3D Systems sPro User manual

SLS process

user’s guide

Thank-you for purchasing 3D Systems® SLS® equipment and

DuraForm® materials. Before you start building parts in your

SLS™ process facility, please read this guide carefully to

enjoy optimum process performance and longer equipment

service life.

CONTENTS

Document 23348-M12-00 Revision B August 2017

3D Systems, the 3D logo, Sinterstation, sPro, SLS, and DuraForm are registered trademarks of 3D

Systems, Inc. Other trademarks are the property of their respective owners.

L In accordance with laboratory equipment safety standards (EN61010-1, Sect. 5.4.4). If this equipment is used

in a manner not specified by the manufacturer, protection provided by the equipment may be impaired.

Observe all warning labels, and conform to all safety rules described in this manual.

™

Contents

` About This Guide . . . . . . . . . . . . . . . . . 2

` Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

` SLS Process . . . . . . . . . . . . . . . . . . . . . . 43

` Prepare to Build . . . . . . . . . . . . . . . . . 55

` Build Parts. . . . . . . . . . . . . . . . . . . . . . . 73

` Break Out Parts . . . . . . . . . . . . . . . . . . 90

` RCM . . . . . . . . . . . . . . . . . . . . . . . . .101

` IRS & IPC. . . . . . . . . . . . . . . . . . . . . . . 133

` SLS System . . . . . . . . . . . . . . . . . . . . 180

` BOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

` Contacting 3D Systems . . . . . . . . . 242

` Glossary . . . . . . . . . . . . . . . . . . . . . . . 245

` Index. . . . . . . . . . . . . . . . . . . . . . . . . . 268

Original Instructions

S

SLS process

user’s guide

ABOUT THIS GUIDE

This guide describes how to create finished SLS parts made of DuraForm® PA plastic

powder laser sintering (LS) material using 3D Systems’ sPro SLS® system and

SLS equipment.

` What’s Inside?. . . . . . . . . . . . . . . . . . . . . . . . . . . .3

` Hazard Warnings. . . . . . . . . . . . . . . . . . . . . . . . .5

` Instruction Formats . . . . . . . . . . . . . . . . . . . . . 6

` Other Useful Documents . . . . . . . . . . . . . . . . 7

SLS process 3 ABOUT THIS GUIDE

user’s guide what’s inside?

What’s Inside?

This SLS Process User’s Guide includes the

sections summarized below. General safety

guidelines are presented first. The rest of the

Guide is organized in two parts. The first part

covers SLS process procedures and the second

covers SLS equipment.

At the end of this guide, you will also find a

Glossary of SLS process terms and an Index. Click

on any red TLA (three-letter acronym) or

SLS process term in this section to display a

definition.

Safety Guidelines and Instructions

The Safety section tells you what you need to

know to avoid injury or equipment damage. Read

this section before you switch on power to any

SLS equipment or handle DuraForm material.

L To verify that your facility was properly

prepared for SLS system installation, see the

sPro SLS Process Facility Guide and SLS Process

Facility Layout. For detailed material safety

information, see the DuraForm Material Safety

Data Sheets (MSDS’s).

Printed copies of these

documents were included in your SLS powder

material shipment. You can also download

MSDS’s for SLS materials

from3D Systems’ website. (See Other Useful

Documents on page 7.)

SLS Process Procedures

The instructions in these four sections step you

through the SLS process in a general way. When

necessary, they refer you to detailed machine

operating and maintenance instructions in the

equipment section of this guide.

SLS Process - overview of the SLS process from

powder to parts.

Build Preparation - how to prepare 3-D parts for

building using the SLS system’s Build Setup

software; how to clean, power-up, and start-up

SLS equipment, and perform pre-build checks.

L A “build” is a 3-D printout of a build packet

containing STL files of one or more 3-D parts.

You create build packets in the Build Setup

application. See your Build Setup online Help

for detailed build packet setup instructions.

Build Parts – how to run builds on the SLS

system, and how to monitor, control, and modify

a build in progress.

L You use the Sinter application to run a build.

See your Sinter application online Help for

detailed build instructions.

SLS process 4 ABOUT THIS GUIDE

user’s guide what’s inside?

Breakout Parts – how to remove and cool down

the part cake after a build, then use the BOS to

remove parts from the part cake. This section also

describes how to recycle or dispose of used part

cake powder.

SLS Equipment

This second half of the User’s Guide provides

detailed instructions for the functions you need

to perform on SLS equipment during SLS process

procedures. The process instructions in the first

part of the gu

ide frequently reference equipment

instructions these sections.

SLS Equipment - overview o

f SLS equipment

feature

s and functions. This section includes

illustrations that help you locate SLS equipment

components and controls and convenient menu

maps for the IRS and BOS operator panel

displays.

The four se

ctions after the equipment overview

contain complete safety, operation,

maintenance, and troubleshooting instructions

for each SLS process machine. They focus on the

following:

IRS and IPC - loading powder from the IPC to the

IRS and transferring po

wder between the IRS,

SLS system, and BOS.

SLS® system - preparing for, and running builds

using the Sinter application and utilities, and

maintaining the SLS system between builds.

BOS - breaking parts out of the part cake and

managing waste and recycled part cake powder.

SLS process 5 ABOUT THIS GUIDE

user’s guide hazard warnings

Hazard Warnings

You will find nine different types of warnings in

this guide. Always heed these warnings. Ignoring

them can expose you and your SLS equipment to

the hazards listed below.

L See the Safety section for descriptions of safety

labels on your SLS equipment.

WARNING TYPE HAZARD

Safety Alert Machine damage, part damage, and/or data loss.

Electric shock Injury or death from electric shock.

Hot surface

Burn injury or fire on hot non-handling surface. Allow surface to

cool before touching.

Hot surface - touch

Burn injury or fire on hot handling surface. Allow surface to cool

before touching.

Laser radiation Eye injury or blindness; burn injury; fire.

Crush Injury or death from crushing weight.

Impeller Injury or death from rotating blade or impeller.

Notched belt

entanglement

Injury or death from entanglement in notched pulley drive belt.

Air-pressurized

powder

Eye injury or blindness; dust-cloud ignition from escaping

pressurized powder.

SLS process 6 ABOUT THIS GUIDE

user’s guide instruction formats

Instruction Formats

Instructions in this guide use special text formats

to highlight menu commands, keys on the

keyboard, operator panel buttons, and text on

the operator panel display.

Text on Computer Display

Text in LS software menus and windows you

need to find or act on is in bold; for example:

“Open the Machine menu and select Manual

Operations > Inerting.”

“Click the Build button on the main toolbar.

Text you enter in LS software programs is

underlined in typewriter font; for example

In the Heater Control window, enter 130.0

for the temperature Setpoint (°C).”

Keys

Keyboard key names are capitalized; for example:

“Press the Enter key.”

Labeled Controls and Indicators

Labeled switches, buttons, lights, and gauges are

in bold, uppercase text; for example:

“Turn the BOS POWDER TRANSPORT switch

to RECYCLE.”

Operator Panel Buttons

The icons represent operator panel

buttons on the IRS and BOS. The buttons

pe

rform these functions:

Scroll menu options up/down; increase/

decrease/change parameter values.

Select option/accept change; similar to

Enter key on keyboard or YES or OK

dialog button.

Cancel/reject change/exit up one menu

level; similar to Esc key on keyboard or

NO, Cancel, or Exit dialog button.

Operator Panel Display Text

Text displayed on the IRS or BOS operator

panel appears in green text; for example:

From the Process Params menu, choose

RCM Type, then press .

SLS process 7 ABOUT THIS GUIDE

user’s guide other useful documents

Other Useful Documents

The documents listed below will help you get the

most out of your SLS process and equipment. You

can find them in the ..dtm\docs folder of your LS

software installation hard drive (...except for Build

Setup Help and Sinter Help. You access these

through the Build Setup and Sinter applications).

` SLS Process Facility Guide – details SLS

process requirements for facility electrical

power, room construction and atmosphere,

compressed air, nitrogen, coolant, powder,

and network. It also provides SLS equipment

specifications, shipping and information, and

moving instructions. (This guide was sent to

you before installation. A pdf copy is included

in the ..dtm\docs folder for reference.)

` SLS Process Facility Layout – illustrates SLS

process requirements for facility electrical

power, room atmosphere, compressed air,

nitrogen, and coolant. It also shows

equipment dimensions and a recommended

arrangement for your SLS equipment. (This

layout was sent to you before installation. A

pdf copy is included in the ..dtm\docs folder

for reference.)

` Material Safety Data Sheets (MSDS’s) –

online copies of the printed MSDS’s that ship

with DuraForm materials. Make sure

everyone in your facility who handles

DuraForm materials reads these MSDS’s and

follows the safety guidelines in them. To

order extra printed copies of these MSDS’s,

contact 3D Systems Customer Support.

` Build Setup Help – provides detailed

instructions on how to use the Build Setup

application to create and modify build

packets you can run on the SLS system. To

view Build Setup Help, run the Build Setup

program, then select Help > Help on Build

Setup ... from the main window menu bar.

For help on the currently selected Build Setup

command or window, press function key F1.

L You can also run Build Setup from the

Sinter Application by clicking the Setup

toolbar button.

SLS process 8 ABOUT THIS GUIDE

user’s guide other useful documents

` Sinter Help – provides detailed instructions

on how to use the Sinter application to run

and manage builds on the SLS system. To

view Sinter Help, run Sinter, then select

Help > Online Help from the main window

menu bar. For help on the currently selected

Sinter command or window, press function

key F1.

` Material Guides – give you the material,

machine, and software configuration

information you need to build good parts

with the SLS process. Each Material Guide

describes SLS processing characteristics for

one family of 3D Systems’ DuraForm powder

materials, such as DuraForm PA. They also

include safety and regulatory guidelines for

DuraForm material handling.

SLS process

user’s guide

SAFETY

This section gives the information you need to use 3D Systems’ SLS equipment and

DuraForm LS materials safely. It includes the following topics:

` General Safety Guidelines . . . . . . . . . . . . . . 10

` SLS Equipment Safety Features . . . . . . . . . 12

` Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

` Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . 17

` Environmental Issues. . . . . . . . . . . . . . . . . . . 18

` Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

` Powder Safety . . . . . . . . . . . . . . . . . . . . . . . . . 28

` Nitrogen/Oxygen Safety . . . . . . . . . . . . . . . . 32

` Mechanical Motion Hazard Locations . . . 34

` Hot Surfaces and Powders . . . . . . . . . . . . . . 35

` DuraForm Material Handling Safety . . . . . 36

` IPC Handling Safety . . . . . . . . . . . . . . . . . . . . 37

` Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

` Emergency Shutdown . . . . . . . . . . . . . . . . . . 40

Before using any SLS equipment, your company should have a safety program in place. The

safety program should do the following:

✓ Label and point out hazardous equipment,

m

aterials, and procedures.

✓ Explain what to do in an emergency

situation.

✓ Provide information about the hazards of

equipm

ent and materials in the form of

Material Safety Data Sheets. These ar

e

pr

ovided with all materials supplied b

y

3D

Systems.

SLS process 10 SAFETY

user’s guide general safety guidelines

General Safety Guidelines

All SLS equipment is designed with safety in

mind. However, improper use, malfunctions, and

excessive exposure could cause injury.

Follow these general safety guidelines when

operating any SLS equipment:

Training and Instructions

` Do not operate any SLS equipment before

receiving proper training.

` Read and follow all operating instructions.

` Follow all safety rules in this section and heed

all hazard warnings in this guide.

` Do not try to do any equipment maintenance

procedures you were not trained to do.

• Operators are trained to operate the

system and perform all the necessary tasks

to print a part.

• Certified service personnel are those

who have completed the 3D Systems

service training package and are certified

to perform service tasks. Certification may

occur at various levels, and servicers

should only perform tasks they are

authorized and certified to complete.

Machine Handling

` Do not try to access, service, or adjust any

components inside any SLS equipment

enclosure.

` Do not try to open any panel or door while a

machine is running.

` Do not access any area of the machine near

the process chamber high-temperature-

material builds.

` Use special caution when handling a heated

RCM and when dealing with the heated, inert

environment inside the SLS system’s process

chamber. Take note of all thermal hazard

warning labels on the machines.

`

Always disconnect the RCM cable before

moving the RCM out o

f the SLS system or

BOS.

` To prevent crush injuries to the body, use

extra caution when rolling the RCM into and

out of the SLS system and BOS, and when

closing the BOS overhead door. Take note of

all crush hazard warning labels on the

machines.

SLS process 11 SAFETY

user’s guide general safety guidelines

` Dress electrical cables, powder transport

tubing, and coolant hoses to prevent

tripping; especially the umbilical tubing that

connects the IPC to the IRS.

Material Handling

` Do not use any material without first

reviewing its Material Safety Data Sheet

(MSDS).

` To prevent injury and equipment damage, be

sure to follow all handling guidelines in

Powder Safety on page 25 and Nitrogen/

Oxygen Safety on page 30.

Laser

` Do not try to access, service, or adjust the

laser system in any way.

` Do not enter any area displaying posted

warning signs during open beam operations.

Open beam operations refer to the laser, and

they only occur during service procedures.

Alarms and Warnings

` If you hear an alarm, or if you see an error,

alarm, or warning message on any SLS

equipment display, note the state of that

machine’s Stacklight and refer to its

troubleshooting section in this guide. Clear

the alarm, error, or warning message before

resuming operation. (The SLS System

Troubleshooting section might refer you to

the Messages and the Message List Window

topic and/in your Sinter application online

Help.)

` Displayed error, alarm, or warning messages

can result from unsafe practices, such as

opening an enclosure door or panel when

equipment is powered up and running.

SLS process 12 SAFETY

user’s guide SLS equipment safety features

SLS Equipment Safety Features

The main design goal for all SLS equipment is to

provide a safe operating environment. The frame

and enclosure designs passively limit hazardous

access while the electronics and software actively

and automatically sense and react to unsafe

conditions when they arise. For example, if the

SLS system detects unsafe operating conditions,

it will immediately stop operating and, in some

cases, shut down completely.

Safety Interlocks

Safety interlock devices on the SLS equipment

help prevent accidental laser exposure, electrical

shocks, crush injuries, burns, and fires.

SLS equipment will not operate unless all safety

interlocks are satisfied.

If any SLS equipment safety features

fail, your actions may be all that will

prevent potentially hazardous

operating conditions.

Never try to disable or override any

safety interlock device on any

SLS equipment. Operating

equipment without all safety

interlocks enabled can cause

equipment damage, injury, or death.

If you suspect a safety interlock

device is not working properly, do

not operate your SLS equipment.

Rather, disconnect power from the

equipment and contact 3D Systems

Customer Support for assistance.

SLS process 13 SAFETY

user’s guide SLS equipment safety features

SLS SYSTEM RESPONSE IF AN INTERLOCK FAILS

Safety interlock devices mounted on the SLS

system sense the hazardous operating conditions

below. The SLS system takes the actions listed

when an interlock fails.

Limited Access And Barrier Shielding

SLS equipment frame and enclosure designs limit

access to the following:

Service areas, such as cabinets and enclosures

for electrical power and automation controls. This

prevents accidental exposure to electrical shock

hazards.

Powder areas, such as powder feed hoppers,

storage bins, and transport tubes. This prevents:

✓ burn hazards by minimizing exposure to

heated powder

✓ slip hazards by keeping powder from

dr

opping on the floor

✓ fire hazards by minimizing airborne dust

cloud formation and potential ignition. Se

e

MSDS

for complete hazard details.

SAFETY INTERLOCKED CONDITION IF THIS INTERLOCK FAILS...

RCM door open when SLS system is attempting to

start a build

• Build will not start

• Warning message appears on SLS system display

• Yellow Stacklight illuminates

RCM not fully raised or engaged with the process

chamber floor after RCM loading

One or more internal process chamber panels are

open

a

E-stop button pressed on user interface console • SLS system shuts down

• Nitrogen generator (if in use) shuts down

• Warning message appears on SLS system display

• Yellow Stacklight illuminates

External oxygen monitor connected to SLS system

detects too little oxygen in room

a. Internal panels are for service access only.

SLS process 14 SAFETY

user’s guide SLS equipment safety features

Laser beam optics and scanning areas,

including the fully-enclosed Image Processing

Module (IPM)—where the laser beam

originates—and the interior of the process

chamber, into which the beam projects. The IPM

and process chamber are designed to minimize

hazards such as burns, eye injury, and fire in the

following ways:

✓ The IPM optics and laser beam duct (at the

top of the process chamber, below the

removable laser window) prevents the laser

beam from being aimed outside the process

chamber.

✓ The fully enclosed process chamber blocks

laser radiation from escaping to the outside.

✓ The process chamber window material also

blocks laser radiation so you can safely

observe the part bed during a build.

Other Active Safety Features

✓ The Breakout

Station (BOS),

coupled with the

Dust Collector, removes airborne powder

during part breakout in accordance with

standard industrial ventilation practices.

✓ An overpressure sensor line monitors the

pressure in the Intelligent Powder Cartridge

(IPC) when it is connected to the Integrated

Recycling Station (IRS). This prevents IPC

container ruptures and accidental material

leakage.

✓ A room oxygen monitor automatically

initiates SLS system shutdown when it

detects too little oxygen in the room.

✓ Software in the SLS system, IRS and BOS

automatically initiates immediate equipment

shutdown if certain unsafe conditions are

detected during operation.

See BOS on page 208.

SLS process 15 SAFETY

user’s guide safety labels

Safety Labels

Safety labels are posted on all SLS process

machines. The following table describes each of

these labels.

SAFETY LABEL WHAT IT MEANS

ELECTRIC SHOCK HAZARD

High voltage electricity is accessible in the vicinity of this sign or behind the access panel.

High voltage can cause severe burns or death. Access panels are for service only and

should be opened only by certified service personnel or trained maintenance personnel.

HOT SURFACES HAZARD

There are surfaces and powders in the vicinity that may be hot and could cause severe

burns or fire.

SLS equipment has two types of hot surface hazard labels; one with a hand and one

without. The label with the hand appears on hot surfaces that are normally handled, such

as process chamber access panels. The label without the hand appears on hot surfaces

that are not normally handled, such as the heat shield around the RCM part cylinder.

LASER RADIATION HAZARD

Invisible laser radiation is accessible in the vicinity of this sign or behind the access panel.

Direct and scattered radiation can cause severe burns and blindness. Access panels are

for service only and should be opened only by certified service personnel. See Laser

Safety on page 20.

SLS process 16 SAFETY

user’s guide safety labels

CRUSH HAZARD

Mechanical motion of machine components presents a crush hazard in the vicinity of this

sign. Crush hazards can result in severe bodily injury or death. See Mechanical Motion

Hazard Locations on page 33.

ROTATING BLADE CUTTING HAZARD

Rotating motion of machine blade or impeller presents a cutting hazard in the vicinity of

this sign. Cutting hazards can result in severe bodily injury or death. See Mechanical

Motion Hazard Locations on page 33.

NOTCHED BELT/PULLEY ENTANGLEMENT HAZARD

Motion of notched drive belt on pulley presents an entanglement hazard in the vicinity

of this sign. Entanglement hazards can result in severe bodily injury or death. See

Mechanical Motion Hazard Locations on page 33.

AIR-PRESSURIZED POWDER HAZARD

Sudden, explosive escape of air-pressurized powder presents a hazard in the vicinity of

this sign. Failing to shut off the main powder valve before servicing can result in sudden

explosive escape of air-pressurized powder. This can result in bodily injury or fire if the

powder cloud ignites. See DuraForm Package Handling Safety on page 35.

SAFETY LABEL WHAT IT MEANS

SLS process 17 SAFETY

user’s guide electrical safety

Electrical Safety

To prevent electrical shock, SLS equipment will

not operate unless all external panels are

installed and all electrical safety interlock circuits

are closed.

All SLS equipment was designed to minimize

operator exposure to electrical hazards during

normal operations. All exposed electrical circuits

are inside limited-access cabinets. This is to

separate the operator from service and

maintenance areas.

When operating any SLS equipment, keep the

following electrical safety points in mind:

✓ Only 3D Systems certified service personnel

should operate SLS equipment with access

panels or service doors open.

✓ Heed high voltage warning signs and labels.

✓ Take common-sense safety precautions when

operating any electrical equipment.

✓ After any change to the electrical wiring,

make sure the equipment is properly

grounded.

Hazardous voltage exists inside the

enclosures of all SLS equipment.

Injury or death from electrical shock

can result if you remove external

panels or try to defeat safety

interlocks. Panels should only be

removed, and interlocks should only

be defeated, by trained and certified

3D Systems Customer Support

personnel.

Verify your facility’s electrical service

ratings before connecting power to

any SLS equipment.z Power must

only be connected by certified

electrician.

SLS process 18 SAFETY

user’s guide environmental issues

Environmental Issues

The SLS system emits no toxic substances when

using materials approved by 3D Systems.

Emissions

Powder heating – Analytical testing on

3D Systems powders indicates no detectable

emissions outside acceptable limits from the

SLS system. (See the MSDS’s.)

Nitrogen – The SLS system uses nitrogen, which

must be passively vented to the outside.

L Do not install a fan in the nitrogen vent. The

nitrogen-inert atmosphere in the SLS system

process chamber is at higher pressure than the

outside atmosphere. The chamber will vent

without a fan. Installing a fan in the nitrogen

vent will draw nitrogen-rich air out of the

process chamber too fast, raising the oxygen

concentration in the chamber. This can keep

the SLS system from reaching inert, or cause an

in-process build to abort.

Waste Heat

Almost all the electrical power used by the SLS

system and RCM is converted to heat that must

be removed from the room. Air conditioning for

the installation room should be sized based on

room dimensions; the size, number, and location

of wall openings (such as windows and doors),

the number of people typically working in the

room, and the electrical power supplied to the

SLS system(s) and RCM(s).

Use the sPro SLS system, RCM-140, and

RCM-230 e

lectrical power requirements below

to

size your facility A/C:

Powder Disposal

Refer to the DuraForm material MSDS for disposal

information. Follow any applicable local

regulations.

MACHINE POWER (HEAT)

sPro 17 kW (~58000 Btu/h)

RCM-140 4.8 kW (~16400 Btu/h)

RCM-230 5.3 kW (~18000 Btu/h)

BOS/IRS negligible (compared to SLS

system and RCM) for the

purpose of A/C sizing

SLS process 19 SAFETY

user’s guide environmental issues

Noise Levels

The following table quantifies the noise levels for

various components of the SLS system.

EQUIPMENT NOISE LEVEL

SLS System

<85 dBA @ operator

standpoint

BOS and Dust Collector

BOS only

Dust Collector only

Dust Collector self-

cleaning cycle

<85 dBA @ operator

standpoint

IRS idle

IRS transporting

powder

IRS blending powder

<85 dBA @ operator

standpoint

SLS process 20 SAFETY

user’s guide laser safety

Laser Safety

The SLS system

contains a 70-watt

continuous-wave CO

2

laser. The laser itself is

designated Class IV. Very brief exposure to a

direct—or specularly or diffusely reflected—laser

beam can cause significant burns or eye damage.

It can also be a fire hazard.

During normal operations of the SLS system, the

laser beam path is wholly contained within the

machine. This makes the entire machine a Class I

Laser System. That means the SLS system does

not produce damaging emissions under normal

operations.

Laser Safety Classifications

Class I and Class IV are designations established

by the U. S. Department of Health and Human

Services, Public Health Service, Food and Drug

Administration, Center for Devices and

Radiological Health (CDRH), and by IEC 60825

(the International Electrotechnical Commission's

Radiation Safety of Laser Products, Equipment

Classification Requirements, and User's Guide). The

Class I and Class IV laser designations also comply

with DIN VDE 0837/02.86+A1/07.90.

You can read more about laser safety and

classifications in ANSI Z136.1-1993 (the American

National Standards Institute standard for the safe

use of lasers).

Reporting Laser Radiation Exposure

If anyone at your site is exposed to laser radiation

from the SLS system, report the following

information to 3D Systems, Inc.:

` Nature of the accident and circumstances

surrounding it

` Where the accident occurred

` Model and serial number of the machine

` Number of people involved

` Any other pertinent information

Please send this information to 3D Systems

within a day of the accident. The information can

be sent by regular mail to 3D Systems marked

“Attention: Laser Safety Officer” or by e-mail to

[email protected].

See Laser Safety

Classifications below.

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