Spectrum Z510 User Manual April 2005 TM Spectrum Z 510 User Manual Rev F © 2004-2005 Z Corporation Part Number 09537
Spectrum Z510 User Manual USE OF EQUIPMENT Z Corporation's Equipment, and use of the Equipment, may be subject to limitations imposed under patents licensed to or owned by Z Corp., and is to be used solely for the fabrication of appearance models and prototypes using new Z Corporation-supplied consumables from Z Corporation or its authorized distributors in the original packaging. Other uses may be restricted; contact Z Corporation for further information.
Spectrum Z510 User Manual TABLE OF CONTENTS 1 2 3 4 5 6 3 Introduction .............................................................................................................................5 1.1 Overview ......................................................................................................................5 1.2 How It Works ................................................................................................................6 1.3 System Components.....................
Spectrum Z510 User Manual 6.16 Print Head Report.......................................................................................................50 6.17 View Printer Log .........................................................................................................50 6.18 Other Service Menu Items .........................................................................................50 6.19 Replace Fluid Lines with Distilled Water............................................................
Spectrum Z510 User Manual 1 Introduction 1.1 Overview This Spectrum User 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 Spectrum System; familiarize you with the terminology we will use to describe the Spectrum System; and illustrate the different parts of the printer. 2. Quick Start Guide.
Spectrum Z510 User Manual 1.2 How It Works The Spectrum System is based on the Massachusetts Institute of Technology’s patented 3DP™ (3D Printing) technology. The software first converts a three-dimensional design built using 3D CAD into cross-sections or slices that can be between 0.0035” – 0.004” (0.0875 - 0.1 mm) thick. The printer then prints these cross-sections one after another from the bottom of part to the top. Inside the printer there are two pistons (see Figure 1.
Spectrum Z510 User Manual The printer employs 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 printer builds an infrastructure by printing strong scaffolding within part walls with a higher concentration of binder solution.
Spectrum Z510 User Manual 1.3 System Components Spectrum Z510 3D Printer ZD5 Powder Recycling System Figure 3: Spectrum Z510 System Components www.zcorp-users.
Spectrum Z510 User Manual 1.4 Printer Components Figure 4: Spectrum External Components 1.5 Control Panel PLEASE NOTE: When the system is online, all buttons except the online button are disabled. Figure 5: Control Panel 9 www.zcorp-users.
Spectrum Z510 User Manual 1.6 Internal Components Figure 6: Spectrum Internal Components Figure 7: Printer Assembly with Carriage Insert www.zcorp-users.
Spectrum Z510 User Manual Figure 8: Service Station 11 www.zcorp-users.
Spectrum Z510 User Manual 1.7 ZD5 Powder Recycling System Figure 9: ZD5 Powder Recycling System www.zcorp-users.
Spectrum Z510 User Manual 1.8 Spectrum Z510 Accessories and Tools The Spectrum Z510 Toolkit contains parts for user maintenance and items frequently used while post processing printed parts. Figure 10: Accessories and Toolbox 1.9 ZPrint System Software ZPrint Software is the file processing tool that sends information from the user’s workstation to the Spectrum Z510. Please refer to the ZPrint User Manual for installation and use instructions. Figure 11: ZPrint Software 13 www.zcorp-users.
Spectrum Z510 User Manual 2 Quick Start Guide 2.1 Preparing the 3D Printer 1. Fill feed box with powder. 2. With the printer offline, spread powder over build area by pressing the ‘Spread’ button on the control button for four spreads. The printer will then automatically spread powder over the build area. 3. Clean service station by rinsing and wiping the parking caps and rubber wiper. www.zcorp-users.
Spectrum Z510 User Manual 4. Check binder necessary. bottles. Fill if 5. Check wash fluid and waste fluid. Fill wash fluid and dispose of waste fluid. 6. Put printer online by pressing the ‘Online’ button on the control panel. Technical Tip LEAVE THE PRINTER ON! This allows the printer to perform a periodic self maintenance. 15 www.zcorp-users.
Spectrum Z510 User Manual 2.2 Preparing the Build in ZPrint Software 1. Open or import your file(s). 2. Orient and scale the file if needed. 3. Check ‘3D Print Set-up’ in ZPrint Software. 4. Press ‘3D Print’ in ZPrint Software. www.zcorp-users.
Spectrum Z510 User Manual 2.3 Removing the Part 1. Wait for part to complete printing. Check software for part orientation. 2. Gross depowder the part and remove from build area. 3. Fine depowder part and post-process as needed. 17 www.zcorp-users.
Spectrum Z510 User Manual 3 Routine Operation 3.1 Preparing the Build Area 1. Preheat printer if needed. Preheating the printer will reduce the print time if the printer has not reached the required temperature. To preheat the printer, select the Preheat Printer option under the Service menu. 2. Lower feed piston by pressing down on the ‘Feed Down’ button until the feed piston automatically drops. 3. Take printer offline by pressing ‘Offline’ on the control panel. 4. Lift top cover.
Spectrum Z510 User Manual 6. Hold the build up button until the build piston raises. The build piston will expose the build plate holders. 7. Place build plate on top of holders. Make sure build plate is secure. Press any button on the control panel to lower the build piston. 8. Fill feed box with powder. First empty the powder from the overflow bin and then add fresh powder if needed. 9. Tamp powder and raise feed piston until powder reaches the top edge of the feed box. 19 www.zcorp-users.
Spectrum Z510 User Manual 10. Close the top cover. Fill build area with powder by pressing and holding the ‘Spread’ button on the control panel for four complete spreads. This will initiate the “Fill Bed” mode. The LCD will display “Filling bed; Online to cancel.” 11. Lift top cover and vacuum loose powder from area surrounding feed and build box. Technical Tip Keep powder containers closed when not in use to keep powder dry. Scoop powder carefully to minimize airborne powder.
Spectrum Z510 User Manual 2. With the service station exposed, rinse rubber parking cap with distilled water (If needed, remove rubber parking caps and rinse under running water). Wipe dry with paper towel. PLEASE NOTE: Make sure the parking caps are sitting flat in their holder. 3. Rinse rubber wiper blade with distilled water and wipe dry with paper towel. Ensure that there is no powder build up anywhere in the proximity of the rubber wiper. 4. Wipe metal spit cover with damp paper towel. 5.
Spectrum Z510 User Manual 3.3 Checking Fluid Levels 1. Open front cabinet tray. 2. Check wash fluid level. If it is less than half full, refill wash fluid bottle. 3. Check waste fluid. If empty fluid. Empty accordance to local safety regulations. cabinet tray. it is half full, contents in or company Close front WARNING: Do not recycle waste solution. The waste is contaminated with powder and use of this waste in the Spectrum 3D Printer will clog the fluid system.
Spectrum Z510 User Manual 4. Check binder bottles. The Spectrum Z510 is not equipped with binder level sensors. The user must check the binder levels prior to each build to ensure the Spectrum Z510 has enough to complete the build. View the binder levels through the cutout windows in the binder bottle cover on the top cover. If it is half full, fill binder bottles. PLEASE NOTE: When printing in monochrome is it still necessary to have binder in the color bottles for servicing.
Spectrum Z510 User Manual 4. Open top cover. Then open carriage cover. 5. Replace print head. 6. Close carriage cover. 7. Using a moist paper towel, wipe the alignment window located on the left side of the gantry. Then dry off with a dry paper towel. Close top cover. www.zcorp-users.
Spectrum Z510 User Manual 8. Press ‘Done’ on the ZPrint Software. 9. Select ‘Auto Alignment’ from the Service menu. 10. The printer will first detect which print head(s) was changed, purge the print head of HP ink and print 60 layers of a gray base. 11. After printing a base, the printer will print out an alignment pattern, read the pattern and then adjust position as needed. 25 www.zcorp-users.
Spectrum Z510 User Manual 12. Lastly, the printer will print a bulls-eye pattern for you to confirm that all print heads have been aligned. You may wish to start a build while the print heads are aligning. By selecting to close the alignment window (clicking the ‘X’ on the upper right hand corner of the dialog box). The part will be built on top of the alignment patterns.
Spectrum Z510 User Manual 4 Using the ZPrintTM Software This chapter will briefly explain how to set up the build, check the settings, and print. For more information about the features in the ZPrint Software, please refer to the ZPrint Software User Manual. PLEASE NOTE: If the ZPrint Software has not been installed, install the software. Instructions are located in Section 1.2 of the ZPrint Software User Manual. 4.1 Tips on Setting up the Build 27 Do not tightly pack parts into the build.
Spectrum Z510 User Manual 4.2 Open or Import the File(s) 1. Open the ZPrint Software. The open dialog box will appear. 2. Choose the file you wish to open. 3. Click ‘Open’ or double-click the file. 4. Choose the dimensions and powder type you will be using. 5. Click ‘OK’. 6. The file will be brought into the software in a new window. 7. If you would like to add additional files to this build, choose the ‘Import’ option under the File menu. 4.3 Part Orientation 4.3.1 4.3.
Spectrum Z510 User Manual 4.4 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 correct. The software settings are 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 User Manual.
Spectrum Z510 User Manual 4.5 Printing the Build It is strongly recommended that the build settings be confirmed before printing. To check build settings, choose ‘3D Print Setup’ under the File 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. 3. Check off the boxes to confirm that these have been inspected before beginning the build.
Spectrum Z510 User Manual 5 Post Processing the Part 5.1 Tips on Gross and Fine Depowdering • • • 5.2 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 (removal of excess powder in the build box) do not plunge the vacuum nozzle into the powder bed.
Spectrum Z510 User Manual 1. Wide Blade Utility Scraper: This part is extremely useful in moving powder from the build chamber or deck surface back into the feed chamber. 2. Polypropylene Scraper: When gross depowdering a bulky part, such as the engine block, the user may choose to carve powder away from the part instead of moving it away with either the vacuum or their hands. 3. Soft Horsehair Brush: This brush has very soft bristles and assists the user with the gross depowdering process.
Spectrum Z510 User Manual 6. Soft Acid Brush: This part can also be used to remove caked powder from hard to reach areas and the soft bristles make this brush perfect for delicate features. 5.3 Removing the Finished Part After the build is complete, remove the finished parts from the build box as follows: 1. Leave the part in the bed for approximately 30-60 minutes. Take a moment to look at the computer screen and determine exactly where parts lie in the build box. 2.
Spectrum Z510 User Manual 4. Remove powder away from the buried parts, and clean powder out of the margins against the walls of the build box. 5. Without raising the build piston, begin removing powder around the part either by using the vacuum or post-processing tools. When vacuuming, hold the end of the hose on a 20° to 30° degree angle over the powder so the hose inlet is 1/4” to 3/8” above the surface of the powder. This generates enough of a draft to lift loose powder without damaging the parts.
Spectrum Z510 User Manual 8. Place a tray on the top of the feed area. Remove the build plate and place on the tray. The part is now ready to be fine depowdered. WARNING: When performing any vacuuming operation, use the vacuum provided as part of the Spectrum System. Vacuuming powder can generate static electricity, and use of a non-grounded vacuum will create static charges, which may affect the operation of the Spectrum System and harm the operator. 5.4 Depowdering the Part 1.
Spectrum Z510 User Manual 3. Turn on air compressor. 4. Change air pressure as needed and check pressure with hand before applying air on part. Technical Tip -The air pressure on your depowdering station is adjustable. For bulky parts, turn the air pressure up. For more delicate parts, turn the air pressure down. 5. Remove excess powder from part. 5.5 Drying the Part Although the part can be handled when it is not completely dried, the part reaches full strength when dried.
Spectrum Z510 User Manual INFILTRANT Wax Z-BondTM Cyanoacrylate Z-MaxTM Epoxy MATERIAL SYSTEM High Composite Material High Composite Material High Composite Material APPLICATION Dip Brush or Drizzle Spray or Brush For an updated list, please visit the Z Corp. Users Website at www.zcorp-users.com 5.6.1 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 parts.
Spectrum Z510 User Manual 5.6.2 Using Z-BondTM Cyanoacrylate Z-Bond cyanoacrylate is an extremely fast setting, low viscosity, general-purpose infiltration resin. This resin is designed to rapidly strengthen parts. Z-Bond is a one part, user friendly, noodor, 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 100 is available in 3.5 ounce bottles and 24 ounce spray bottles.
Spectrum Z510 User Manual 5.6.3 Using Z-MaxTM Epoxy SAFETY PRECAUTIONS • • • • • Wear lab coat, gloves (we recommend PVC Examination Gloves), face shield or goggles. Face shield is required if spraying. Apply in ventilated hood. Use specialized containers recommended for dispensing and application. A system for avoiding spills includes: Catch pan, waxed paper, or plastic drop cloth. Label disposal materials. Wear dust mask when sanding finished parts.
Spectrum Z510 User Manual CURING INFORMATION • • • • • • Allow the part to cure for 1 hour at ambient temperature to avoid discoloration prior to placing in the oven for accelerated cure. 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.
Spectrum Z510 User Manual 6 Service Menu and Other Maintenance The ZPrint service menu is the user’s primary interface from the desktop when performing routine maintenance functions on the Spectrum Z510 3D Printer. 6.1 Unpark Unpark moves the carriage from its parked position, in the service station, allowing the user to freely move the gantry and carriage in order to perform routine cleaning. 6.2 Purge Print Head New print heads will be automatically purged of ink when ‘Auto Alignment’ is selected.
Spectrum Z510 User Manual 6.7.1 Fast Axis Lubrication 1. Assemble grease gun as instructed on packaging. 2. Unpark the gantry by choosing ‘Unpark’ under the Service menu. 3. Open top cover. 4. Wipe fast axis rails of residue with a dry paper towel. www.zcorp-users.
Spectrum Z510 User Manual 5. Place grease gun on grease fitting on carriage and squeeze once. 6. Wipe excess grease off with a dry paper towel. 7. Move carriage back and forth manually to distribute the grease. Close top cover. 43 www.zcorp-users.
Spectrum Z510 User Manual 6.7.2 Slow Axis Lubrication 1. Assemble grease gun as instructed on packaging. 2. Select ‘Unpark’ under the Service menu. 3. Open top cover. 4. Wipe off slow axis rail. www.zcorp-users.
Spectrum Z510 User Manual 5. Locate the two grease fittings located behind the gantry. Manually move gantry if needed to gain access to grease fittings. 6. Engage the grease gun into the fittings and squeeze once. 7. Wipe of excess grease with a dry paper towel. 8. Close top cover. 9. With the printer offline, press the ‘Spread’ button on the control panel to distribute the grease. 45 www.zcorp-users.
Spectrum Z510 User Manual 6.8 Piston Screws Lubrication 1. Lower feed and build pistons all the way down. 2. Open front cabinet tray. 3. Locate piston screws and apply grease onto the pistons from top to bottom. 4. Use your finger to distribute grease throughout pistons. Close front cabinet tray www.zcorp-users.
Spectrum Z510 User Manual 6.9 Bleed Air ‘Bleed Air’ moves the carriage to the front of the Spectrum allowing easy access to the carriage. Bleed air should be performed on initial machine setup and whenever air enters into he binder fluid lines. Air in the binder fluids system will cause premature print head death. 1. Select ‘Bleed Air’ under the Service menu. 2. Open carriage cover and remove print heads. 3. Use syringe (found in toolbox) to draw water through each fluid line.
Spectrum Z510 User Manual 6.10 Service Print Heads ‘Service Print Heads’ will initiate a standard service on the print heads. 6.11 Prime Wash Line ‘Prime Wash Line’ will remove any air from the wash fluid pumping system. This should be performed upon initial machine setup and any time the wash fluid is allowed to run dry. 6.12 Stripe Test Authorized Z CORPORATION service personnel use ‘Strip Test’ to aid in troubleshooting. 6.13 Cleaning the Spreader Roller / Toggle Roller 1. Open top cover. 2.
Spectrum Z510 User Manual 5. Put printer offline, and lift top cover. 6. Move gantry manually over the build area. 7. Put online. printer 8. Select ‘Toggle Roller On/Off’ from Service menu. 9. Using a moist paper towel, wipe under the gantry making sure to remove all powder residue. Dry the area with a paper towel. Select Toggle Roller On/Off to turn off the roller. 49 www.zcorp-users.
Spectrum Z510 User Manual 6.14 Check Status ‘Check Status’ prompts a window that states information that may be valuable to a service provider such as firmware version and compile date as well as the current position of the feed and build pistons. 6.15 Report Capabilities ‘Report Capabilities’ is a tool used by authorized Z Corporation service provider to evaluate the logical state of the Spectrum. 6.16 Print Head Report ‘Print Head Report’ is a useful tool for identifying how old each print head is.
Spectrum Z510 User Manual 6.19 Replace Fluid Lines with Distilled Water If the printer will not be in use for more than two weeks, replacing all the fluid lines with distilled water will prevent binder from coagulating in the fluid lines. 1. Remove binder from bottle and place in an airtight container. 2. Rinse out binder bottle. 3. Fill binder bottle half way full with distilled water. 4. Select ‘Bleed Air’ under the Service menu. 5. Open carriage cover and remove print heads. 6.
Spectrum Z510 User Manual 7. Close carriage cover, and top cover, and ‘Cancel’ in the software. www.zcorp-users.
Spectrum Z510 User Manual 7 Troubleshooting 7.1 The binder solution is being applied in erratic stripes If the binder appears to be applied in fragmented stripes, check the following: 1. Rinse the squeegee clear of any debris. 2. Make sure binder supply is full. If this does not correct the problem, your print heads may be worn out. Replace the print heads as outlined above in Section 3.4, Changing the Print Heads. 7.2 ZPrint Software freezes up during the print job.
Spectrum Z510 User Manual 7.5 Parts are unusually weak or crumbly • Is the data file known to be without errors? If the *.stl file is not near perfect you will have problems printing the part. Open the file in the software and inspect it layer by layer to ensure there are no gaps and the part does not overlap other parts. • Is there enough binder in the feed bottles? When you start the build, a reminder box will pop up asking you to check if there is enough binder in the feed bottles.
Spectrum Z510 User Manual 3. Remove syringe and place on a paper towel to prevent binder from dripping. 4. Empty the syringe into a waste container. PLEASE NOTE: Dispose of binder fluid in accordance to company, local, and state regulations. 5. Press ‘Cancel’ to complete bleed air function. 6. After reinserting print heads, close the carriage cover, and top cover. Then run ‘Auto Alignment’ from the Service menu. 7.
Spectrum Z510 User Manual 4. The progress bar will close when priming is completed. 7.9 Communication Errors Between Print Head and Printer In general, there is no need to clean the pogo pins upon replacing the print heads. At times, they may need to be cleaned due to errors in communication between the print head and printer (such as when receiving Print Head errors) or when it is dirty. To clean the pogo pins, follow the instructions below: 1.
Spectrum Z510 User Manual 8 Spectrum System Details 8.1 System Specifications Dedicated power outlet requirements 100-120 VAC 50-60Hz, 15A max -or220-240 VAC 50/60Hz, 7A max Network Ethernet 10/100 base T Temperature 68-85° F. (20-30° C) Relative Humidity 20-60%, non-condensed Weight 470 lbs. (210 kg) Spectrum Z510 Dimensions Cover Closed 42” x 31.25” x 50.5” (107cm x 79cm x 128cm) Cover Open 42” x 31.
Spectrum Z510 User Manual 8.2 Symbols Used This is the international symbol for ‘warning’ or ‘caution’. It indicates the need to consult your manual for further information. This symbol is in two places on the SPECTRUM 3D Printer. 1. It is used on the rear, lower left to call your attention to the fact that only trained personnel should open the SPECTRUM 3D Printer rear cover. None of the normal operation procedures described in this manual require you to remove this cover.
Spectrum Z510 User Manual 9 Appendix 9.1 Restoring Network and Firmware Settings Configuration mode is entered by holding the ONLINE key pressed when the printer is powered up. Configuration mode is indicated by the LCD displaying: NETWORK SETTINGS Main menu consists of 5 selections: NETWORK SETTINGS RESTORE FIRMWARE DIAGNOSTIC MODE SAVE AND EXIT DISCARD AND EXIT < Build UP > and < Build DN > keys are used to select an item to edit.
Spectrum Z510 User Manual Selecting NETWORK SETTINGS displays: NETWORK SETTINGS USE NETWORK? YES < Build UP > and < Build DN > keys toggle YES/NO Note: NO means the serial port will be used < Feed UP > key will display: DHCP/STATIC IP USE DHCP? YES < Build UP > and < Build DN > KEYS toggle YES/NO If “NO” is displayed, and < Feed UP > is selected, LCD displays: IP ADDRESS 0. 0. 0. 0. < Feed UP > key will move the cursor to the right. < Feed DN > key will move the cursor to the left.
Spectrum Z510 User Manual Selecting RESTORE FIRMWARE displays: RESTORE FIRMWARE RESTORE FIRMWARE? NO < Build UP > and < Build DN > keys toggle YES/NO Note: YES means the printer will use the firmware previously to that which was just loaded. If < Feed UP > is pressed, MAIN MENU is displayed Selecting DIAGNOSTIC MODE DIAG MODE? DIAG MODE? NO < Build UP > and < Build DN > keys toggle YES/NO Note: NO is normal operation.
Spectrum Z510 User Manual 9.2 Error Codes PLEASE NOTE: %d and %x are place holders for numbers corresponding either to print head number or a value.
Spectrum Z510 User Manual INDEX 3D Print, 30 Accuracy, 7 Air in Fluid Lines, 54 Air in Wash Fluid Line, 55 Alcohol Swabs, 56 Alignment Window, 24 Auto Alignment, 25 Bleed Air, 47, 51, 54 Build Open File, 28 Build Settings 3D Print Setup, 29 Override, 29 Change Print Heads, 23 Clean Pogo Pins, 56 Clean Roller, 48 Collision Detection, 29 Control Panel, 9 Error Codes, 62 External Components, 9 File Import, 28 Open, 28 Fill Bed, 20 Fill Feed Piston, 19 Firmware Settings, 59 Fluid Levels, 22 Fluid Lines Air, 54
