manual 2 Check the zc10 wash fluid reservoir When the depository is dry refill with one bottle of zc10 wash fluid 3 Wipe the squeegee scraper with a dry paper towel Technical Tip The cover plates may be detached and cleaned under running water to remove any debris Keeping the machine clean will ensure that it works optimally
53. through resulting in metal fouling the core vent e Cores can sometimes be incorporated directly into either mold half these internal cores possess the benefit that they are always aligned and that no requirement exists that venting pass through a parting surface e Position parting line where flash can be tolerated and or ground off putting the parting line across a complex region without room to grind will limit the possibilities of finishing the part e Keep parting line as far away as possible from core vents since some metal can leak along the parting line be careful that it does not reach the openings for core vents Metal will potentially leak out of the mold and into the core preventing the vent from performing its function e Minimize the number of jogs keep the design as simple as possible The more angles and steps in the parting line the more difficult it will be to assemble the mold accurately ZCast Design Guide 25 Appendix vents The vents may not function properly and cause the Parting lines near core vents may leak molten metal into the CAUTION unexpected release of molten metal and personal injury 6 7 Depowderability Fixed vs Removable Cores Part depowdering refers to the removal of loose unprinted 4 AN powder from the mold cavities following the printing process gt While the possibility to print complex geometries exists such as n undercuts and runners that tunnel under
54. used The pressure is obtained by evacuating the space between the sheet and the mold in order to utilize this atmospheric pressure Vacuum forming will give satisfactory reproduction of the mold configuration in the majority of forming applications Manufacturers can use all types of thermoplastic materials 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 where you can search SPI s Membership Directory amp Buyer s Guide for thermoformers In the example below the industrial designer wanted to get a feel of his design in the actual material He was able to generate a mold and produce a sample in a period of days MOLD PROTOTYPE The packaging company that produced the prototypes below uses the parts to generate samples for their sales department who then use them to collect customer feedback Z Corporation Service 781 852 5050 887 88 ZCORP 13 Z Corporation Z810 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 The process for m
55. used by design engineers and other professionals in the production of early stage 3D appearance models and prototypes The Equipment is not to be used to produce either directly or indirectly medical or other products that may require precise dimensions or tolerances to ensure the safe and effective operation of such products 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 lf you have purchased all relevant casting specific products as recommended by Z Corp casting specific service contract hardware software and consumables as well as a casting license then you are authorized to utilize the Equipment to fabricate molds for casting www zcorp users com 6 7810 System User Manual Z Corporation 1 INTRODUCTION 1 1 OVERVIEW This Z810 Color 3D Printer Manual will speed you along the path towards quickly and inexpensively building parts The manual contains the following sections 1 Introduction This section will give you an overview of the principles behind the Z Corporation Z Corp 3D Printer 2 The System Components This section will provide a guide for the Z810 System components and features detailed diagrams It will describe the Z810 3D Printer Printer ZF8 Powder
56. vacuum switch will not turn on the vacuum until powder is dispensed from the feeder Z Corporation Service 781 852 5050 887 88 ZCORP 37 Z Corporation Z810 System User Manual 4 6 CHECK FLUID LEVELS 4 6 1 BINDER CONTAINERS Check the fluid levels on the binder and waste containers It is good practice to fill the binder bottles when they are half empty The color binder containers can hold half a gallon 2 liters of color binder The large clear binder container can hold up to four gallons 16 liters of clear binder PLEASE NOTE If the printer will be printing in monochrome mode only fill color containers with distilled water See Section 12 2 Flush System with Distilled Water To fill the binder bottles 1 Unscrew the top cap 2 Fill container with binder 3 Replace cap PLEASE NOTE Binder level sensors will indicate via the software when the binder level is low For color binder the sensors will Indicate a low level when it reaches one liter of fluid For clear binder the sensors will Indicate a low level when it reaches six liters Corp System Software You may want bo check these Binder jugis may be empty of fluid These amounts are enough to complete a large build The warning will appear before the printer begins a build so that you may fill up the binder bottles to prevent errors in the print job and damage to the printer www zcorp users com 38 Z810 Syste
57. 1 Arching is a concavity phenomenon that occurs as moisture evaporates from the first few layers of a part that has been printed ZCast Design Guide 28 Appendix e 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 Layer Thickness 0 005 Bleed Compensation Settings ae ZPrinter 310 Z 406 22810 Table 1 6 14 Degassing and Filtering Metal To help achieve improved part quality steps should be taken to properly prepare the metal for pouring Two typical foundry practices are degassing and filtering When properly taken these steps help to yield quality parts in any foundry Filters can be added directly to the mold This can be accomplished by Figure 12 Refractory sleeves and strategically locating filters within the drag assembly as shown in Figure 13 filters Design slots or shelves in the drag for filter placement Other options include using foundry consumables with ceramic inserts as shown in Figure 12 Accumulated slag on the top of the crucible should be removed prior to pouring ZCast Design Guide 29 Avovoendix Cope x _ Cope rl Filtered metal Filtered metal Direction of incoming Figure 13 a b c Horizontal filter orientation Metal rises up t
58. 1ccccscccceccceececeecceeecsececsecececenneecaeeesseseceesaesesnessnneess 94 11 1 2 USING ZCAST ON YOUR Z810 3D PRINTER 0 ccccccccceeccneccneecneecnsecnsecneeeneesneeens 94 TLIIS SETING UP ZGAST BUILDS coa isis eae cao e hae 95 TELA POST PROCESSING ZGAST PARTS ta eee nas ee ieee 95 11145 MATERIA ORDERIN E es iweton 95 MELO RECON a e e do eo e ero le dd 96 ILL STORAGE A Ea nee Tee rc a ee een PETE RES meee Are rns LO eT 96 MO DOFO DARD Rae tee ca to aR PEE e TPE e caro cuen cd 96 1119 QUESTIONS AND SIPPOR Td asa 96 11 2 E 250 POWDER sesessceesssinscetsiciacobsiesn eeeateedacctiinvctlesebusn ctu bacabalieaatlsesietacaevwscevcuades 96 Z Corporation Service 781 852 5050 887 88 ZCORP 3 Z Corporation 7810 System User Manual Led Macael a A A a dd 96 PA SOWNO OCUP A 96 11 23 Part Removal and Post Processing ccsscccccsseeeccnseuscensanseccnscsescnseesensaussessausesensaness 98 1124 IANA OR AOGENOUM ccs fo 25sec clcdec fo a r On de seeks Jeet 100 12 CHANGING INI VARIABLES 0c ccccccececcececesceceececescecnscscecnseeenseseuseseusesenensenensenensnseas 101 13 MAINTENANCE a a a ed 104 13 1 ADD ZC10 WASH EE ad 104 13 2 FLUSH SYSTEM WITH DISTILLED WATER cccccececcececcececcecececcecccecaecececaeaecueaececaceeeeeseeaees 105 1353 GREASING THE FAS TAXIS vases aioli e de o o o a lao o eo 108 13 4 GREASING THE O OVA O dd ae o 109 135 gt GEEAN UNDER GANTRY Selected e da e dd e in 109 13 50 CLEAN PAN e E E
59. 33 9 Material TIGIN GUNG sisi 34 Q Slr A 0 A 34 de DISPOS Alsan id 34 93 POWER RECIEN e e o DE Tn 34 o A PA 35 10 1 DESMONTAR AAN N 35 10 2 Secondar Opera Sc A VENE NE 35 10 3 OVENS si O a 35 11 Foundry ConsumMables oocccocccccnccocncccccconnconncconnccnnonncnnnnnnss 36 11 1 Sand Casino AOSS Vat da e 37 Mt Cope and Drag cit dt da iaa ate 37 A A Per ee Tee eee ee 37 MS DOS lt a oe mere Ce rer re ee arr tias een 37 AA OUD trenirani ra ie aiaiai Meiers ee 38 ARA O a aa eaen rA 38 E O a a a r eet 38 LE RUMO onea eira a aa ar aaa e N 38 ETS O O 39 TIAS RISOS iuern a a a a tatexnaneadoeuneids 39 12 COn USIO oneee E A 39 ZCast Design Guide 3 Appendix 1 Introduction The ZCast process was created to allow for the rapid fabrication of metal parts It allows cast metal parts to be verified without the time and expense that is typically associated with production tooling While the range of uses is broad the ZCast process most closely resembles sand casting in both the finished part and the functionality of the mold It is suggested that anyone making parts with ZCast powder should Become familiar with the design of sand casting molds Locate a foundry experienced with the sand casting process ZCast users range from individuals with little or no mold design to Knowledgeable experienced pattern makers or foundrymen Since ZCast users possess a wide range of experience this guide has been written with
60. 8 Cart 24 Z810 System User Manual Z Corporation 2 3 DESPATCH LBB FORCED CONVECTION OVEN OPTION Key Features e 42 inches 1 07 meters deep x 45 inches 1 14 meters wide x 84 inches 2 13 meters tall Height includes oven stand Oven alone is 51 inches 1 3 meters tall e Forced convection Temperatures up to 400 204 C Precise digital controls Stainless steel interior Ventable Nickel plated shelves Five year heater warranty UL and C UL listed Optional CE mark Power 208 240V 50 60 Hz For more information contact your Z Corp Sales representative or look on the Despatch website at http www despatch com For information on how to transfer parts from the ZD8 Cart to the Oven please see Section 7 Depowdering the Part PLEASE NOTE Mold preparation and metal pouring requires adequate ventilation to ensure that exposures to dust particulates fumes and vapors are controlled below occupational exposure limits Ventilation designs need to meet each customer s respective governmental health and safety requirements A reference frequently used by U S firms to comply with OSHA regulations is the American Conference of Governmental Industrial Hygienists Industrial Ventilation Manual Please review the Material Safety Data Sheet for ZCast powder Z Corporation Service 781 852 5050 887 88 ZCORP 25 Z Corporation Z810 System User Manual 3 QUICK START GUIDE Here is a quick guide to prin
61. COrp users coOmM 14 4 ERROR CODES PLEASE NOTE d and x are place holders for numbers corresponding either to print head number or a value 1000 Unknown head error 1001 Can t turn on head 5 12 V 1002 ROM read failed for head d 1003 12C read failed for head d 1004 Head d fire voltage failed 1005 Head d temperature too low 1006 Head d temperature too high 1007 Head d current too high 1008 Head cover is open 1009 Head d fire voltage stuck 1010 Invalid head temperature 1011 Out of binder 1100 SYSTEM out of memory in thread d 1101 SYSTEM can t log ETS events 1200 THREAD d can t create events 1201 THREAD d can t initialize window system 1202 THREAD d can t make window 1203 THREAD d can t begin 1204 THREAD d can t set priority 1205 THREAD d illegal state 1206 THREAD d refuses to stop 1207 THREAD d refuses to die 1300 QUEUE out of memory 1301 QUEUE can t create event www zcorp users com 118 Z810 System User Manual Z Corporation 1302 QUEUE received null pointer 1400 KEYBOARD can t add callback 1401 KEYBOARD can t create pipe 1402 KEYBOARD error writing pipe 1403 KEYBOARD error reading pipe 1500 KEYMAP duplicate key d 1501 KEYMAP bad key index d 1600 COM d is not a valid port 1601 COM d queue is too small 1602 COM d ETS monitor is using port 1603 COM d port already in use 1604 COM d can t create event 1605 COM d can t create thread 1606 COM d can t set priori
62. ERING Gross depowdering is the initial removal of excess powder from the build 1 Put printer Offline 2 Turn on the vacuum 3 Insert the vacuum hose into a vacuum receptacle in the powder feeder and turn on the vacuum 4 Lift the top cover of the printer to gain access to the build area www zcorp users com 46 Z810 System User Manual Z Corporation 5 Vacuum powder around the edges of the build area and part Technical Tips e Place the vacuum nozzle at an angle to facilitate airflow into the powder feeder and improve suction control Use the vacuum attachments to control suction and for ease of vacuuming powder in tight areas Use the second vacuum receptacle located in the back of the powder feeder to access the rear of the build area 6 Carefully vacuum around the part from the top to the bottom and from the outside edges of the build area to the inside 7 Raise the build piston as needed for easier access to the part 8 Leave powder underneath the part to Support any overhanging surfaces Z Corporation Service 781 852 5050 887 88 ZCORP 47 Z Corporation Z810 System User Manual 9 Carefully vacuum around the part to remove as much powder as possible Technical Tip Leave enough powder around the part to cradle the part during build pallet transfer 6 3 TRANSFERING THE PARTS TO THE DEPOWDERING STATION 1 Put printer Offline Press the Load Unload
63. NG Z SNAP EPOXY Z Snap epoxy is a flexible toughened epoxy infiltration system specifically formulated for Z Corporation for use with zp 250 powder Parts made from zp250 powder and infiltrated with Z Snap exhibit the appearance and snap fit characteristics of plastic These parts can be easily sanded and finished For detailed instructions on how to use Z Snap epoxy with zp260 parts see Section 11 2 3 Part Removal and Post Processing of zp250 Parts 8 3 1 GENERAL APPLICATION NOTES e All part surfaces should be clean dry and free of contaminants prior to applying Z Snap epoxy e The part should be oven dried for 2 4 hours at 150 F 200 F 65 C 85 C depending on part volume and wall thickness to drive off any excess moisture that remains in the part after depowdering e Z Snap epoxy can be sprayed brushed or drizzled onto parts Multiple thin coats applied liberally during the resin s working time will produce maximum infiltration depth 8 3 2 MIXING INSTRUCTIONS e Inaclean plastic non porous container mix Z Snap Resin to Hardener in a 2 1 ratio by volume 100 47 by weight Mix the two parts thoroughly for 2 minutes stirring in a figure eight pattern being sure to scrape the sides and bottom of the container e The material has a working time of 85 minutes in a 450 gram mass at room temperature Mix only what you need Please be aware that the mixed solution will increase to a maximum temperature of 122 F 50 C af
64. R BRICKS BLD a warrior zec l Color Bar zcp 9 Manifold BLD 3 Z Corp Ball stl you will be using 5 Click OK Filename fark 2000s l ne Me he y be broug nt into the software Files of type All Part Files zbd stl bld ply zcp sfx zec wl Cancel and sliced Z If you would like to open additional files choose the Import option under the File menu 5 2 ORIENTING THE PART We recommend that only one level of parts be printed All parts should be seated on the build pallet Place parts in the center of the build pallet by choosing either Justify or Justify Group under the Transform menu and select center justify for the left and right and front and back options Parts that need to be built separately and then mated are dependent on part geometry If you need assistance for best accuracy with mating parts please contact the Applications Engineering Team at applications zcorp com 5 2 1 PART CONTAINING AN OPENING OR HOLLOW AREA f the part has an opening or is hollow place the opening or hollow side up This will allow for the removal of powder during the gross depowdering process www zcorp users com 40 Z810 System User Manual 5 2 2 PART CONTAINING OVERHANGS Unsupported overhangs should be placed on the left hand side and as close to the build plate as possible The plaster powder being extremely fine is more fluid in the build Placing
65. Start Done For information on how to design a ZCast mold read the ZCast Design Guide which can be found at the appendix of this manual or in the Applications section of the User Group Website at www zcorp users com Z Corporation Service 781 852 5050 887 88 ZCORP 93 Z Corporation Z810 System User Manual 11 1 USING ZCAST 501 POWDER 11 1 1 GENERAL INFORMATION ZCast 501 powder is a plaster ceramic composition that allows you to print sand casting like molds and or cores with your Z Corp printer Once printed depowdered and baked you have the ability to immediately pour molten metal yielding a cast metal part Arguably the ZCast process is the fastest and most direct way to obtain a metal part from digital data ZCast 501 has been optimized for non ferrous materials ranging from zinc to brass including aluminum and magnesium WARNING Do not pour magnesium without first contacting a Z Corporation technical representative NEVER ATTEMPT TO POUR FERROUS METALS IN ZCAST MOLDS You will find a detailed document entitled ZCast Direct Metal Casting Design Guide located in the appendix of this manual for additional information 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 to applications zcorp com Be sure
66. Z810 System User Manual September 2004 Z 810 Color 3D Printer User Manual Z CORPORATION Copyright O 2002 2004 Part Number 09524 Z Corporation Z Corporation 7810 System User Manual TABLE OF CONTENTS Y INTRODUCTION cunsarsrarisa A A E 7 1 1 OVERVIEW tt e e dr de t 7 t2 HOWIT WORKS a a cae cid 8 2 SYSTEMCOMPONEN TS od 11 2 1 ZO PRINTER COMPONENTES a a e do a A eden 11 2 1 1 LAIR A AA A A A IN O 11 2 1 1 1 Z810 Carriage ASSOMDIV escindida ideas 14 2 1 1 2 Z810 Service Station 2 0 cc ccc eecceccececeeceeeeeeceeceecueceeceeceecueceeaecaeeaesaeceeeneeaeens 15 2 1 1 3 Z810 Rear Connector Panel cccecceececceeceeeceeceeceeceeceeceecuececeeesaesaesaeeueeaeens 16 2 1 1 4 Z810 Printer Control Panel cee ccccccceceeceecceeceeceeceeceeceecuecaeeaeceecueseeseeeneeaeeas 17 2 1 2 ZF8 Powder Ferris 18 2 1 2 1 ZF8 Rear Connector Panel cc cece cecceeceeceecceeceeceeceeceecuecueceececeeaeeaecuesueeaeens 19 22 ZG DEPOWDERING UNIT a a 20 2 2 1 EA A A IAE 22 222 ZD8 Control Al ad 23 2 2 3 Powder Collection Drawer 2 12 11cccccecceeceecneceeceecnecseceecsecnecaeedecaeeseesecesaesaeeaseneeaeeaess 24 o A 8S OF EA EE CANE a a a PEE eee 24 2 3 DESPATCH LBB FORCED CONVECTION OVEN OPTION coocccccccnnncconncononnconnnonnancnnnonnnancnnnnnnns 25 S QUICK START GUIDE aiii aa 26 3 1 PRINTER PREPARA TON escamas a a a a ra 26 e JOE TRING UP THE BUIL Diiren e a 29 3 3 TRANSFERRING THE PART TO THE DEPOWDERING
67. aces The offset can be created on either side of the parting surface or split between them Even with an intentional gap there will likely be some portion of the mold or core that rubs against another part when the mold is assembled When one ZCast object rubs against another ZCast object they essentially sand each other down leaving a little bit of loose sand Since this is bound to happen you should prepare for this by leaving room between cores and core prints and where possible at junctions on the parting line taking care not to extend this gap into the path of metal Add a small Figure 11 Tapered core and core print l Core has radiused bottom edge Add Cast Design Guide 26 offset between mating surfaces Appendix 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 6 9 Geometry Guidelines For the majority of metals that can be poured in ZCast 501 molds the following are the geometric limitations Minimum core size 0 14 to 0 16 in 3 5 to 4 0 mm some distortion will occur if small cores project across large distances Minimum cast feature size positive feature 0 12 in 3 0 mm thinner ribs have be
68. acrylate 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 Z Bond 10 which can be used with starch models is available in 0 5 lb bottles and Z Bond 100 which can be used with plaster models is available in 3 5 ounce bottles and 24 ounce spray bottles 8 2 1 SAFETY PRECAUTIONS Do not use or handle this product until the Material Safety Data Sheet has been read and understood Wear lab coat gloves we recommend Nitrile Examination Gloves face shield or goggles Face shield is required if spraying Apply in ventilated hood Specialized containers recommended for dispensing and application System for avoiding spills Catch pan waxed paper or plastic drop cloth Label disposal materials Wear dust mask when sanding finished parts GENERAL APPLICATION NOTES Part should be fully dried before applying resin Resin reacts with water and produces heat If the part is not dried it will heat up the part and produce gas that may be an irritant to the mucous membranes Material can be brushed dripped or sprayed Material will penetrate between 0 8 0 12 inches 2 3 mm Do not over apply the material as it will pool off the part during cure cycle SPRAYING INSTRUCTIONS
69. acuum Hose Receptacles The vacuum hose connects to these receptacles to allow for loading powder from container vacuuming up powder from the build area emptying the overflow chute and emptying the ZD8 Powder Drawer Access Panel Allows access to the ZF8 Screen which screens out powder chunks from being deposited into the powder Vacuum Switch Turns vacuum on and off Handle Allows user to remove Powder Feeder when changing material systems Vacuum Hose and Attachment Storage Holds vacuum hose and all attachments for easy access and storage Figure 9 ZF8 Powder Feeder Front View Www zcorp users com 18 Z810 System User Manual 2 1 2 1 ZF8 Rear Connector Panel Z Corporation Powder Feeder Serial Cable Connector provided Air Connector Connecting Hose provided Power Input Connector provided Figure 10 ZF8 Powder Feeder Rear Connector Panel Z Corporation Service 781 852 5050 887 88 ZCORP 19 Z Corporation Z810 System User Manual 2 2 ZD8 DEPOWDERING UNIT Site Requirements Power Voltage Receptacle For Plug Type 190 200 VAC 50Hz 10 5A IEC 60309 2 RED 6h 32A 3p N E 208 230 VAC 60Hz 15A IEC NEMA L15 30 Plug 380 400 VAC 50Hz 5 3A IEC 60309 2 Plug Red 6h 16A 3p N E Plug Compressed Air Clean dry air dew point 40 F 4 C or below Air Fitting Industrial quick disconnect or other quick disconnec
70. adequate ventilation to ensure that exposures to _ dust particulates fumes and vapors are controlled below occupational exposure limits Ventilation designs need to meet each customer s respective governmental health safety requirements A and reference frequently used by U S firms to comply with OSHA regulations is the American Conference of Governmental Industrial Hygienists Industrial Ventilation Manual 55 Z Corporation Z810 System User Manual out certain sections of your part using your respective CAD software package to decrease volume For more information refer to the ZCast Design Guide located in the appendix of this manual or found on the User Group Website at www zcorp users com 8 Remove part from oven and complete depowdering for plaster and ZCast parts only 9 Remove part from depowdering unit 10 Clean depowdering unit by using the external vacuum to remove any debris www zcorp users com Z810 System User Manual Z Corporation 8 INFILTRANTS INFILTRANT MATERIAL SYSTEM APPLICATION Z Max Epoxy Starch and Plaster System Spray or Brush Z Bond Cyanoacrylate Starch and Plaster System Spray Brush Drizzle Z Snap Epoxy zp250 Material System Spray Brush Drizzle Starch and Plaster System Spray or Dip For an updated list please visit the Z Corp Users Website at www zcorp users com All parts can be infiltrated with a variety of resins to produce a range of material properties As an
71. adhesive After spraying with activator the ink must sit for 3 minutes Transferring The parts are dipped into the water through the layer of liquefied ink The image is pressed to the parts evenly by the pressure of the water If there are several parts to be dipped they are mounted to a fixture and dipped simultaneously Washing and Drying The printed parts are washed to rinse off remaining pieces of film and dried Due to the exposure to water here Z Corp parts must be well infiltrated and finished completely with the primer even if the image is to be partially applied 68 Z810 System User Manual Z Corporation 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 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 Typical Site Requirements from www dips n pieces de e sufficiently sized and ventilated room with a humidity of less than 60 and with a waterproof and solvent agent resistant floor dip printing system with suitable power requirements water supply for filling and refilling the basins drainage for used water compressed air supply for the activator pistol dry and dark place for storing the printing films suitable painting
72. aking molds is straightforward Good design of the molds will be the first and most important step in the process Design Considerations 1 2 Material Plaster Thickness Capital equipment presses will vary from plant to plant The optimum thickness minimum material use minimum cost for the mold will vary as well but we recommend beginning with a minimum thickness of 1 5 38 mm Printing the small size holes needed for the vacuum is unrealistic The tool designer may place guide holes or marks in the part to act as guides for drilling but the process will require the use of a mechanical drill to fully incorporate the hole into the mold Drill diameters should be the same as used when creating molds from aluminum or other non permeable materials Drying the molds will need approximately four hours minimum of drying time at 150 F 66 C to maintain a usable strength It is often useful to use STL editing features to improve the accuracy of the final mold If using the Magics RP software for STL file editing read the help section regarding the offset function In summary a For applying correction to the part on flat faces of the block use the Extrude command on each face For the faces of the part that have curved features use the offset command Resin a Epoxy resin works best in terms of speed ease of use and strength Sanding is optional some users are satisfied with the surface finish as is Usage l
73. al can cause serious injury to unprotected eyes and skin Operators must wear at least heat resistant gloves face shields and aprons suitable for foundry operations Other protective clothing may be necessary depending on the casting operation 2 2 Safety Symbols An exclamation mark inside a triangle is a safety alert symbol The safety alert symbol is used to draw attention to safety information in this manual It is followed by a signal word WARNING or CAUTION which tells the level of risk to the user Means if the safety information is not followed someone could or A WARNING can be seriously injured or killed Means if the safety information is not followed someone may be A CAUTION _ injured The following symbol is used for information purposes only for example Ensure that the any loose material on the mold is removed before proceeding penile to the next step ZCast Design Guide 5 Appendix 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 Do not bake ZCast molds in unvented ovens Irritating and toxic fumes are formed at elevated temperatures during WARNING Oven baking Ovens must be vented to the out
74. all users in mind It is meant to be a guide to provide a framework for designing molds for use with 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 ZCast Design Guide 4 Appendix 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 Designers fabricators and foundry operators should be experienced or under supervision to perform these process steps using safe operating procedures The mold baking step emits smoke and gases that are toxic and irritating Refer to the ZCast 501 Powder MSDS for more information on these health hazards Ovens must have exhaust fans and be vented to the outside Operators must wear heat resistant Personal Protective Equipment PPE while handling molten metal Molten met
75. amount of powder being deposited by the metering system Generally this occurs under humid conditions If this is the cause of the problem there is now an ini variable that will solve the problem by causing the metering system to deposit more powder Z Corporation Service 781 852 5050 887 88 ZCORP 101 Z Corporation Z810 System User Manual To adjust the INI variable to control the amount of powder fed per layer follow the instructions below Select Edit INI file from the Z810 810Service Service menu Purge Print Heads Alignment Change Binder Supply Unpark Bleed Air Print Head Report View Printer Log Edit INI File Send File Receive File Fill Bed Empty Overflow Spit on Deck WARNING If there is a problem with communication a dialog such as this one will show Or you may get a similar box with Printer busy or not found Press Cancel Make sure the printer is online and not busy and try again ZPrint x Printer is not online Please check before retrying E Cancel Here is the important part If this dialog box shows press No ZPrint Ea AN IM file notfound continue The only correct answer is NO www zcorp users com 102 Z810 System User Manual Z Corporation Assuming there are no errors an edit box will be shown similar to the one at the right Add the line EXTRA POCKETS 1 and select lacouLo rosmonesa OK
76. and state regulations 11 1 9 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 11 2 USING ZP 250 POWDER zp250 powder is the newest powder system formulated for Z Corporation 3D Printers utilizing the Hewlett Packard print head technology the ZPrinter 310 Z406 and Z810 3D Printers Specifically formulated to have an open matrix to absorb infiltration resins zp250 powder is an extremely versatile composite based powder used to fabricate models with plastic flexural properties which are ideal for snap fit applications It can be used as your sole powder to fulfill a number of application needs zp250 powder is best suited for monochrome parts It is also recommended for parts that have a wall thickness that is greater than 0 06 1 5 mm 11 2 1 MACHINE SETUP e Remove all of the powder currently in the Z810 3D Printer build piston overflow bin Consult the Z Corporation Service Department for documented instructions on changing a ZF8 Feeder from zp102 to zp250 powder e zb056 binder is the required binder system for zp250 powder If you are not currently using zb56 binder replace the current binder with zb56 binder then flush and purge the fluids system e Fill the ZF8 Feeder with zp250 powder 11 2 2 SOFTWARE SETUP Help i Software Manual e ZPrint Software version 6 2 or highe
77. aper and the plate 2 Bring the build piston to the top open the top cover and place the alignment plate in the build area to the right and rear of the build area Technical Tips e When the alignment plate is too low on the build pallet the pattern will become blurred To print a sharp pattern the pad should be at the height of the top deck PLEASE NOTE If it is too high up the roller will hit the pad and move it www zcorp users com 84 Z810 System User Manual 3 4 Z Corporation Service 781 852 5050 887 88 ZCORP Close the top cover and put the printer online Select the Alignment option under the 810Service menu Click on Print Test Pattern in the alignment dialog box It will take a minute to initialize the printer send the pattern and print 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 Z Corporation 610Service Purge Print Heads Change Binder Supply Unpark Bleed Air Lube Fast Axis Lube Slow Axis Print Head Report View Printer Log Edit INI File Send File Receive File Fill Bed Empty Overflow Spit on Deck 810 Alignment Edit Alignment E sil 85 Z Corporation Z810 System User Manual Bull s eye targets one for each print head When it looks centered the print head is i
78. arts By contrast simple parts require simple gating and are more straight forward If you do not have the experience but have complex parts consult a local experienced foundryman They should be capable of helping you design your mold properly Several references are available on the topic of designing castings There are numerous publications be the American Foundry Society as well as textbooks Among the best of these are Campbell J Castings Butterworth Heinemann 2000 Heine R W and Rosenthal P C Principles of Metal Casting McGraw Hill 1955 Ammen C W The Complete Handbook of Sand Casting Tab Books McGraw Hill 1979 Important aspects in good mold design are Even filling of the mold Accurate cooling of the casting Proper mold ventilation The conventional features of designing molds for sand casting apply equally well to ZCast patterns Some of the special properties of ZCast powder affect some of the design considerations To make high quality castings a strong emphasis should be placed in the design of risers These will be discussed below Properties of light metals such as aluminum and magnesium cause them to be especially sensitive to exposure to air water vapor and mold gases Gating design for these metals should focus on minimizing turbulence during filling These metals also tend to shrink a great deal during solidification Figure 3 Direct pour molds in aluminum after pouring note sig
79. ation 16 Clean the service station of any HP ink residue as described in Section 4 2 Cleaning the Service Station Clean the deck and fast axis rails Oil the fast axis rails Technical Tip The first 50 layers of your part will have a tint of black HP ink You may place a flat brick such as the purge brick build 810purge stl under Sample files under your part to purge all black ink before printing your part www zcorp users com Z810 System User Manual 8105ervice Purge Print Heads Alignment Change Binder Supply Bleed Air Lube Fast Axis Lube Slow Axis Print Head Report View Printer Log Edit INI File Send File Receive File Fill Bed Empty Overflow Spit on Deck 90 Z810 System User Manual Z Corporation 11 CHANGING MATERIAL SYSTEMS To change material systems on the Z810 3D Printer use the following procedure 1 Remove all powder from the top deck and under the build plate 2 Remove the powder from the overflow bin and empty into the ZF8 Feeder Removing powder through the overflow access panel will allow you to clean out the overflow bin more thoroughly once it has gone through the Empty Overflow function in the ZPrint Software Remove the access panel by removing the thumb nuts turn on the ZF8 Feeder and vaccum all remaining powder from the overflow chute Then replace overflow access panel Z Corporation Service 781 852 5050
80. by unprinted powder the chances of breaking that small feature during depowdering is greatly increased When building delicate parts use the Fixture function to cradle the part Raising the part 0 25 6 4 mm from the bottom of the build and creating a fixture under the part will produce a cradle that can be handled The part inside the cradle can easily be transported to an oven or the depowderer Do not enable the bleed compensation feature if you are building a part with features under 0 050 12 7 mm To increase the strength of thin parts you can decrease the layer thickness to 0 0035 0 089 mm if you are using one of the zp 00 series plaster based powder systems Then choose to override the saturation values Input the saturation values used for printing at 0 004 0 102 mm This increases the binder to powder ratio and wets more of the resins in the powder system As you increase the strength of the part in this manner you are also inceasing the amount of time to dry the part Use of the removable build plate and oven drying the part are recommended www zcorp users com 32 7810 System User Manual Z Corporation 3 7 1 2 3 7 1 3 3 7 2 3 7 2 1 3 7 2 2 Gross and Fine Depowdering Become familiar with where the parts are placed and how they are oriented in the build box so you do not accidentally bump or brush against a fragile part during the depowdering process When performing the gross depowdering re
81. ccccononnionononioni danna 60 83 1 General ApPICANON NOLES coli di tado idas 60 Be MIXINOANSVTUCHONS versa ito tias 60 833 DUNAGINMOR NAO pd oido iba 60 A A 60 G4 WSING PARAPLAST Aa TRA WA Costas ri 61 8 41 Sdlety PICCAUUONS ss its da iia 61 8 4 2 General Application NOTES ooooonccccconccoooconnconononnononononnnnononononnnnnnnnnnnnnnennnnnnnnnnos 61 9 4 9 sGUMAG NNGMNAUON sarta dida 61 9 APPLICATIONS eeina aaa a e idad 62 9 1 GLUING MULTI PIECED PARTS a o Eo 63 92 A A a a AA 64 99 POLYESTER RES Niceea O N a E A iia 65 OA EHEGTEROPLA IN a a R a E licaiahs 66 9 5 WATER TRANSFER PRINTING cocccocccooncnononononononononnronorrnnronoronarrnnrrnnrrnrrnnrrnnrrnnrrnnrrnnrennrenanos 67 9 0 INVESTMENT GASTING wisicte eee decree AA a a a ate RA 70 Oe FEE APLE PART na a ered emcee ase eee 72 OB THERMOFOR MINO a aaa aae aa aa a iaaa ana 73 99 TIO IHD IN Gets ae a ees a a a aA De ed et da 75 10 CHANGING AND ALIGNING THE PRINT HEADS 0 c0ccceecceecceecceecceeeceesceeseeeeeeeeees 81 10 1 CHANGING THE PRINT HEADS ve siecs betcha diidis 81 10 2 ALIGNING THE PRINT HEADS cccccscccscccscccscccscccseccseccacccuccossenscecseccsecnseenseenseenseeseeesaeenes 84 11 CHANGING MATERIAL SYSTEMS oocconccccnncconnncnnnnonnnonnnnonnono recon nnnnrnnnnr cnn n cnn nnrr nara 91 11 1 USING ZCAST 501 POWDER vecececccscesccsscecccsscsscssccsscsecsscssecseccsscaccsucaccsecacsssesesaseseceeeees 94 11 1 1 GENERAL INFORMATION
82. ce the part is completed post process the part Measure the x y and z axes Divide the nominal value by the measured value For example if the printed part had a nominal value of 1 and had a measured value of 0 98 the scaling value would be 1 02 After calculating the anisotropic scaling values input them into the software and reprint the part and follow the post processing procedure 1 Plaster Material System The plaster material system has been found to remain dimensionally accurate during printing and thus the recommended anisotropic scaling values are one 1 in all axes If the infiltrant system being used changes the accuracy of the part please alter the values as needed 2 Starch Material System The shrinkage found in the starch material system is proportional to the part geometry and the drying time of the part The longer the part is left to dry the larger the shrinkage value The part is most stable in the x and y axis and shrinks more in the z axis Thus the anisotropic scaling factor of the z axis will always be greater than the values for both the x and y axes 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 www zcorp users com 42 Z810 System User Manual Z Corporation 5 3 1 2 Saturation Values The saturation values determine how much binder is placed on the powder to p
83. ce to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense CENELEC Class A Warning Note this equipment has been tested and found to comply with the limits for a Class A digital device pursuant to EN 55022 Class A devices are for office and light industrial environments and are not generally suitable for home use WARNING This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Z Corporation Service 781 852 5050 887 88 ZCORP 117 Z Corporation Z810 System User Manual 14 3 MATERIAL STORAGE PRECAUTIONS Carefully read the Material Safety Data Sheets MSDS before using any Z Corporation materials Material Storage Usage ___ _ Fawag Store powder on pallets in a cool dry Use of powder in ventilated area away from sources of heat environments with more moisture and incompatible materials than 30 relative humidity Keep containers tightly closed will affect powder performance Binder and Store in cool dry place away from sun Binder is NOT recyclable Wash Fluid Keep tightly capped pam eee Keep tightly capped Infiltrants Store in cool dry place away from sun Keep tightly capped For more information visit the User Group Website at WWW Z
84. cific powder systems 12 Changing INI Variables This section contains detailed instructions on how to change the INI variables to vary the amount of powder metered out by the ZF8 Powder Feeder 13 Maintenance This section contains recommended periodic maintenance procedures 14 Z810 System Details This section contains system specifications about the Z810 3D Printer Z Corporation Service 781 852 5050 887 88 ZCORP 7 Z Corporation Z810 System User Manual 1 2 HOW IT WORKS The Z Corp Printer Systems are based on the Massachusetts Institute of Technology s patented 3DP 3D Printing technology The ZPrint Software first converts three dimensional data from CAD or other sources into cross sections or slices that can be between 0 0035 0 009 thick The Z810 3D Printer then prints these cross sections one after another from the bottom of the part to the top Inside the Z810 3D Printer there is a build piston where the part is built see Figure 1 Also represented in the diagrams are the roller print heads build area and cleaning area The roller moves horizontally across the build area When beginning the 3D printing process the printer first spreads a layer of powder in the same thickness as the cross section to be printed The print heads then apply a binder solution to the powder causing the powder particles to bind to one another and to the printed cross section one level below The build piston descends one
85. d and foundry sand is packed around the printed parts ZCast Design Guide 14 Appendix r _ _ _ HTA fy Eo oe 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 5 2 3 Combination Method Combining ZCast with the traditional sand casting techniques can keep the cost per prototype down to a minimum Mold sections cores in particular are made in ZCast while the rest of the mold is made conventionally In the combination method foundry sand is packed around a pattern The pattern can be machined from a variety of materials or the pattern can be printed on a Z Corp 3D Printer If printed the patterns would be made with one of the Z Corp plaster based materials zp100 series infiltrated with an epoxy and mounted to a board A zp100 series pattern can be used multiple times This method requires an intimate understanding of the design of conventional sand molds ZCast mold components used in the Combination method are subject to most of the same restrictions that apply to conventional mold components The advantage to using ZCast in this case is that cores and inserts can be made without any special tooling e g core boxes that would lengthen the time to produce the first casting A further enhancement of the sand casting process appl
86. ders PART INFILTRATION When Using Z Bond Resin Always infiltrate the most delicate features of the part first Z Bond resin gives almost immediate strength to the area of the part that has been infiltrated As you handle the areas of the part that have been infiltrated it will be less likely to break it Try to avoid infiltrating the part by applying Z Bond resin from spot to spot Pick a good starting place and hold that area upward relative to the rest of the part With your free hand place the tip of the Z Bond bottle against the part and allow the cyanoacrylate CA to flow from the bottle It is important that the CA flows at a uniform rate making it easier for you to judge how quickly it will flow from the tip of the bottle before it wicks into the part By seeing how quickly it wicks into the part you will be able to judge where and how quickly to move the tip of the bottle while applying the CA being sure not to apply the CA to the same place more than once When Using a Z Snap or Z Max 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 This will decrease the chance the feature will break from the part if nudged or bumped If the part has multiple delicate features or it is impossible to handle the part without breaking a feature you may infiltrate these features only Allow the Z Snap or Z Max epoxy to cure Then infiltrate
87. e Station Cleaning 34 Set Times 45 Short Spreading See Powder Spreading Shortage Slow Axis 9 Grease 109 Software See ZPrint Software Spreader Roller 111 Squeegee Scraper 111 Squeegee Wipers 112 Storage Materials 118 System Details 117 System Specifications 117 T Thermoforming 73 Toggle Roller On Off 111 Tools Post Processing 52 Tracks Z810 Printer 49 124 Z810 System User Manual ZD8 Cart 49 ZD8 Depowdering Unit 50 W Waste Container 39 Water Transfer Printing 67 Wax 57 61 Z Z810 3D Printer 11 Carriage Assembly 14 Components 11 Control Panel 17 Error Codes 118 Gantry 109 Power Entry Module 16 Service Station 15 Site Requirements 11 Spreader Roller 111 Z810 Printer Part Removal See Part Removal Part Transfer See Part Transfer Z Bond 100 59 zc10 Wash Fluid 104 ZCast Powder 94 Scraper Blade Removal 92 ZF8 Powder Feeder Change 93 ZD8 Cart Tracks 24 ZD8 Depowdering Unit 20 Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation Air Curtain 22 Air Gun 54 Cart 24 Control Panel 23 Control Switch 23 Depowdering 54 Emptying Powder Drawer 115 Filter Cleaning 23 Light Push Button 23 Powder Collection Drawer 24 Powder Collection Drawer Handle 24 Selector Lever 22 Site Requirements 20 Warning Lamp 23 ZF8 Powder Feeder 18 Powder Level 37 Powder Screen 115 Power Entry Module 19 Refill with Powder 37 Site Requirements 18 Z
88. e commercially available for a range of budgets Note that the volume of the mixture will increase dramatically until all of the air has been removed Choose a container that holds approximately 3 times the volume of the mixed silicone Once the de gassing is complete pour the silicone mixture slowly into the mold box letting it run smoothly around the pattern Take your time to decrease the chance of air being trapped anywhere Best practice is to de gas the mold after the silicone has been poured to remove any air that was introduced Manufacturers of Vacuum Chambers and Casting Systems BJB Enterprises www bjbenterprises com equipment Innovative Polymers http www innovative polymers com MCP Equipment www mcp group com Removing the Master Pattern and Creating the Parting Line Remove the mold box from around the mold Using a razor blade or scalpel begin to cut the mold open at the gate and vent This will begin to create the parting line for the mold Cutting in a smooth zigzag motion will make the mold halves easier to re assemble in preparation for urethane casting Slowly cut deeper to the edge of the pattern Keep in mind where the mold parting line will be on the pattern The parting line should be placed on an edge of the part to avoid witness lines flash from the cast urethane When the cut is finished the mold halves should easily separate and the master pattern can be removed 6 Open Time The amoun
89. e noted www zcorp users com 70 Z810 System User Manual Z Corporation Preparation 1 Starch based powder parts should be used Oven drying the part at 104 F 40 C after removal has been included in the process at some locations especially where humidity may be an issue with green part characteristics Additional gate s may be incorporated in the set up of the mold to increase air flow during burn out of the casting pattern Patterns should be infiltrated with either wax or resin Wax infiltration is an excellent treatment for investment casting patterns Wax infiltrated parts will behave similarly to common wax patterns when they expand The ZW4 or ZW3 Waxer and hand application methods have both been successfully used on Z Corp 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 Patterns can also be infiltrated with resin for increased strength Surfaces should be sanded to their desired finish after this step Then coat with wax Casting ile Z Corp patterns can be assembled on standard wax gates and runner systems They should be coated with the normal 6 8 shell layers of slurry 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 380 F 193 C and 130 psi 9 bars The pattern should then be put
90. e printer leaving the powder underneath to support the model 2 Transfer build pallet to cart using track system 3 Transfer build pallet to depowdering unit 4 Turn depowdering unit on and leave part in the depowderer to dry www zcorp users com 30 Z810 System User Manual 3 4 DEPOWDERING THE PART 1 Turn air gun on and adjust air pressure 2 Depowder part Leave supporting powder underneath plaster parts Depowder starch parts completely 3 Remove part from depowdering unit 4 Clean depowdering unit Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation 31 Z Corporation Z810 System User Manual 3 5 TRANSFER TO OVEN Transfer part to oven for additional drying 3 6 FINISH PART Depowder or infiltrate as needed Infiltrate part with Z Corp recommended wax or resins More information on infiltrants can be found in Section 8 Infiltrants 3 USER TIPS 3 7 1 3 7 1 1 SET UP AND POST PROCESSING Part Setup Orientation and Print Settings Do not tightly pack parts into the build Keep in mind that you will need to depowder and remove them from the build box Allowing a little bit of room around the part so you can vacuum the powder away and get your fingers around or under it will go a long way Orient parts so delicate features are supported in the z axis i e keep the attaching feature directly below the fragile features If a delicate feature is only supported
91. e software to adjust for expected shrinkage and bring your parts into true scale More information on anisotropic scaling factors can be found in Section 5 3 1 1 Anisotropic Scaling Values www zcorp users com 10 7810 System User Manual Z Corporation 2 SYSTEM COMPONENTS 2 1 Z810 PRINTER COMPONENTS The Z810 System consists of the following hardware components 2 1 1 2810 3D PRINTER Site Requirements Power 100 240 VAC 50 60 Hz Dimensions 46 5 inches 1 18 meters deep x 64 5 inches 1 64 meters wide x 54 5 inches 1 38 meters tall with top cover closed 111 inches 2 82 meters tall with top cover open PLEASE NOTE Left to right width dimensions are not additive for the System because the printer and powder feeder overlap by several inches when the feeder is docked Z Corporation Service 781 852 5050 887 88 ZCORP 11 Z Corporation Z810 System User Manual Vacuum Switch ZF8 Feeder ZF8 Powder Feeder Zz A Top Cover Power Switch Z810 Printer f L o oee M lo Color Binder Container Cyan a 4 s Magenta Yellow f Electronics Enclosure Clear Binder Container NAT Overflow Vacuum Receptacle Figure 4 Z810 3D Printer Front View www zcorp users com 12 7810 System User Manual Z Corporation Y Squeegee Scraper Removable N Build Pallet YY 4 Top Deck Carriage E Head W
92. ection view Figures 6c Shelled section view Unshelled molds may not bake thoroughly to remove all residual moisture Residual mold moisture after baking when contacted with molten metal can cause the unexpected release of molten metal from the mold and personal injury WARNING ZCast Design Guide 19 Appendix 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 In either case rib thickness should be roughly one half inch 0 5 in or 13 mm in thickness Rib spacing is subjective However as a guideline distances greater than four 4 inches 102 mm should not be spanned without placing a rib in between walls or adjacent ribs NOTICE Spacing ribs more than four inches is not recommended because of possible part deformation during the molten metal process Figure 7 Addition of stiffening ribs printed in the shelled mold 6 5 Venting Perhaps the most important Metal in concept in ZCast mold design is 7 venting The mold must be rk properly vented to avoid entrapping ll LA Gasses gases in the cast part and more PM importantly to avoid violent release of gases through the molten metal For those familiar with traditional sand casting it will be observed that a ZCast mold even when properly vented may smoke more than conventional
93. ed upon request to your Z Corp account representative 5 4 Printing Your Model Setting up your build using ZCast is the same as using other Z Corp powders Use the ZPrint software to optimize placement of your parts to be printed Be mindful that round objects are stronger printed in the X Y plane Use the Make Fixture option under the Edit menu to support overhanging features ZCast powder is denser than the zp10 zp100 and zp200 series products and therefore requires no tamping 5 5 Conclusion In summary whichever method you choose to implement the basic steps remain the same when using ZCast powder as shown in Figure 5a ZCast Design Guide 18 Appendix The ZCast process Step 1 Design the mold with gating This is done on the computer screen using design software CAD Step 2 3D print the mold This step is completed on a Z Corp 3D Printer Step 3 Finish and assemble the Step 5 Demold and finish metal casting Figure 5 Steps involved in using ZCast powder Appendix 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 Such a design can exceed the size of the build volume of the 3D Printer Consider bypassing the runner system entirely by gating the sprue and risers This al
94. en cast but there are limits on how far the feature can extend Volume no tested limit Size limitations are related to build size However molds can also be built in sections and assembled to make much larger molds Closed nearly closed volumes if the core does not have enough body at the core print to support itself for example the core of a two liter soda bottle very narrow neck with respect to the size of the core then the core may break in the mold If the core narrows down at the core print so that the bulk of the core cannot be vented then there is risk of high porosity in the casting 6 10 Wall Thickness Guidelines As indicated in the section 6 3 Shelling Your Mold thinner sections bake quicker and more efficiently Maintain the following guidelines for modeling your mold with thin walls Any mold wall that is in contact with metal should be no less then 0 5 in 13 mm thick and no more than 1 in 25 4 mm thick with exceptions below The mold should be able to sit square on a base for pouring Ribs should be added where necessary to provide rigidity typically in the drag where a supporting surface is being built up Ribs should be about 0 5 in 13 mm thick Maintain large enough areas for clamping Use off the shelf pouring cups and risers Mold wall thicknesses of less than 0 5 inches 13 mm may allow A CAUTION molten metal to leak from the mold unexpectedly and cause personal injury De
95. er 13524 as follows 1 Unpark the carriage by choosing the Unpark option under the 810Service menu The carriage will move away from the service station 2 Clean top deck 3 Repark the carriage by clicking OK on the dialog box 4 The printer should be online From the PRA Service menu select Change Print Heads Press Start to begin the print head change procedure When the print heads are changed press Done Start Dore 5 Press the Start dialog box button to begin the process The front panel lights will flash rapidly and the gantry and print heads will move into position Technical Tip 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 changing print heads Complete the procedure by pressing the Online button on the printer when complete Z Corporation Service 781 852 5050 887 88 ZCORP 81 Z Corporation Z810 System User Manual 6 Wait for the printer to finish moving and the front panel lights to begin blinking This indicates that it is safe to open the top cover and remove the print heads 7 Twist the carriage cover latch in the front and back of the carriage 8 Unlock the head clamp latch by pushing the top cover down and unlatch Open the carriage cover 9 To remove the print head lift the blue handle on top of each pr
96. f the part Technical Tip Spin the turntable so that the part face you are depowdering is aimed away from the front opening This will direct most of the air jet reflection toward the wall allowing you to use a lower setting on the air curtain 7 Transfer part into oven The oven removes any moisture left in the part The requirement for this step will be dependent on application and infiltration needs Drying times are dependent on wall thickness Material Drying System Temperature 130 F 54 C 100 F 38 C 400 F 200 C Average drying time for plaster and starch parts e 0 0 25 0 6 mm 60 minutes e 0 25 0 50 6 13 mm 90 minutes e 0 50 1 00 13 25 mm 120 minutes e More than 1 00 More than 25 4 mm 180 minutes PLEASE NOTE Drying starch parts at a higher temperature may distort and damage the part Average drying time for ZCast parts e 4 12 hours e Drying times will depend on the volume and surface area of the part s and oven temperature The parts need to dry in an oven with a constant air temperature of 400 F 204 C If you would like to reduce drying time hollow Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation PLEASE NOTE Remove all loose powder from the starch part Any powder left on the part will adhere to the part during oven drying WARNING Mold preparation and metal pouring requires
97. ght fine structure The result is a sound casting with a uniform distribution of the alloying elements Chills can be used in ZCast molds in much the same way they are used in traditional sand casting While they can be complicated externally cooled components they are often as simple as steel or iron blocks which can be inserted into cavities designed or cut into a ZCast mold 6 13 Printing For general printing techniques you should refer to the User Manual for your 3D Printer and the ZPrint System Software Manual e When choosing your powder type in 3D Print Setup simply select ZCast 501 from the powder list it will show up on the list for any printer that is capable to use the powder system with the proper upgrade The proper settings for saturation layer thickness and scaling factors are already set for you e Using Bleed Compensation is recommended This will improve the accuracy so parts will fit together better e Orient parts so that the most critical faces are facing up in the build For example when possible put the outside of the mold components non molding surfaces facing down in the build Under certain conditions a slight arching effect can occur on the bottom surfaces in the build e When cores are being printed you may choose to build a fixture underneath it This will improve the accuracy for critical fit items Refer to the ZPrint Manual for instructions on using fixtures 3 See Table
98. hrough filters maximum are achieved with horizontal placement d e f Vertical filter orientation ZCast Design Guide 30 Appendix 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 It is typically a suspension of silica or other refractory materials which can be sprayed brushed or used as a dip to coat the surface of the mold and cores It can improve the surface finish of a part to between 60 and 120 RMS It should be used with caution The surface can be built up too much causing unevenness and flaking Follow the mold wash manufacturer s instructions regarding the drying requirements for such products Bake MOLDS MUST BE BAKED PRIOR TO POURING A ZCast mold in its untreated raw state contains about 10 moisture per unit weight Casting molten metal against untreated material releases large amounts of steam and smoke To use the ZCast mold properly it MUST be baked in an oven from 350 F 180 C to 400 F 230 C for between 4 and 8 hours depending on volume until it is bone dry and preferably medium brown in color on all cavity surfaces that contact molten metal THERE WILL BE SMOKE GENERATED WHEN BAKING ZCAST MOLDS THEREFORE THE OVEN MUST BE PROPERLY VENTED Bake ZCast molds until all moisture is
99. ial System Set Time Plaster Material System 60 minutes or more Starch Material System No more than 60 minutes Leaving the part in the build area for a longer time period may lead to part damage due to shrinkage Parts that enclose loose powder may be susceptible to cracking due to the pressure from shrinkage around the volume of loose powder Leaving the part in the build area for a longer time period may cause caking of the part Caking is characterized by adhesion of loose powder onto the printed part ZCast Material System 60 minutes or more Technical Tip e To control the amount of time that starch parts sit in the build area use the print time delay feature in the ZPrint Software This will allow you to start your build at a later time and thus finish at a designated time To use the print time delayer choose this option before printing in the Printing Options dialog box Printing Options Layer Print Range Entire Build i From layer E through 157 Printing instructions displayed in the print queue T Bleed Compensatic To speed up the setting process vacuum off the excess powder surrounding the part which will allow air to circulate around the printed part See Section 6 2 Gross Depowdering After gross depowdering leave part to sit in build area for approximately 30 minutes Z Corporation Service 781 852 5050 887 88 ZCORP 45 Z Corporation Z810 System User Manual 6 2 GROSS DEPOWD
100. ies to both the Shell Cast and Combination methods One can fabricate conventional patterns using Z Corp materials most preferably with zp100 series plaster based materials as shown below Use only ZCast 501 material for the mold sections and cores for the Combination Method casting technique Other mold CAUTION materials can unexpectedly release molten metal and cause personal injury during metal casting For step by step guide on this topic contact your Z Corp account representative ZCast Design Guide 15 Appendix 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 It is necessary to create the most accurate representation of your design digitally as it will be represented by a 3D print 5 3 1 Direct Pour Method Before addressing the mold design specifics we will consider the basic steps of designing a mold using a standard CAD package Most middle to high end CAD packages such as Pro E SolidWorks Catia Unigraphics and Autodesk Inventor etc as well as some tooling packages such as Magics Tooling will contain the tools you need to create a mold These are the steps required to design a mold 1 Noe ohN Import part data It is advantageou
101. ife Individual molds have consistently produced 10 20 parts successfully without the use of a release agent www zcorp users com 74 Z810 System User Manual Z Corporation 9 9 RTV MOLDING Room Temperature Vulcanization RTV molding also known as Silicone Rubber Molding SRM is an inexpensive soft molding solution for creating dozens of prototypes accurately The benefit of RTV molding is that anyone can do it because of its simplicity Factors such as draftl complex parting lines and undercuts are not factors in building effective molds as they are when using hard tooling Additionally hard tooling may not be practical during the design process due to cost production time and likelihood of design changes RTV molding effectively bridges the gap between one off prototypes and hard tooling in a fraction of the time RTV molding requires the production of a single master pattern which is encased in low durometer silicone rubber Using a part printed on a Z Corporation 3D Printer is the fastest and least expensive method for creating a pattern for RTV molding Once the silicone rubber encasing the pattern cures 2 48 hours depending on chosen material the master is cut out leaving a cavity The cavity is used as a soft rubber tool for molding investment casting wax epoxy foam or in most cases polyurethane or a similar thermoset material that has physical properties similar to injection molded themoplastics Cast pro
102. infiltrated with wax epoxy or other materials to increase strength and durability More information on different infiltrants can be found in Section 8 Infiltrants There are several important issues to consider when preparing a build that will help you print the best parts for your intended purpose Part Placement The ZPrint Software will place the parts within the build box to maximize build speed the most important criteria for the majority of our users The ZPrint Software positions the parts with the smallest dimension in the z vertical axis For more information refer to the ZPrint Software User Manual Strength The ultimate strength of the part will be somewhat affected by its orientation within the print box The part will be strongest along the x axis and the y axis and less strong along the z axis This is because the cross sections are printed in continuous strips along the y or the fast axis the print heads direction of travel bands across the x or the slow axis the gantry direction of travel and laminated layers along the z axis Z Corporation Service 781 852 5050 887 88 ZCORP 9 Z Corporation 7810 System User Manual Z axis Less Strong X axis Strong SI Strong y axis Figure 3 Illustration of Z Corp System Print Orientations Accuracy The accuracy of the printer depends on the materials you choose and the offset and scaling factors used You can employ the anisotropic scaling feature in th
103. int Graphite paint is used as a non stick coating release that is applied to patterns when forming a mold from a pattern Green sand or Pepset Common foundry sand mixed with bonding agent Pouring sleeve The pouring sleeves are essential to any mold design whether they are printed as part of the mold or inserted as a separate consumable Sleeves can also double as risers and provide a reservoir to continuously feed molten metal into the mold cavity Companies that market these consumables into the metal casting industry include e www ashland com e www foseco com e HA International LLC ZCast Design Guide 36 11 1 Sand Casting Glossary 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 These components are traditionally formed by packing sand typically with a chemical binder around a machined pattern There is often a separate machined pattern for each the cope and the drag 11 1 2 Cores Cores form the internal surfaces of a casting In traditional sand casting cores are also used to form features that are undercuts with respect to the parting line The limitation in traditional casting is the pattern must be pulled out of the packed sand and therefore must not contain undercuts in the pull direction Some castings will not have a
104. int head and pull up gently Repeat for all six print heads PLEASE NOTE All print heads are to be changed at the same time to ensure proper print head alignment and logging For more information about the logging feature refer to the ZPrint Software Manual 10 Before inserting new print head clean the contacts in the carriage with an alcohol crush swab Z Corp part number 12073 www zcorp users com 82 Z810 System User Manual 11 12 13 Remove the print head from the packaging Remove plastic covering from the print head Insert the new print head and push down firmly on top to make sure the print head is seated securely in the carriage Repeat for all print heads Replace the carriage cover and tighten the clamps in the front and back of the carriage Press the Online button once to complete the process or click Done in the software The print heads will now need to be aligned Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation 83 Z Corporation Z810 System User Manual 10 2 ALIGNING THE PRINT HEADS PLEASE NOTE After every print head change you must perform the alignment procedure 1 Place a piece of adhesive paper onto alignment plate by removing one piece of backing placing the edge of the paper to the edge of the plate Remove the remainder of the backing slowly while placing it down on the plate Make sure there are no air pockets between the p
105. ions and cores ZCast Design Guide 6 Appendix Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten metal WARNING Causing personal injury during metal casting Venting paths in the mold must be arranged and directed away from the metal path to avoid entrapment of gases Do not cast molten metal in molds with multiple sections WARNING Without using core paste or adhesive Molten metal can leak from the mold and cause personal injury Unshelled molds may not bake thoroughly to remove all residual moisture Residual mold moisture after baking WARNING When contacted with molten metal can cause the unexpected release of molten metal from the mold and personal injury Insufficient venting of thick mold sections can result in the unexpected release of molten metal and personal injury WARNING during metal casting Design molds with adequate venting capacity and proper location Vents not located in the core vents too close to parting lines or vents that break through to the casting surface may CAUTION leak molten metal and cause personal injury Locate vents in the core away from the casting surface and as far as possible from parting lines Mold wall thicknesses of less than 0 5 inches 13 mm may allow molten metal to leak from the mold unexpectedly and CAUTION cause personal injury Design molds to ensure at least 0 5 inches 13 mm mold wall thickness
106. ipe Area Print Head Y Parking Area Sa 5 Print Head Spit Atea Gantry Moves along the slow axis Overflow Chute J Printer Assembly Rests on the Gantry Figure 5 Z810 3D Printer Top View Z Corporation Service 781 852 5050 887 88 ZCORP 13 Z Corporation 2 1 1 1 Z810 Carriage Assembly Print Heads Numbered from 0 5 from front to back Carriage Cover i 47 Carriage Cover Latch Note One is located in the back of the carriage not shown Figure 6 Z810 3D Printer Carriage Assembly www zcorp users com Z810 System User Manual 14 Z810 System User Manual 2 1 1 2 Z810 Service Station ae A Squeegees l Removable Top Cover for Wash Fluid Refill Figure 7 Z810 3D Printer Service Station Z Corporation Service 781 852 5050 887 88 ZCORP Print Head Wipe Area Print Head Park Area Print Head Spit Area Z Corporation 15 Z Corporation Z810 System User Manual 2 1 1 3 Z810 Rear Connector Panel D Power Entry z J Module Detailed Diagram Diagnostic Keyboard Powder Feeder Serial Connector No Cable Connector connector provided Power Input provided Connector provided Network Connection Connector provided Diagnostic Video Serial Inout ircuit Break Connector No Connection connector provided Connector provided Figure 8 Z810
107. it until you do not see any air entering into the syringe characterized by bubbles in the fluid 9 Continue for every septum 10 Close the carriage cover repark the carriage using the ZPrint Software and change print heads as described in Section 10 Changing and Aligning the Print Heads 13 11 CLEAN FAST AXIS PULLEYS Powder build up on the fast axis pulley will prevent proper function of the carriage and may result in a 2303 1 error or similar errors lt is recommended that you clean your fast axis pulley after every print head change This will prevent build up of powder on the fast axis pulley 1 Unpark the gantry by selecting the Unpark option under the 810Service menu 2 Using the dental pick provided in the tool box remove powder from pulley Z Corporation Service 781 852 5050 887 88 ZCORP 113 Z Corporation Z810 System User Manual mD ba e lt ei Teeth of pulley E y E y al Pick 3 Clean idler pulley www zcorp users com 114 Z810 System User Manual Z Corporation 13 12 CLEAN POWDER SCREEN ON THE ZF8 POWDER FEEDER The powder screen in the ZF8 Powder Feeder prevents any large pieces of debris from entering the Feeder Periodically the screen needs to be cleaned in order to allow steady airflow through the Feeder 1 Remove wing nuts to expose powder screen PLEASE NOTE Be careful when opening the access panel to the powder screen
108. kling putty Both putties are applied wet and dry quickly at ambient temperatures www zcorp users com 76 Z810 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 parts infiltrated with cyanoacrlylate and Dupont Corlar Epoxy Primer for parts infiltrated with epoxy Apply 2 3 thin coats 6 Allow the part to dry Wet sand the pattern with 400 grit sand paper Wet sanding the part re wets the primer making it extremely smooth and fills in any remaining pits 7 Dry sand the pattern with 400 grit sand paper This step will remove any residual surface defects such as drips in the primer A gate to feed the casting material into the mold must be set up prior to creating the mold The gate also acts as a vent to allow air to escape the mold cavity If the part is complex the master pattern may require numerous vents The master pattern usually has the gate mounted to the highest feature and is almost always oriented in a manner such that air rising up through the mold will not be trapped If the pattern cannot be oriented to prevent trapping air additional vents will need to be added to allow the air to escape Gates and vents are usually attached permanently to the pattern using an adhesive but Klean Klay and wax can als
109. lect Printer Save Printer as Default Powder ZP250 y Use Default Powder Save Powder as Default P102 Shell Core Anisotropic Bleed Scaling Compensation Binder Volume Ratio 28 0 7 0 On Saturation Level 100 100 Xx 1 x 001 Mn Saturation za o5 i EA T 0003 in Z EA o 0 003 in Override Use Default Save as Default Reset Factory Settings 11 2 3 PART REMOVAL AND POST PROCESSING 1 Remove the part and depowder Dry the parts in in an oven at 150 F 66 C for at least 2 hours or longer depending on the mass volume of the part a Ifa fixture was used during the printing process it should be used as a cradle for the part during the infiltration and curing steps as well 2 Depowder the part and the fixture 3 Remove part from build plate and place on a clean surface Then separate the part from the fixture www zcorp users com 98 Z810 System User Manual Z Corporation 4 Apply a silicone mold release such as IMS Paintable Neutral Oil Mold Release www imscompany com or_Hapco GREASE IT FDG www hapcoweb com liberally onto the top surface of the fixture where the part will make contact with the fixture This is done to prevent the infiltrated part from adhering to the fixture during the infiltration process 5 Gently apply Z Snap or Z Max epoxy to the bottom surface of the part and carefully place the part back onto the fixture 6 Apply Z Snap or Z Max epoxy to the rest of the par
110. lows for a simple compact design which can easily be printed 6 2 Mold Parts Larger Than Build Volume It is quite possible that your mold will exceed the size of the build volume of your Z Corp Printer Multiple sections of the mold can be printed and assembled separately Use core paste between the shell seams to bridge the shell section together Clamp the mold halves together with dowel pins for alignment Do not cast molten metal in molds with multiple sections A WARNING without using core paste or adhesive Molten metal can leak from the mold and cause personal injury 6 3 Shelling your Mold As will be discussed in the Mold Preparation section baking is a requirement for all ZCast molds To ensure thorough baking throughout the entire mold hollow out the backside of your mold for better performance Take the following example Figure 6a illustrates a mold cavity surrounded by a solid mass of ZCast material Figure 6b shows the same mold with a section passing through it for clarity With a thick section of ZCast powder it becomes difficult for the heat to penetrate the depths at uniform levels Figure 6c illustrates the same mold with a section view This is the optimal situation With uniformity to the walls throughout it is easier for the heat to thoroughly disperse throughout the mold Mold Cavity Shelled exterior of Mold Section View of Mold Figures 6a Unshelled solid Figures 6b Unshelled s
111. m User Manual Z Corporation 4 6 2 CHECK WASTE CONTAINER The waste bottle should be emptied before each build To empty the waste container 1 Hold and lift waste container 2 Release the latch on the bottom of the waste container shelf Lever Located Under Shelf Remove botile Pull Out Empty out waste fluid Replace waste container Ss e Replace shelf to original position f ik Lift shelf back into place Z Corporation Service 781 852 5050 887 88 ZCORP 39 Z Corporation Z810 System User Manual 5 USING ZPRINT SOFTWARE This chapter will briefly explain how to set up the build check the settings and print For more information about features in the ZPrint Software please refer to the ZPrint Software Manual PLEASE NOTE If the ZPrint Software has not been installed install the software Instructions are located in Section 1 2 of the ZPrint Software Manual 5 1 OPEN OR IMPORT THE FILE 1 Open the ZPrint Software The open Mi o A dialog box will appear Look in Samples ere E 2 circle zbd Color_Chain wrl 13 mini_printer stl 2 Choose the file you wish to open ek ala 9 Big Z 8 colorchain zcp plate sfx 3 Click Open or double click the fi le cable ee 18 Porsche_Colorl 3 ply P 3 cellphone2 wl 18 hand_left_green ply 4 Choose the dimensions and powder type i colgate2 pi E heli ply wf colgate2 2bd 20 2BD a L amp
112. more information please contact one of our applications engineers at applications zcorp com www zcorp users com 100 Z810 System User Manual Z Corporation 12 CHANGING INI VARIABLES In certain situations you may encounter the need to change your INI variables One situation that may require you to change the INI settings is the need to increase the amount of powder deposited by the ZF8 Powder Feeder Below you will find instructions on how to change this INI variable Please contact the Z Corporation Service Department before changing the INI settings The ZF8 Powder Feeder metering system does not always deliver enough powder to the spread roller to fill an entire layer This short spreading will cause a noticeable shortage of powder near the overflow during the course of a large build It can also increase Z axis inaccuracy on plaster powder parts and may ruin a part printed near the overflow Parts with features near the overflow may have very rough surfaces on those features There may be a depressed area or cavity near the overflow where powder has not been deposited see picture TR There are two causes of short spreading and it is important to determine the real cause of the problem 1 The powder feeder may be running out of powder If there is short spreading at the end of deep builds check to be sure the ZF8 Powder Feeder is really full at the beginning of the build 2 Short spreading may be the result of an inadequate
113. moval of excess powder in the build box do not plunge the vacuum nozzle into the powder bed Begin at the outer perimeter of the build box slowly work your way into the build Hold the tip of vacuum nozzle approximately 0 25 6 4 mm to 0 375 9 5 mm away from the powder and allow the vacuum to pull the powder up Slanting the vacuum nozzle will enable you to control the suction This will decrease the chance of breaking a part that is hidden beneath the surface of the powder While fine depowdering in the depowderer always start with a low air pressure and gradually increase the pressure as the fine details and features of the part become visible When the top and sides of the part are completely depowdered tilt the part onto one of its sides Handle the part carefully The part may be fragile and brittle before infiltration If none of the sides of the part will be able to support the weight of the part you can apply a small amount of resin or epoxy to strengthen it You want to be careful not to let any of the infiltrant come into contact with any unprinted powder that may still be on the part Let the infiltrant dry before continuing to depowder Oven Dry the Part Although the part can be handled when it is not completely dried the part reaches full strength when dried Placing the part in an oven at temperatures less than 200 F 93 C for 2 4 hours will increase the strength of the part This is only recommended for plaster based pow
114. n alignment ME Y H 1 4 amp 4 sr 25 29 S s gt eg i F1 S1 These additional targets will be most even when the alignment is correct corresponds to the entries in the dialog box These reticules are for the slow axis E 4 H l E y E Notice how the ES ld lt 8 8 EN n S lines are centered a A Lua a A These reticules are E 5 3 1 B 9 iOD for the fast axis Notice how the 5 IC 3 5 J IC 3 3 E E lines are centered AN m ll Il I mi I I I for the 0 choice ay p 4 G 8 9 iI a a Pr pe sji E Sa ae Sd Si Se 3 SU IC 4 This area warms up the print heads to get them printing evenly It does not factor into the alignment Ml TB IIll MN ALE Ul O O In this pattern a properly aligned set has four longer lines with three shorter lines centered between them Print head 0 is the reference print heads 1 through 5 are aligned to print head 0 Each row is labeled at the left F1 and S1 correspond to Fasti and Slow1 on the dialog box and following www zcorp users com 86 Z810 System User Manual Z Corporation See the examples below for properly and improperly aligned reticules Normal reticule patterns Fast axis to the left Good fast axis reticule Fast axis to the ight The th
115. n be unclamped and broken apart Breaking a mold can usually be done with a hammer or other blunt object Once the majority of the mold material has been broken off the cores and detailed sections can be cleaned out with a high pressure water jet or by simply breaking them apart with a tool a simple screwdriver will work well All sand casting foundries will be set up with the means to remove ZCast material from a finished casting Figure 14 Despatch baking ovens offered through Z Corporation releases airborne objects and may cause personal injury Breaking molds with a hammer or high pressure water jet A CAUTION Wear eye face and hand protection while breaking molds 10 2 Secondary Operations Castings will often need secondary operations all of which are identical in process to traditionally cast parts At the very least the material formed in the gating system will need to cut off The flashing will probably need to be ground off Machining may need to be done on critical surfaces remember to add machining stock typically around 0 080 in 2 mm Holes may need to be drilled out and tapped The surface may be bead blasted or sand blasted Castings may be heat treated and dusts and may cause personal injury Wear eye and Drill cutting or grinding cast parts releases airborne objects A CAUTION face protection while performing these tasks 10 3 Ovens You can bake your parts in one of the ovens offered through Z Cor
116. net against the electronics panel 4 Remove the fan filter by removing the plastic cover It will snap off 5 Separate filter from plastic cover 6 Wash and rinse the filter with soap and water 7 Dry the filter PLEASE NOTE The filter needs to be completely dry before it is replaced Powder may adhere to a wet filter and prevent airflow into the electronics area 8 Replace fan filter into plastic cover and snap plastic cover back into place 9 Close cabinet door www zcorp users com 110 Z810 System User Manual Z Corporation 13 7 CLEAN SPREADER ROLLER The spreader roller may become dirty with powder and binder debris after printing Cleaning the spreader roller will prevent uneven spreading of powder over the build pallet Service Check Status Fl Squirt Squeegee F2 Service Print Head F3 Toggle Roller on off Check Powder Level Change Print Head Flush Binder 1 Choose the Toggle Roller on off option under the Service menu or press F4 Report Capabilities Report Print Head Usage Stripe Test Upload New Firmware Upload New Printer Configuration 2 Using a moist paper towel wipe the spreader roller Dry spreader roller with a dry paper towel 3 To untoggle roller choose Toggle Roller on off option again or press F4 13 8 CLEAN SQUEEGEE SCRAPER 1 Remove squeegee scraper by removing the thumb screws manually 2 Remove the squeegee scraper and wipe or
117. ng them too often 4 Select Done in the ZPrint Software The carriage will move along the fast axis a few times to distribute the grease that was applied to the bearings 5 Clean up excess grease near each end of the fast axis rails with a paper towel Upper Grease Fitting Lower Grease Fitting Lower Front Grease Fitting PLEASE NOTE Greasing too often may result in the excessive grease accumulating on the fast axis that may drop onto the build area during printing Please be sure to check the fast axis after greasing and to wipe off excess grease www zcorp users com 108 Z810 System User Manual Z Corporation 13 4 GREASING THE SLOW AXIS 810Service 1 Select the Lube Slow Axis option under the 810Service menu panies 2 There are two locations for greasing the slow axis The gantry will change Binder Supply move to the first position Grease both the front and back slow axis Unpark rails Bleed Air 3 REMOVE grease gun BEFORE pressing Done in ZPrint Lube Fast Axis Software Lube Slow Axis 4 The gantry will move to the second position Grease both the front P E ta and back slow axis rails ES 5 REMOVE grease gun BEFORE pressing Done in ZPrint Edit INI Fife Software Send Fie 6 The gantry will move across the slow axis in order to spread the heset SEs grease deposited into the bearings Fil Bed Empty Overflow Spit on Deck 13 5 CLEAN UNDER GANTRY It is necessary to clean
118. ngates connect the runners to the casting Runners dead end at dirt traps Figure 21 Risers are often placed at the ingates but could be put anywhere Vents are shown coming off the high points Their diameters are small so they will likely freeze off before they reach the upper surface of the cope Principles of Mutual Casting Heine amp Rosenthal Castings John Campbell ASM Mutuals Handbook Volume 13 12 Conclusion If you have questions about any of the information contained herein or need additional information please contact us at applications zcorp com ZCast Design Guide 39
119. nificant number of risers ZCast Design Guide 13 Appendix 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 5 2 1 Direct Pour A mold designed by this method incorporates the cavity of the casting and the entire gating system including risers and vents This keeps the mold setup simple by minimizing parts It is most handy for small molds up to 5 lbs in aluminum or 15 lbs in bronze Larger castings can be feasible if the gating system is kept simple For example a short sprue leading to a single gate These molds are least complicated usually only two or three parts Using the Direct Pour method the parting surface need not be a flat plane as usually is the case in conventional sand casting Nor does the gating system need be constrained to the parting surface The requirement for draft with respect to the parting surface is absent as well This method is ideal for molds for which the components entire cope entire drag and cores can each be printed out in their own build without modification 5 2 2 Shell Method In this method the mold cavity is formed by a 0 5 in 13 mm thick shell of ZCast material and is held in place by backing it with conventional sand The gating system sprue wells runners and risers are constructed in the foundry sand merging with ingates and riser holes that penetrate the
120. nnrnnennnnnos 18 A A O O PORO O IA 18 6 Design Techniques with ZCast Patterns oocccccccccnccnniconinos 19 61 A e O a E a E eae 19 6 2 Mold Parts Larger Than Build VoluM cccccoonncnccconcnnconcnnconononcnnoncnnononcnnoonanononancnnnnnnoos 19 6 3 Shelling your MOJO ccccooonncnnccconccnncccnonnnnncnonnnconnnnonnnnnnnnnnnnncnnnnnnancnnnnnnnnnnnnnnnnannnnnnnnnnns 19 64 zonenn AIDS ia dl id dic c ScaE 20 OS o O 20 6 5 1 o S aia a ota hava a stock ua dente peels he deeds Aaedan seat 21 652 Vening the MONG tie diaria di id a A 22 60 PATENG e a la 25 6 7 Depowderability Fixed vs Removable Cores oooccccccccoonoooncccnnncconooncccnnononononanccnnnonnnnnnns 26 sO Mating SU AC CS diia 26 6 3 Geometry GUC CII CS ti alos 27 6 10 vWallThickness Guideline S ut iaa 27 6 11 POUNING Sleeves e RI Ss 28 6 12 A ST nee Re O ee eee 28 6 13 o aed Nr actas te a a el ana aad anata daa heat 28 Bal Machine Settings vase attest leet o ease aa alah etre Mahe tae 29 6 14 Degassing and Filtering Metal ccooonccccccononccconnncoconnnnnonononnnnannnononnononnanoncnnanons 29 Z Mold Prepara Musso 31 Mola Wasi ii ics 31 Bake eR SOL a ee ee eC 31 Filta DEO OW OE exe caesto race tents dea olaaa nicas 31 ZCast Design Guide 2 Appendix e A EEA 31 A ee ee eer en eee E ee 32 Sn ai a end a seats teaea tae ecchencetu taal t 32 G POURING Metales rieles 33 Bak Metal VOCS nips aren E ECO EE eteageenaaduaveatcnantauet
121. ntilation during molten metal casting leading to the unexpected release of entrapped gases and molten metal causing personal injury A WARNING Design vents to avoid gas entrapment in thin mold geometries Ensure venting paths in the mold are arranged and directed away from the metal path to avoid entrapment of gases ZCast Design Guide 24 Appendix 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 Runner Bar 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 The mold must then be split along a generated surface or a plane Traditionally the parting line is very carefully chosen to create a pair of patterns to form the cope and drag without undercuts and minimize the number of cores necessary Since ZCast molds are printed using the 3D printing process the choice of a parting line becomes a much less demanding chore The parting line can theoretically cut through any portion of the mold cavity without regard for undercuts Below is a list of the few things to consider when choosing a parting line e Avoid thin edges thin edges can break easily during either handling or pouring e Keep cores intact splitting cores will leave flash where the parting line passes
122. ny cores others will need several as shown in Figure 16 The mold in Figure 15 has three separate cores In traditional casting for every core a tool called a core box must be made A core box is essentially a machined mold used to form sand cores on a large scale basis Complexity varies from simple to complex with separate cores and multiple components Figure 17 11 1 3 Core Prints Core prints are simply the locations at which the core lock into the cope or drag typically the drag These are designed to minimize the amount of flash metal leaking between mating surfaces between the cores and the cope and drag They also key into the drag typically utilizing drafted walls to help maintain accuracy and positioning of the core in the proper location Appendix Figure 15 Cope and drag manifold Figure 16 Cores for manifold casting Figure 17 Multi piece core ZCast Design Guide 37 Appendix 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 Pouring Cup l Figure 18 Core prints pockets where cores lock in place draq of manifold from Fiqure 15 11 1 5 Sprue The sprue connects the pouring cup to the gating system Figure 19
123. o be used It is common to draw a line on the part where the desired parting line will be This serves as a reference when removing the master pattern from the mold as to where two pieces of the mold should be separated A mold release may need to be applied to the master pattern to prevent it from bonding to the mold depending on the silicone chosen Use a dry mold release if cast parts are to be painted A part cast after using a dry mold release will be easier to clean in preparation for painting Use a mold release that is recommended by the manufacturer of the silicone used to create the mold Mold releases can be purchased through most silicone distributors Z Corporation Service 781 852 5050 887 88 ZCORP 17 Z Corporation Z810 System User Manual Choosing a Silicone There are several aspects to consider for the novice mold maker when choosing a mold material The foremost aspect should be whether to use a silicone with a tin or platinum based catalyst A catalyst is a substance that initiates or accelerates a reaction Tin catalysts work extremely well for the beginner because they generally have a low durometer cure at room temperature and are virtually inhibition freee Low durometer materials make it easy to create a parting line and remove the master without damaging it Inhibitors can be powder from gloves rubbers plastics or chemicals not cleaned from the surface of the master pattern Platinum catalysts have a cure
124. ode This is particularly helpful when you want to inspect or unload parts immediately after depowdering Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation Main Control Switch The main control for the ZD8 Depowdering Unit is a 3 position switch See the table below for a description of each position Position Symbol Mode Powder Left Drawer Release Power On Middle Stand by Light Push Button The light push button serves two functions 1 Briefly pressing the push button will toggle the lights in the workspace On Off This feature is only available when the ZD8 Depowdering Unit is in Stand by mode 2 By pressing and holding the push button until the lamp goes on the user can initiate the automatic filter cleaning cycle While the filter cleaning cycle can be initiated at any time the cleaning will only start if the ZD8 Depowdering Unit is in Stand by mode Warning Lamp The lamp indicates the status of the automatic filter cleaning cycle See the table below for description of each lamp state Lamp ae Off Filter cleaning is NOT currently scheduled Notice Filter cleaning cycle has been initiated Cleaning is scheduled for next Stand by mode and will start shortly thereafter Caution Filter cleaning currently in Flashing progress Den Please stand clear of machine Steady On 23 Z Corporation 2 2 3 POWDER COLLECTION DRAWER Powder Collection Drawer
125. olten metal into the mold Leaking CAUTION of molten metal may cause personal injury Attach sleeves with clamps and securing wires as needed gt gt gt POURING MOLTEN METAL Do not use ZCast 501 molds with molten ferrous metals or other metals with pouring temperatures above 1100 C WARNING 2000 F The molds can suddenly fail unexpectedly releasing entrapped gases and molten metal causing serious personal injury Do not handle molten metal without heat resistant WARNING _ faceshield gloves and apron and tools suitable for handling molten metal in foundry operations Do not handle molten metal without adequate local exhaust ventilation Hot gases emitted during the casting process WARNING can burn skin and are irritating and toxic Refer to the ZCast 501 powder MSDS for more information Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten metal WARNING Causing personal injury during metal casting Venting paths in the mold must be arranged and directed away from the metal path to avoid entrapment of gases Do not cast metal parts in molds with multiple sections without core paste or adhesive Molten metal may leak from CAUTION the mold seams and cause personal injury Avoid blocking vents with paste or adhesive Attachment of risers and cups without core paste may result in the unexpected release of molten metal and personal CAUTION injury Always use co
126. on INI Variables 101 Extra Pockets 102 Investment Casting 70 L Load Unload Replacing Build Pallet 34 Maintenance 104 Add zc10 Wash Fluid 104 Bleed Air 112 Clean Gantry 109 Clean Spreader Roller 111 Clean Squeegee Wipers 112 Emptying Powder Drawer 115 Fan Filter 110 Fast Axis 108 Fast Axis Pulley 113 Flush Binder 105 Powder Screen 115 Slow Axis 109 Squeegee Scraper 111 Material Storage 118 Multi pieced Parts 63 O Open File 40 Oven Recommended Model 25 P Painting 64 Part Drying Time 55 Part Removal from the Z810 Printer See Part Removal Part Orientation 40 Circular Features 41 Hollow Area 40 Opening 40 Overhangs 41 Part Removal 45 Gross Depowdering 46 Raise Build Pallet 47 Set Times 45 Part Transfer 48 To Oven 55 Tracks 49 Polyester Resin 65 Post Processing Tools 52 Powder Depositing 101 www zcorp users com Z810 System User Manual Drying Time 55 Fill ZF8 Powder Feeder 37 Level in ZF8 Powder Feeder 37 Saturation Values 43 Set Times 45 Settings 42 sotropic Scaling Values 42 Spread on Build Area 36 Spreading Shortage 101 Powder Screen 115 Powder Settings 42 Print Heads 81 Align 84 Change 81 Purge 89 Printing the Build 44 Q Quick Start 26 R Refill Binder Containers 38 Refill Powder 37 RTV Molding 75 S Saturation Values 43 Plaster 43 Starch 43 ZCast Powder 43 Scraper Blade Removal 92 Servic
127. on TCP error d binding socket TCP error d listening on socket TCP error d accepting socket TCP error d selecting socket TCP error d getting received byte count TCP error d receiving from socket TCP error d looking up host by name TCP error d connecting to host TCP error d sending to socket TCP error d setting non blocking mode UDP error d creating socket UDP error d setting socket mode UDP error d setting socket option UDP error d binding socket UDP error d looking up host by name ZDNS can t launch thread ZDNS thread refuses to die NETWORK can t find ethernet device NETWORK can t get device configuration NETWORK can t set device configuration BITBUS object already exists BITBUS object not initialized BITBUS readback error FLUIDS object already exists FLUIDS object not initialized FLUIDS unsupported pump rate Z Corporation Service 781 852 5050 887 88 ZCORP 121 Z Corporation 4503 4504 4600 4601 4602 4603 4700 4701 4702 4800 4900 4901 4902 4903 9000 9001 9002 9100 9200 30000 30001 30002 30003 30004 30005 30100 30101 30102 30103 30200 30201 30300 90000 50100 50101 50102 50103 50200 90300 90301 50400 50401 90402 90403 50404 90405 50406 Z810 System User Manual FLUIDS waste bottle full FLUIDS lost pressure on pump d CARWASH object already exists CARWASH object not initialized CARWASH carwash is stuck CARWASH can t finish s
128. onnect by pushing in the fitting button and pulling the fluid line away from the bottle 3 Connect the supplied flush tubing accessory part number 06452 to the printer binder line fitting Z Corporation Service 781 852 5050 887 88 ZCORP 105 Z Corporation Z810 System User Manual 4 Place other end of tubing in a bottle of distilled water 5 Disconnect clear binder fluid line through the quick disconnect 6 Connect accessory binder flushing tube to the end of the fluid line www zcorp users com 106 Z810 System User Manual Z Corporation 7 Place other end in a bottle of distilled water 8 Choose the Flush Binder option under the Service menu Flush Binder 9 Click Start to begin flush process Flush distilled water into the fluid lines for three Press Start to begin flushing binder minutes Press Online to complete flush When the binder is flushed press Done process Start Done PLEASE NOTE The printer will continue ton NES flushing unless the Online button or Cancel button is pressed to complete the operation 10 Then choose the Purge Print Heads EE option under the Service menu Purge Print Heads Alignment Change Binder Supply Unpark Bleed Air View Printer Log Edit INI File Fill Bed Spit on Deck Z Corporation Service 781 852 5050 887 88 ZCORP 107 Z Corporation Z810 Sys
129. ou 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 for more information If you have an application you wish to share or have questions regarding any of these applications please contact the Z Corporation Applications Team at applications zZcorp com 9 1 GLUING MULTI PIECED PARTS Instructions 1 Remove and depowder the part as described in Section 6 Removing the Part and Section 7 Depowdering 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 3 Glue seams use of clamps can assist in the bonding process 4 Sand the seams after they have cured to blend and smooth the edges You may also fill the seams with loose powder 5 Priming filling and sanding before painting are critical steps in the process Achieving the best results sometimes requires application of two coats of primer A wide variety of paints and primers have been successfully used for hi quality finishes SEM products www semproducts com Bondo www bondomarhyde com Rustoleum Acrylic www rustoleum com Interlux Brightside Polyurethane 6 You may proceed with painting the part See instructions below for more information on painting Follow all
130. poration or any other oven that will reach temperatures up to 400 F Since ZCast molds will tend to smoke when baking it is a requirement to ensure that your oven is properly vented to the atmosphere For more information about the ovens offered through Z Corp contact your local representative or go to http despatch com on the web Do not bake ZCast molds in unvented ovens Irritating and toxic fumes are formed at elevated temperatures during A WARNING oven baking Ovens must be vented to the outside Refer to the ZCast 501 powder MSDS for more information on the irritating and toxic fumes ZCast Design Guide 35 Appendix 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 Core paste This liquid material is a refractory that is used to seal the mold halves together The net result keeps liquid metal from reaching the outside of the mold minimizing flash Core paste can also be used to glue pieces together such as a sleeve to the mold or mold halves together Core wash Use core wash to improve surface finish and reduce gassing into the mold cavity Graphite pa
131. 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 Make sure to remove any dust NOTE Many service bureaus capable of water transfer printing will take an infiltrated part and do all of the sanding and finishing for you included in the fee Film Printing The decor or pattern is printed on a special high molecular water soluble film Any image can be printed Common images include realistic wood grains carbon fiber patterns metals and metalics stone camouflage and decorative images Z Corporation Service 781 852 5050 887 88 ZCORP 67 Z Corporation www zcorp users com Z810 System User Manual Priming Z Corp parts should be primed and painted in a base color e g brown for parts which are to be printed in a wood grain decor Spreading Film The film is spread out on the water surface of the dipping basin The water bath is heated and kept at a constant 86 F 30 C The film dissolves and only the ink image remains floating on the water Activating The ink is sprayed with an activating material so that it becomes
132. ps 8 4 1 8 4 2 8 4 3 SAFETY PRECAUTIONS Liquid wax is hot and may cause burns Follow all manufacturer recommended safety precautions for your dip tank prior to use Wear gloves when handling hot parts GENERAL APPLICATION NOTES Parts should be dried in an oven at 100 F 38 C prior to infiltrating with wax for deeper wax penetration If the part is bulky you may preheat it at 150 F 66 C for up to 30 minutes Soak part in the liquid wax tank follow all tank manufacturer s instructions Remove infiltrated part from dip tank Place part in an oven at 150 F 66 C until the wax has penetrated or melted off your part usually around 15 minutes Be aware that these are simple guidelines Your specific applications may require additional steps CURING INFORMATION Allow your parts to cool after removal from the oven until the part is no longer warm to the touch Below is a list of links to websites of leading wax dip tank suppliers http www 3candles com commercial htm http www dccoopertanks com directlyheated html http Awww wenesco com wax2 htm waxtop Z Corporation Service 781 852 5050 887 88 ZCORP 61 al Z810 System User Manu Z Corporation APPLICATIONS 9 D oo l A Ll i x a A le SYFZLNIYd GE NOILVUYOdUYODZ Anessa 9ZILIIeIN x h M O A U O a gt j O WWwW zcorp users com Z810 System User Manual Z Corporation In this section y
133. quirt BINDER weak pressure from pump d BINDER can t write plumbing state BINDER invalid plumbing type d MATERIALS unknown combination STICKY object already exists STICKY object not initialized STICKY too many keys STICKY duplicate variable POWDER no more build POWDER no more feed POWDER tray full ROLLER speed calibration failed ALIGNMENT can t update god variable SPIBUS SPIBUS SPIBUS object already exists object not initialized invalid ADC channel specified SPIBUS timeout waiting for Read SPIBUS write verify failed SPIBUS unknown device TIGER object already exists TIGER object not initialized TIGER temp calibration exceeds range dmA TIGER head TSR exceeds range dohms HEADCARD object not initialized HEADCARD object already exists SMART CHIP unknown block type CUSTOM can t find CBDIO PCI card POWDER feeder timeout POWDER feeder not present POWDER can t find feeder POWDER overflow full SERVICE failed head check PISTONS build piston is tilted PISTONS illegal move TIDIO TIDIO TIDIO TIDIO TIDIO TIDIO TIDIO www zcorp users com invalid command invalid port invalid adc channel pockets out of range vomiter timeout invalid toggle argument unknown error 122 Z810 System User Manual 15 INDEX 3 3D Print 44 A Add zc10 Wash Fluid 104 Air Gun 54 Aligning the Print Heads See Alignment Alignment 84 Edit Alignment 88 Alignment Plate
134. r should be used when printing with zp250 powder To check the version of ZPrint Software currently installed Contact lt Corporation About 2 Corp System Sofware select About Z Corporation Software from the Help Corp web site Menu If ZPrint version 6 2 or higher is not installed a x contact the Z Corporation Service Department for an upgrade at service zcorp com i Feed Piston has 12 00 inches remaining i f Build Position has 6 70 inches remaining e You will also need firmware version 1 027 or higher ra e L To check the firmware version you are currently Compile date Aug 14 2003 using choose the Check Status option under the Service menu www zcorp users com 96 Z810 System User Manual Z Corporation Due to the nature of the open powder matrix of zp250 powder and its capacity to absorb Z Snap or Z Max epoxy infiltrant the use of a fixture generated in ZPrint Software is recommended for parts with a wall thickness less than 0 375 9 5mm should be built with a fixture as well For a complete explanation of how to use the Make Fixture function in ZPrint Software refer to the ZPrint Software Manual Fixtures used as cradles for zp250 powder parts should be built with the following parameters Clearance 0 125 0 25 3 175 6 35 mm Top Surface Thickness 0 1 0 25 2 54 6 35 mm Wall Thickness 0 1 0 25 2 54 6 35 mm Distance Between Wall by X 0 5
135. re paste or adhesive for attachments Additional clamps or securing wires may also be needed gt PP PP DP ZCast Design Guide 8 FINISHING A A CAUTION CAUTION Appendix Breaking molds with a hammer or high pressure water jet releases airborne objects and may cause personal injury 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 face protection while performing these tasks ZCast Design Guide 9 Appendix 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 With the ZCast process Z Corp provides the option to skip the pattern or tooling step significantly reducing the time required to obtain metal castings while also reducing the cost The production of prototype castings using conventional methods can often take several weeks and be prohibitively expensive These constraints limit the number or preclude the production of metal prototypes during the development process Specific time and cost savings will depend on the size and complexity of the desired part but can also be substantial for most customer needs
136. ree short lines are interleaved with the long lines Slow axis too low Good slow axis reticule Slow axis too high The three short lines are interleaved with the long lines Examples El problem secs The top short line is above the Here the lines are overlapping long lines The three short lines instead of interleaved should be between the long lines Z Corporation Service 781 852 5050 887 88 ZCORP 87 Z Corporation Z810 System User Manual 7 Look up the numbers that are next to the best aligned pattern as described above 810 Alignment Print Test Pattern 8 Choose Edit Alignment in the alignment dialog box Technical Tip 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 9 Enter numbers for the best aligned pattern in each row into the Print Head 1 x corresponding boxes fast and slow axis Fast f Cancel Slow jo F1 Head 1 Fast S1 Head 1 Slow F2 Head 2 Fast S2 Head 2 Slow F3 Head 3 Fast S3 Head 3 Slow F4 Head 4 Fast S4 Head 4 Slow F5 Head 5 Fast S5 Head 5 Slow Set Defaults LEE www zcorp users com 88 Z810 System User Manual 10 Click OK The software will ask you to update the alignment Click OK to update the printer s configurations 11 Remove the paper off
137. rint the part The part is made up of two areas the shell and the core as described in Section 1 2 How It Works Thus there are two saturation values one for the shell and core In general the shell saturation is higher than the core saturation The ZPrint Software will display the recommended values for each powder type 1 Plaster Material System The shell and core saturation values for the plaster material system are generally constant values meaning that there is only one value for all geometry types PLEASE NOTE When printing parts that are thinner than 1 8 of an inch 3 mm Increase saturation values Shell Saturation 2 Core Saturation 1 2 Starch Material System The shell and core saturation values for the starch material system depend on part geometry A thick walled part will have lower shell saturation than a thin walled part Core saturation is dependent on the wall thickness of the part The thinner the wall thickness the higher the core saturation the thicker the wall thickness the lower the core saturation 3 ZCast Material System The shell and core saturation values for the ZCast material system are generally constant values meaning that there is only one value for all geometry types The ZPrint Software will recommend shell and core saturation values based on the part geometry These values will work for most parts except the following Parts where a large volume will be unsupported when the part is fully
138. rovide dip printing as a service Website www plasticscommerce com dorchase Cubic Co Ltd Located in Japan This company manufactures dip printing equipment Look at the network page on their website to find a comprehensive list of owners of their equipment throughout the world Website www cubic co jp 9 6 INVESTMENT CASTING Z Corp parts can be used as investment casting patterns to quickly get metal parts Starch based parts can be infiltrated with cyanoacrylate resin or wax and used instead of a standard wax pattern in the investment casting process The parts burn out well and do not have any expansion problems that would lead to shell cracking Investment casting of Z Corporation parts is a good way to get a final prototype or a near net shape part made of the specific alloy your application requires It can also be used for short run production when time is extremely important 25 of Z Corp users have had a part cast at some point in their design process General Notes e Consult with experienced foundry personnel to incorporate best practices in casting design when designing your pattern They will help the designer or engineer to design their part with the gate runners and secondary operations in mind Operations and equipment vary from foundry to foundry Success has been achieved consistently in a variety of situations and locations using the notes below as a guide Steps that have been varied to achieve success ar
139. s greatly simplifies the mold design process Design alternatives include e The Direct Pour Method involves printing an entire mold cores and all in the ZCast material This usually uses the most material but allows for virtually no set up time and very quick production of your prototype casting e The Shell Method involves printing only a thin 1 2 inch thick mold to surround the entire part This shell is then backed with traditional foundry sand in a flask to create a mold Suitable for pouring This helps to minimize the amount of ZCast material used and is ZCast Design Guide 10 Appendix particularly useful for assembling large molds that are too large to fit in the build volume of the Z Corporation Printer The Combination Method involves printing cores with ZCast material and using them in conjunction with a conventional sand mold 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 1 00 series materials ZCast Design Guide 11 Appendix 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 Typically any foundry will find their end of the process the set up and pouring to be very much the same as traditional sand casting therefore
140. s to use native files If it is not possible next best would be an IGES or STEP file If neither choice is available an STL sterolithography Slice file would be suitable with a package like Magics RP Processing tends to be much slower when working with STL files Add finish stock to machined surfaces typically 0 080 in 2mm Apply shrinkage factors based on material to be cast and part geometry Define and divide out cores using surfaces generated within the model Add core prints to the cores Design the gating system as a positive component around the part to be cast Encapsulate the part and gating within a larger form typically a rectangular block Subtract the casting and gating and core prints away from the larger block leaving the mold cavity Generate a parting surface and split the mold block ZCast Design Guide 16 Appendix 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 Add flanges or seats for prefabricated pouring cups if utilized direct pour only 12 optional Lighten mold pieces by cutting out material from heavy mold sections direct pour only or shell the entire mold to approximately 0 5 to 0 75 in 13 to 19mm Shell method only 13 Add mating surface offsets to facilitate assembly of components 14 Divide the mold
141. se a material with a Shore A hardness lt 50 Z Corporation Service 781 852 5050 887 88 ZCORP 15 Z Corporation Z810 System User Manual Process Overview KAURIN Printed Part Mold Box Setup Pour Silicone Make Parting Line l 0 l Bl l d Mold with Cavity Pour Urethane Cast Part Master Pattern Production Preparation of the master is the key to successful mold making and part casting Every detail of the master s surface finish will translate to the cast pieces The polished appearance of an injected molded part is often the goal when prototyping with RTV molding To achieve the polished appearance prepare the surface finish of the master pattern by following the seven steps listed below Note that it is only necessary to follow these steps to achieve the appearance of an injected molded part with an ultra smooth finish 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 2 Sand the part with 100 grit sand paper after it has been infiltrated with either epoxy or cyanoacrylate Sand the part so there are no pits in the surface 3 Coat the part with a filler such as Bondo No 907 Glazing amp Spot Putty being sure to fill in any remaining pits You can also use a fast curing spac
142. side Refer to the ZCast 501 powder MSDS for more information on the irritating and toxic fumes 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 use ZCast 501 molds with molten ferrous metals or other metals with pouring temperatures above 1100 C WARNING 2000 F The molds can suddenly fail unexpectedly releasing entrapped gases and molten metal causing serious personal injury Do not handle molten metal without heat resistant WARNING faceshield gloves and apron and tools suitable for handling molten metal in foundry operations Depowdering with compressed air will generate airborne particles Only trained or supervised individuals should CAUTION depowder a mold Use hood ventilation and safety goggles or faceshield to protect the eyes and face Refer to the ZCast 501 powder MSDS for more information gt PP PP DP DESIGNING MOLDS Improper design of molds can result in the release of molten WARNING Metal and personal injury during the metal casting steps Only trained or supervised individuals should design molds for the Combination Method casting technique Other mold WARNING materials can unexpectedly release molten metal and cause personal injury during metal casting Use only ZCast 501 material for the mold sect
143. sign molds to ensure at least 0 5 inches 13 mm mold wall thickness ZCast Design Guide 27 Appendix 6 11 Pouring Sleeves amp 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 Pouring sleeves are inexpensive come in several sizes have a variety of filters available and work well with ZCast molds A conical seat should be printed in the mold to accommodate and position the sleeve The sleeves should be attached to the ZCast mold with a foundry adhesive or core paste For safe measure they can be clamped or wired in place to prevent shifting during pouring Additionally you can design a pouring sleeve to be integrated as part of your ZCast mold Be sure to make allowances for filter insertion to help alleviate impurities when pouring Pouring sleeves attached to the ZCast mold with core paste A CAUTION May shift while pouring molten metal into the mold Leaking of molten metal may cause personal injury Attach sleeves with clamps and securing wires as needed 6 12 Chills Chills will be familiar to experienced foundrymen The purpose of a chill is to help rapidly solidify the molten metal in a portion of a casting Controlling the solidification rate in this manner helps to control the grain structure keeping a ti
144. skin and are irritating and toxic Refer to the ZCast 501 powder MSDS for more information Z Corp tested and approved materials Alloy Pouring Temperature s Melting Temperature s Aluminum 319 1250 1450 F 1120 Aluminum 356 1250 1450 1135 Aluminum 390 1250 1450 F 1156 F Bronze Silicon 1900 F 2150 F 1880 F 1940 F Bronze Phosphor 1900 2150 F 1830 1970 F WARNING NO ATTEMPT SHOULD BE MADE TO POUR FERROUS METALS IN ZCAST 501 MOLDS 5 ASM metals handbook 4 edition Heine amp Rosenthal Foseco foundryman s handbook Consult Z Corporation prior to pouring ZCast Design Guide 33 Appendix 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 Dispose of ZCast powder according to local and state regulations 9 3 Powder Recycling Unprinted ZCast material can be recycled Z Corp recommends that you add new powder with recycled powder to maintain powder consistency ZCast Design Guide 34 Appendix 10 Finishing 10 1 De molding Removing a casting from a ZCast mold is virtually identical in process to the removal of a casting from a traditional chemically set sand mold After cooling and solidifying the mold ca
145. strongly recommended that slice viewing View and collision detection if more than one part is Toolbar being printed be used before beginning the Y Status Bar build These features are found under the View menu of the software Entity Selection o One Layer Up A Slice viewing allows you to view the cross One Layer Down sections of the part to identify any slice errors Ten Layers Up Shift A o l l l Ten Layers Down Shift Z Collision detection will scan through the slices and report the layer in which part overlapping is Colision Detection found Fast Rendering Calculate Part Statistics View Job Log View Detailed Report Refresh 5 3 1 POWDER SETTINGS 5 3 1 1 Anisotropic Scaling Values Anisotropic scaling values scale the model to accommodate any shrinkage or expansion of the part either due to characteristics of the material system or infiltrant system A scaling value of one 1 is equal to 100 of the part in a specific axis lf the part shrinks 1 in a certain axis the correct anisotropic scaling value would be 1 01 in that axis The ZPrint Software will display the recommended values for each powder type The scaling factors may differ according to wall thickness and geometry of the part A higher accuracy level may be obtained by measuring the part and adjusting anisotropic scaling values as needed To obtain new anisotropic scaling factors that are part specific print the part with scaling factors of one 1 in all axes On
146. t 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 7 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 one hour prior to the oven cure Z Corporation Service 781 852 5050 887 88 ZCORP 99 Z Corporation Z810 System User Manual 8 If using Z Snap epoxy place the part with fixture into an oven for 30 minutes at 120 F 49 C This step reduces the occurrence of unsightly bubbling or pooling of the resin Parts infiltrated with Z Snap epoxy should then be cured for an additional 2 hours in the oven at 165 F 74 C 9 If using Z Max parts should be oven cured for an additional 2 hours at 160 F 71 C 10 Let the part sit for 30 minutes at room temperature to cool before handling 11 2 4 INFILTRATION ADDENDUM Parts with large unsupported overhangs that are difficult to manually handle without breaking should be left on the fixture Remove as much powder as possible from the top and side surfaces while the part is on the fixture Lightly infiltrate the exposed top surfaces of the part with Z Snap or Z Max epoxy DO NOT apply too much infiltrant to prevent the infiltrant from wicking through to the bottom side of the part Cure the part for one hour at 165 F 74 C For
147. t cases for easy disassembly of the mold box All seams of the mold box must be sealed to ensure the liquid silicone does not leak Hot melt glue silicone caulk or clay are effective choices again be sure the material chosen will not inhibit the cure of the silicone 9 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 www zcorp users com 78 Z810 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 The open time of RTV silicone is typically 1 2 hours see your product s Technical Data Sheet for specific information allowing enough time to carefully mix and prepare the liquid rubber Though mixing can be done by hand it is difficult to determine if both components are thoroughly combined in large volumes The use of a Jiffy Mixer is recommended Mixing the components together will whip air into the mixture Air trapped in the mixture must be degassed which separates the air out of the silicone mixture Place the mixture in a vacuum chamber and degass Removing the air until a minimum of 27 Hg has been reached vacuum chambers and casting systems ar
148. t of time it takes to gel or double in viscosity Flash Cast material that has squeezed into the space between mold halves typically at the parting line Z Corporation Service 781 852 5050 887 88 ZCORP 79 Z Corporation Z810 System User Manual Mold Preparation and Casting Spray mold release onto all areas that will be exposed to the casting material and place the mold halves together Use tape rubber bands or clamped boards to hold the mold together preventing the cast urethane from leaking through the parting line Do not squeeze a soft mold too tightly as the mold cavity may flex or distort A cup or sprue is usually placed at the gate of the mold as a receptacle for pouring or injecting the casting material Preparation and dispensing of the casting materials varies Two part urethanes are typically packaged in cartridges and dispensed through a handheld pneumatic static mixer for smaller scale applications Automated meter mix dispense equipment is usually used by small production facilities The use of hand pumping static mix dispensers is not recommended as they tend to produce off ratio mixtures Placing the mold in pressure pot after material has been cast into it to minimize any bubbles present is acommon practice This will reduce the effects trapped air will have on the final part Follow the cure cycle of the cast material before attempting to de mold the cast part Conclusion RTV molding is an extremel
149. t results when designing vents for your cores e The cores should be shelled in by approximately 0 25 in 6 35 mm wall thickness where possible e Any single wall of the core should be no thicker than 0 5 in 13 mm or thinner than 0 14 in 3 5 mm Very slender cores with thinner Core Vent walls are possible over short renee lengths distortion will limit how long they can be e The core vents should continue through the mold walls and out to Figure 9 Venting the core the atmosphere This should typically be done through the core print as far away from the parting lines as possible to limit the possibility of metal leakage Vents not located in the core vents too close to parting lines or vents that break through to the casting surface may A CAUTION leak molten metal and cause personal injury Locate vents in the core away from the casting surface and as far as possible from parting lines e Depowdering heavily contoured core vents can be a challenge if 0 12 in 8 mm diameter vents curve into a tight radius ZCast Design Guide 21 Appendix 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 Therefore when designing mold vents
150. t with 1 4 inch NPTM pipe thread Requires a 14 NPTM mate Dimensions 46 inches 1 17 meters deep x 40 inches 1 02 meters wide x 105 inches 2 67 meters tall Ceiling clearance of 120 inches 3 meters is needed to upright the Depowdering Unit from shipping orientation www zcorp users com 20 Z810 System User Manual Z Corporation Selector Level Adjusts the amount of air used for air curtain across the ZD8 window and opening ZD8 Window Creates a shield to reduce airbourne powder particles Tracks Allows for pallet transfer from cart Control Panel Allows for ZD8 Control and indicates self cleaning status Blow Off Hose and Nozzles Located inside the depowderer Allows for removal of powder from part Powder Drawer Handles Allows for easy pull out and mobilization of powder drawer Powder Drawer Collects loose powder Figure 11 ZD8 Depowdering Unit Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation 2 2 1 AIR CURTAIN A fraction of the clean air exhausting from the blower is focused into a curtain and directed downward across the ZD8 window and front opening This air curtain helps powder from being ejected from the part during depowdering Figure 12 ZD8 Air Curtain Selector Lever www zcorp users com Z810 System User Manual Selector Lever The user can adjust the strength of the air c
151. tem User Manual 11 Remove the rubber tubing from the bottle of distilled water Disconnect the end of the fluid line to the rubber tubing and reconnect Close cabinet door 12 Turn Printer off 13 When ready to use the Z810 3D Printer turn Printer on replace the distilled water with Z Corp binder and flush fluid system for three minutes Then purge the print heads 13 3 GREASING THE FAST AXIS 8105ervice It is necessary to add grease to these fittings approximately every two e naga weeks The grease lubricates and protects the bearing The grease also Pcie made Se coats the fast axis rails and prevents powder from adhering to them This aak further protects the bearings For instructions on how to assemble the Bleed AF grease gun please refer to the instructions on the grease gun be Fact AXE packaging Lube Slow Axis Print Head Report 1 Before lubricating the fast axis empty the build box of both parts and View Printer Log powder 2 Select the Lube Fast Axis option under the 810Service menu The Se build piston will be lowered and the ganiry will move to the ideal A location for greasing 3 Push the grease gun onto the Zerk fitting and compress the lever on Fill Bed the grease gun once to inject grease Then pull the grease gun off Empty Overflow the fitting It may be harder to remove the grease gun than to insert SEU See it It is not possible to damage the bearings by greasi
152. ter 40 minutes PLEASE NOTE The gel time decreases when preparing quantities of material greater than 450 grams 8 3 3 CURING INFORMATION e infiltrated parts should be pre cured at ambient temperature for 30 minutes e Cure the infiltrated part for 30 minutes at 120 F 50 C then 2 hours at 165 F 74 C ona non stick wax paper Teflon polyethylene etc material or it will adhere to the surface it is sitting on while curing PLEASE NOTE Z Snap epoxy should not be cured at temperatures greater than 165 F 74 C and longer than 3 hours because flexibility may decrease making the parts more brittle 8 3 4 CLEAN UP e Any remaining mixed infiltrant beyond the working time should be kept in a well ventilated area to avoid fumes 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 www zcorp users com 60 Z810 System User Manual Z Corporation 8 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 powder parts This material cures rapidly and enhances the vibrancy of color parts PARAPLAST is available in a case of eight 2 2 lb 1 kilogram bag of chi
153. the first choice would be to find a foundry with experience in sand casting The foundry should be set up for running prototype quantities or be able to comfortably adapt to pouring parts in low volume Depending on the design style direct pour shell method etc the foundry should be an active participant in the design The more experience you and your foundry have in pouring ZCast molds the more efficient your digital to prototyping process becomes Though not a requirement your chosen foundry should be near the location where the molds are printed Close proximity minimizes the amount of travel the molds must endure Molds and cores may be shipped even around the world but they must be packaged carefully Shipping molds long distances can add days to the development cycle and increase risk of damage due to shipping We recommended that you provide a copy of this design guide to your chosen foundry partner 4 1 Foundry Trial Parts Once you have a foundry you ll want to introduce them to the ZCast process with a trial mold Z Corporation can supply you with files for two such parts One is a cover plate and the other is a manifold Figure 1 Cover Plate mold and casting Figure 2 Manifold mold and casting The molds can be printed baked and brought to your foundry All of the instructions necessary to pour these parts are in the ZCast Direct Metal Casting Quick Guide contact your Z Corp sales representative for a copy
154. the mold cavity the risk remains that all of the powder may not be removable during depowdering Loose powder left in the mold when metal is poured has the possibility of affecting the outcome of the finished casting by creating pockets or voids Rubber Hose Figure 10 Attach a flexible plastic hose like the one shown above to reach blind spots In order to avoid the aforementioned ensure that your mold has undergone a thorough removal of powder In difficult to reach areas such as blind channels and areas not visible use a small flexible hose like the one shown in Figure 10 to extract loose powder A 1 8 in 3 2 mm O D and 1 16 in 1 6 mm I D urethane tube is ideal because it slides firmly over the nozzle on the ZD4 or ZD8 depowdering units Loose powder left in molds may create pockets voids or A CAUTION block vents during metal casting resulting in the unexpected release of molten metal Ensure that all loose powder is removed before casting Depowdering with compressed air will generate airborne particles Only trained or supervised individuals should A CAUTION depowder a mold Use hood ventilation and safety goggles or faceshield to protect the eyes and face Refer to the ZCast 501 powder MSDS for more information 6 8 Mating Surfaces The mating surfaces of the mold should be offset to accommodate for surface imperfections A total gap of 0 02 in 0 51 mm should be created in the model at all mating surf
155. ting a part in the Z810 3D Printer 3 1 PRINTER PREPARATION 1 Clean the top deck 2 Clean service station 3 Clean the squeegees and wiper scraper with a dry paper towel www zcorp users com 26 Z810 System User Manual 4 Spread powder over the build area using the fill bed feature 5 Empty powder overflow chute 6 Check fluid levels of binder Fill if needed Z Corporation Service 781 852 5050 887 88 ZCORP Z Corporation 27 Z Corporation 7 Empty waste container www zcorp users com Z810 System User Manual 28 Z810 System User Manual Z Corporation 3 2 SETTING UP THE BUILD 1 Set up the build on the ZPrint Software Lopra HH ip EHE lacha 2 Check 3D Print Setup for MET x build settings and edit as Printer 2810 Offline Select Printer Save Printer as Default needed Powder HAJA Use Default Powder Save Powder as Default Powder Parameters Layer Thickness 0 004 in Saturation 3 Press 3D Print to begin printing process Anisotropic Bleed Shell Core Scaling Compensation Binder Volume Ratio 298 149 Saturation Level 100 100 x 1 Saturation EN 0 85 k i Z 1 Override Use Default Save as Default Reset Factory Settings Z Corporation Service 781 852 5050 887 88 ZCORP 29 Z Corporation Z810 System User Manual 3 3 TRANSFERRING THE PART TO THE DEPOWDERING UNIT 1 Gross depowder the part in th
156. to include preferred meeting times The session is approximately one hour 11 1 2 USING ZCAST ON YOUR Z810 3D PRINTER Before using ZCast powder on your Z810 3D Printer you will need to remove the scraper blade and change powder feeders Temporary Scraper Blade Removal When using ZCast powder on the Z810 3D Printer the scraper blade should be removed Failure to remove the scraper blade when running ZCast powder will result in excessive wear on the scraper blade and require replacement Remember to reinstall the scraper blade when printing with ZCast powder is complete www zcorp users com 94 Z810 System User Manual Z Corporation Loading ZCast Powder into the Z810 3D Printer 1 Remove all powder from the build box and overflow chute Use the overflow chute window to help you remove all traces of powder 2 Disconnect the electronic cable power cable and air line to the ZF8 Feeder 3 Pull the release lever on the back side of the printer and simultaneously remove the ZF8 starch or plaster feeder 4 Slide the ZF8 ZCast Feeder locking it into place and reconnect all hoses and cables 11 1 3 SETTING UP ZCAST BUILDS Follow normal practices for printing parts in Z Corp printers 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 Design Guide
157. totypes will have the look and feel of a production piece Additional Resources for the Novice Mold Maker www build stuff com O002book htm www bare metal com articles gremlins how to htm www smooth on com moldmaking htm www eagerplastics com intro htm www theminiaturespage com ref fgmolds html www micromark com part_mold html The quality of the pattern directly affects the quality of the part from the RTV mold because RTV rubber molds will pick up details as fine as a fingerprint from the master pattern 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 1 Draft Angle A slight taper to the shape of a cast part to allow it to be easily removed from its mold Draft angles should be used on interior or exterior part walls in the direction of draw A minimum 1 draft angle per side is recommended for parts having no textured surfaces Textured surfaces need additional draft to easily release the part and eliminate drag marks or scuffing of the part surface 2 Parting Line Line in which two halves of a mold will separate Parting lines should be located to provide good part appearance and function 3 Undercut A protuberance or indentation that impedes withdrawal from a two piece rigid mold 4 Durometer The hardness of a material RTV molds typically u
158. ty 1607 COM d bad interrupt number 1608 COM d IRQ already in use 1609 COM d can t save interrupt vector 1610 COM d can t set interrupt vector 1611 COM d UART isn t 16550 compatible 1612 COM d input queue overrun 1613 COM d UART not found 1614 COM d bad UART identifier 1615 COM d UART already in use 1700 STATUS spurious read event 1701 STATUS bad thread index d 1702 STATUS unknown system message d 1703 STATUS invalid state d 1704 STATUS unknown dispatch type d 1705 STATUS message queue overrun 1706 STATUS can t save state 1707 STATUS can t restore state 1708 STATUS too many held layers 1800 PACKETS layer is too big 1801 PACKETS invalid upgrade file 1802 PACKETS network init failed 1900 LAYERS spurious read event 1901 LAYERS zlib Inflatelnit error d 1902 LAYERS zlib Inflate error d 1903 LAYERS zlib InflateEnd error d 1904 LAYERS missing layer info packet 1905 LAYERS layer is too big dK bytes 2000 STRIPES spurious read event 2001 STRIPES bad saturation 2002 STRIPES too many lines per stripe 2003 STRIPES line is too long 2004 STRIPES bad print mode d 2005 STRIPES bad line offset 2100 UNRLE bad layer number 2101 UNRLE bad print mode d Z Corporation Service 781 852 5050 887 88 ZCORP 119 Z Corporation 2200 2201 2300 2301 2302 2303 2304 2305 2306 2307 2308 2308 2400 2401 2402 2403 2500 2501 2600 2700 2701 2800 2801 2900 3000 3001 3002 3003 3004
159. tying the overflow chute gt d Overflow Chute Vacuum Receptacle www zcorp users com 36 Z810 System User Manual 4 5 CHECKING POWDER LEVELS PLEASE NOTE Never add powder from container until all powder has been vacuumed out of the build area and overflow chute has been emptied If you do not have enough powder to complete your build you will need to fill the powder feeder To view how much powder is left in the feeder choose Check Status under the Service menu or using the control panel raise or lower the build piston the LCD will read F X B Y Where X corresponds with the powder level in the feeder and Y corresponds with the build level available The powder levels are given in four inch increments ONLY To fill the feeder 1 Turn on vacuum 2 Place vacuum hose into powder feeder vacuum receptacle 3 Vacuum powder from powder container 4 The powder feeder vacuum will shut down when it is full Z Corporation Technical Tip Use a nozzle or vacuum at an angle when filling the powder feeder This will promote airflow through the vacuum hose PLEASE NOTE If the feeder detects that it is full it will shut off the vacuum and stir the powder in the feeder for 30 seconds If it no longer detects that it is full after stirring the feeder will turn the vacuum back on This continues until the detector reads full after stirring When the feeder detects that it is full the
160. under the gantry when powder and binder have adhered to the bottom causing layers to be dragged when printing It is also good practice to clean under the gantry to prevent powder and binder build up once a month ATA 1 Lower build piston 50 E down by pressing the Build Down button on the control panel 2 Unpark the gantry by choosing the Unpark option 810Service in the 810Service menu Purge Print Heads Alignment Change Binder Supply Unpark Bleed Air Lube Fast Axis Lube Slow Axis Print Head Report View Printer Log Edit INI File Send File Receive File 3 Push the gantry over the build piston Z Corporation Service 781 852 5050 887 88 ZCORP 109 Z Corporation Z810 System User Manual 4 Using a moist paper towel wipe underneath the gantry Dry the bottom of the gantry after cleaning with a dry paper towel 5 Repark the gantry by clicking OK on the dialog Unpark box Press OK to re park the carnage 6 Raise build piston to original position and vacuum up any powder or debris that has fallen into the build area 13 6 CLEAN FAN FILTER The fan filter is located on the left side of the electronics panel It circulates and filters air into the electronics area The filter should be cleaned once a month 1 Turn off the Printer 2 Open the front left cabinet door 3 Locate the filter on the upper right side of the cabi
161. urtain that is the fraction of the blower exhaust that is recycled into the air curtain via the selector lever on the left side of the machine The air curtain is useful for preventing the escape of powder particles and helping the window stay clean Stronger air curtains more effectively prevent powder jets reflected off the part from escaping the booth However since the air curtain recycles air within the machine a strong air curtain reduces the amount of net fresh airflow and allows for less visibility While the air curtain can be adjusted as often as you like most users will find a single setting they are most comfortable with The table below summarizes the various positions of the selector lever Positions 1 through 5 are ordered from the rear to the front Pos Curtain Strength Visibilit Very Good 3 Medium Good 4 Strong _ OK 5 Very Strong 22 Z810 System User Manual 2 2 2 ZD8 CONTROL PANEL Main Control Switch Light Push Button Warning Lamp o Figure 13 ZD8 Control Panel PLEASE NOTE If the warning lamp is illuminated indicating that the filter cleaning cycle has been initiated and you would prefer that the cleaning not occur at that time you can pause the cleaning cycle by turning the main control switch to either Powder Drawer Release mode or Power On mode The cleaning cycle will restart when the main control switch is returned to Stand By m
162. w zcorp users com 66 Z810 System User Manual Z Corporation 9 5 WATER TRANSFER PRINTING Water transfer printing is a process that enables 2D printed patterns to be applied to three dimensional objects The process is suitable for production as well as prototyping Currently the most prevalent use of water transfer printing may be in auto finishing As shown in the picture below many trim packages utilize the process to mimic high end wood finishes on plastic or metal components The process is also often used on small electronics equipment decorative items and architectural trim The process transfers a 2D image onto a 3D object by floating the image on the surface of a heated water bath and dipping the 3D object through the image into the bath A subsequent sealing step with a spray lacquer gives the part durability with a wide range of surface finishes Any part that can be primed and spray painted can be dipped Equipment manufacturers such as Dips n Pieces claim that virtually any geometry can be dipped With proper masking parts can be dipped from all directions to give a near continuous pattern on every surface of a part There is some equipment to purchase and set up to be able to perform this printing process in house however there are several service bureaus that will dip parts for a fee Any image can be transferred to the object however standard patterns and color combinations prevail at most service bureaus The
163. wash clean 3 Restore squeegee scraper and tighten thumb screws Z Corporation Service 781 852 5050 887 88 ZCORP 111 Z Corporation 13 9 CLEAN SQUEEGEE WIPERS 1 Remove squeegee wipers by loosening and removing the screws located at each end of the wiper assembly with a hex wrench 2 Wash the wipers 3 Restore wipers and tighten screws Z810 System User Manual A a T a E ih ifs 13 10 BLEED AIR FROM THE FLUID SYSTEM Air will enter the fluid lines anytime the bottle fittings are disconnected This is normal and is expected You will need to bleed air to remove air from your system Follow the procedure below Flush Binder Press Start to begin flushing binder When the binder ts flushed press Done Bleed Air Press Start to begin bleeding air from the feed lines When all of air ig removed press Done WwWw zcorp users com 1 Fill the binder jug with binder solution 2 Select the Flush Binder option under the Service menu 3 Flush binder for three minutes 4 Unpark carriage and remove print heads 5 Select the Bleed Air option under the 810Service menu 6 Assemble the syringe part number 10674 and needle part number 13115 if needed from your toolkit by screwing on the needle at the end of the syringe 112 Z810 System User Manual Z Corporation 7 Remove plunger from syringe 8 Insert needle into septum and wa
164. y efficient method of generating multiple parts with thermoplastic properties There is no faster method of generating the master pattern than with a Z Corporation 3D 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 www zcorp users com 80 Z810 System User Manual Z Corporation 10 CHANGING AND ALIGNING THE PRINT HEADS 10 1 CHANGING THE PRINT HEADS WARNING Do NOT touch or contaminate the gold contacts on either the print heads or the Carriage with your fingers Avoid spilling binder on the contacts If you do get binder or anything else on the gold contacts clean them with an alcohol swab The print head will need to be changed when the print becomes uneven A print head should be able to print at least 1 2 liters of binder about 30 Billion pixels equivalent to about 2500 cubic centimeters of parts Print head life can depend upon the geometry of the parts printed so some print heads may last longer Signs of a worn print head are weak parts rough surface finish or visibly uneven printing in the build The software will display a warning when the print heads will be exceeding the expected print head life during the build To ensure that the build will be completed and good print quality replace the print heads Z Corp part numb

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