Z406 System User Manual September 2004 Z®406 3D Color Printer User Manual Z Corporation Type II Revision D © 2003-2004 Z Corporation Part Number 09520
Z Corporation Z406 System User Manual Table of Contents: 1 YOUR Z406 SYSTEM .................................................................................................. 8 1.1 1.1.1 OVERVIEW ..................................................................................................................8 1.1.2 HOW IT WORKS..........................................................................................................9 1.2 THE PARTS OF THE Z406 3D PRINTER.............................
Z406 System User Manual 4.2 6 7 DEPOWDERING THE PART ...............................................................................35 4.2.1 ZD4I DEPOWDERER DETAIL...................................................................................36 4.2.2 ZD4 DEPOWDERER DETAIL....................................................................................39 4.2.3 USING THE EXTERNAL VACUUM BAG LINER .......................................................42 4.
Z Corporation Z406 System User Manual 8 CHANGING THE BINDER SUPPLY ......................................................................... 91 9 CHANGING MATERIAL SYSTEM ............................................................................ 92 9.1 USING ZCAST POWDER.................................................................................... 97 9.1.1 GENERAL INFORMATION ........................................................................................97 9.1.
Z406 System User Manual Z Corporation APPENDIX I ZCast 501 Design Guide....................…………………………………………………..119 www.zcorp-users.
Z Corporation Z406 System User Manual Table of Figures Figure 1. The Printing Process ................................................................................................. 9 Figure 2: The Z406 3D Printer Shelling and Infrastructure Features ..................................... 10 Figure 3: Illustration of Z406 System Print Orientations ........................................................ 11 Figure 4: The Z406 3D Printer .....................................................................
Z406 System User Manual Z Corporation 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 used by design engineers and other professionals in the production of early-stage 3D appearance models and prototypes.
Z Corporation Z406 System User Manual 1 YOUR Z406 SYSTEM 1.1 1.1.1 INTRODUCTION OVERVIEW This Z406 3D Color 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 Z406 System, familiarize you with the terminology we will use to describe the Z406 System and introduce you to some of the features of this manual.
Z406 System User Manual 1.1.2 Z Corporation HOW IT WORKS The Z406 System is based on the Massachusetts Institute of Technology’s patented 3DP™ (3D Printing) technology. The software first converts a three-dimensional design built using 3D CAD into cross-sections or slices that can be between 0.003” – 0.009” (0.0762 - 0.2286 mm) thick. The Z406 3D Printer then prints these cross-sections one after another from the bottom of part to the top. Inside the Z406 3D Printer there are two pistons (see Figure 1.
Z Corporation Z406 System User Manual The Z406 3D 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 Z406 3D Printer builds an infrastructure by printing strong scaffolding within part walls with a higher concentration of binder solution.
Z406 System User Manual Z Corporation z-axis Less Strong x-axis Most Strong Strong y-axis Figure 3: Illustration of Z406 System Print Orientations Accuracy. The accuracy of the system depends on the materials you choose. You can employ the anisotropic scaling feature in the software to adjust for expected shrinkage and bring your parts into true scale. More information on anisotropic scaling factors are found in Section 3.3.1, Powder Settings. www.zcorp-users.
Z Corporation 1.
Z406 System User Manual 1.3 Z Corporation THE PARTS ON THE PRINTER ASSEMBLY AND GANTRY Grease Fittings Carriage Cover Scraper Cover Snowplows Scraper Print Heads Figure 5: Gantry and Printer Assembly www.zcorp-users.
Z Corporation 1.
Z406 System User Manual 1.5 Z Corporation PRINTING A PART OVERVIEW Printing a part using the Z406 3D Printer is fast, easy, clean and fully compatible with an office environment. This manual will show tips on how to print the most challenging parts, but for most purposes, printing a part is as simple as 1-2-3. 1.5.1 STEP 1: PREPARING THE 3D PRINTER Carefully following the steps outlined in Chapter 3, you can prepare the 3D printer in less than ten minutes.
Z Corporation Z406 System User Manual 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. 1.6.1.2 • • • 1.6.1.3 • • 1.6.1.4 • 1.6.2 1.6.2.
Z406 System User Manual Z Corporation tip of the bottle while applying the CA, being sure not to apply the CA to the same place more than once. 1.6.2.2 • • When Using a Z-MaxTM and Z-SnapTM 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.
Z Corporation Z406 System User Manual 2 PREPARING THE Z406 3D PRINTER 2.1 HARDWARE CONTROLS The front control panel on the Z406 3D Printer has the following features: PLEASE NOTE: When the system is online, all buttons except the online button are disabled. LCD Panel. Displays the current status of the Z406 3D Printer. Feed Up/Down Buttons. Allows the user to raise or lower the piston in the feed box. A light tap raises or lowers one layer thickness; holding down causes continuous motion.
Z406 System User Manual 2.2 Z Corporation PREPARING THE 3D PRINTER If the printer is off, switch it on by pressing and releasing the power ON/OFF switch. The gantry will move slowly as it orients itself. We recommend that you leave the printer on at all times—in sleep mode the printer will exercise the print heads during periods of inactivity to prevent clogging. 1. Wait for the green online light indicating that the power-up procedure has completed.
Z Corporation 2.2.1 Z406 System User Manual FILLING THE FEED BOX WITH POWDER 1. Press and hold the feed down button until the piston automatically moves towards the bottom of the feed box. The piston will stop when it reaches the bottom. Move the build up button until it reaches the top. When completed, the front display will read “F: 100% B: 100%” 2. Carefully scoop powder from the bucket and place in the feed piston. 3.
Z406 System User Manual Z Corporation 5. Vacuum up any powder spilled on the top deck. 6. Move the gantry so that it is above the feed piston. Press and hold the feed up button until the surface of the powder in the feed piston is even with the top deck. 7. If using a build plate, see below for instructions. The build plate is a useful tool in making the most out of your 3D Printer. It allows you to lift delicate parts from the printer without handling them.
Z Corporation Z406 System User Manual 2. The build plate will project above the top of the build box. In this position, the gantry would hit the build plate if you tried to spread powder. 3. Lower the build piston so that the top of the build plate is slightly below the top of the build box. WARNING: If the gantry or the spread roller hits the build plate, you may damage your printer. 4. Spread powder over the build plate as you normally would over the build piston. 5.
Z406 System User Manual Z Corporation Technical Tip Keep powder containers closed when not in use to keep powder dry. Scoop powder carefully to minimize airborne powder. Make sure that you carefully vacuum up excess powder. It only takes a minute, and the tidier the machine is, the less often it will need maintenance! Carefully read the Material Safety Data Sheet for powder before use. www.zcorp-users.
Z Corporation 2.2.2 Z406 System User Manual CLEANING THE SERVICE STATION Squeegee Print Head Parking Caps Nozzl e Figure 8: Service Station Detail The service station cleans the array of the print heads during printing. The service station should be cleaned before every build. This will remove any deposits of powder. Make sure parking caps are dry before beginning the build.
Z406 System User Manual Z Corporation To clean the service station: 1. Move the gantry to the left of the top deck by pressing the ‘Spread’ button. 2. Lift the top cover. 3. Manually lift up the metal plate covering the service station. 4. Squirt distilled water onto the squeegee and clean with the small brush provided with your Z406 3D Printer until all debris is removed. 5. Squirt the distilled water onto the parking cups and clean with the small brush until all debris is removed. www.zcorp-users.
Z Corporation Z406 System User Manual 6. Use a paper towel to soak up any standing water in the parking caps. 7. Squirt distilled water on the nozzles. Use the brush to clean off any debris. 8. When finished, replace the service station cover. 9. Close the top cover. 10. Gantry will park in 15-30 seconds. 2.2.3 CHECKING FLUID LEVELS 1. Open the front cabinet doors. Color Binder Solution 2. Check the binder, wash fluid, and waste bottle.
Z406 System User Manual Z Corporation 3. Unscrew the lid covering the binder or wash fluid bottle. 4. Fill the bottle up with binder or wash fluid. Replace the lid. 5. Close front cabinet doors. WARNING: Do not recycle waste solution. The waste is contaminated with powder and use of this waste in the Z406 3D Printer will clog the fluid system. Use only binder and wash fluid supplied by Z Corporation.
Z Corporation 2.2.5 Z406 System User Manual PUTTING THE MACHINE ONLINE Press the ‘Online’ button. The green ‘Online’ indicator light will illuminate. The Z406 3D Printer is now ready to print. Technical Tip - 28 ¾ Keep the machine clean! ¾ Make sure that you have enough powder to complete the build. It is wise to always begin a build with a full feed box. ¾ CHECK THE OVERFLOW BIN! If the overflow bin becomes full, powder will back up through the system and cause errors with your printer.
Z406 System User Manual 3 Z Corporation USING ZPRINT SOFTWARE This chapter will briefly explain how to set up the build, check the settings, and print. For more information about the features in the ZPrint Software, please refer to the ZPrint Software User Manual. 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. 3.1 OPEN OR IMPORT THE FILE 1. Open the ZPrint Software.
Z Corporation 3.2 ORIENTING THE PART 3.2.1 PART CONTAINING AN OPENING OR HOLLOW AREA • Part with Opening If 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 depowdering process. 3.2.2 Hollow Part 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.
Z406 System User Manual 3.3 Z Corporation CHECKING BUILD SETTINGS ALWAYS check before printing: build settings 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.
Z Corporation 3.3.1 3.3.1.1 Z406 System User Manual POWDER SETTINGS 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. If the part shrinks 1% in a certain axis, the correct anisotropic scaling value would be 1.01 in that axis.
Z406 System User Manual Z Corporation 3.3.1.2 Saturation Values The saturation values determine how much binder is placed on the powder to print the part. The part is made up of two areas, the shell and the core, as described in Section 1.1.2, How It Works. Thus, there are two saturation values, one for the shell and another for core. In general, the shell saturation is higher than the core saturation. The ZPrint Software will display the recommended values for each powder type.
Z Corporation Z406 System User Manual 4 POST PROCESSING THE PART 4.1 REMOVING THE FINISHED PART After the build is complete, remove the finished parts from the build box as follows: 1. With starch-based parts, wait approximately ten to fifteen minutes to ensure that the uppermost layers of the part have had a chance to dry. With plaster-based parts, leave the part in the bed for approximately 30-60 minutes. With ZCast parts, leave parts in the bed for approximately 30-60 minutes. 2.
Z406 System User Manual 4.2 Z Corporation DEPOWDERING THE PART 1. Place parts depowdering unit. inside 2. Attach and turn on the vacuum cleaner. 3. Using the compressed air system included in the depowdering station, remove any excess powder that remains in any concave surfaces. 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. www.zcorp-users.
Z Corporation 4.2.1 Z406 System User Manual ZD4I DEPOWDERER DETAIL Vacuum Nozzles External Vacuum Air Gun Air Compressor 1. Turn on air compressor.
Z406 System User Manual Z Corporation 2. Turn external vacuum on. ON/OFF Switch 3. Open the top cover, place part(s) in depowderer and close top cover. www.zcorp-users.
Z Corporation Z406 System User Manual 4. Place hands in depowdering unit. Check air pressure and adjust on the air compressor. 5. Depowder your part(s). Press down on airgun knob to release air.
Z406 System User Manual 4.2.2 Z Corporation ZD4 DEPOWDERER DETAIL Vacuum Nozzles Handles to Lift Top Cover Air Pressure Control ON/OFF Switch Vacuum Suction Control Air Compressor External Vacuum www.zcorp-users.
Z Corporation Z406 System User Manual 1. Turn on depowdering unit. Vacuum and air compressor should be on. ON/OFF Switch Vacuum Suction Control 2. Lift top cover, place parts in depowderer and close top cover. 3. Place hands in depowdering unit. Test air pressure of the air gun. Adjust air pressure if needed.
Z406 System User Manual Z Corporation 4. Depowder your part(s). Press down on airgun knob to release air. www.zcorp-users.
Z Corporation 4.2.3 Z406 System User Manual USING THE EXTERNAL VACUUM BAG LINER Z Corporation has developed an accessory to the vacuum cleaner to assist the user with the removal of the vacuum bag from the canister. The vacuum cleaner liner is easy to use and will prevent ripping and tearing of the blue vacuum bag once it is full of powder. The vacuum cleaner liner is placed in the vacuum canister prior to the bag, and once the bag is full the liner handles are used to lift the bag out of the canister.
Z406 System User Manual Z Corporation 3. Install the vacuum vacuum cleaner liner. bag inside the 4. Fold the handles of the vacuum cleaner liner up onto the top of the empty vacuum bag. 5. Install the vacuum filter. www.zcorp-users.
Z Corporation Z406 System User Manual 6. Install the vacuum motor. 7. Once the vacuum bag is full, remove the motor and filter. Remove the vacuum bag from the canister by lifting the vacuum cleaner liner handles straight up. 8. Rotate the vacuum canister, in the direction of the inlet, from under the vacuum bag.
Z406 System User Manual Z Corporation 9. Once the vacuum cleaner inlet tube is disengaged from the vacuum bag, you can lift and remove the bag and liner. 4.3 4.3.1 DRYING THE PART STARCH AND PLASTER PARTS To infiltrate starch or plaster parts with wax, the parts must be hot and dry. Preheat part at 165oF (74oC) in the Automated Waxer or in a drying oven, remembering that drying time and part wall thickness are directly related. If the average wall thickness is 0.25” (6.
Z Corporation 4.3.3 Z406 System User Manual 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. 2 4 5 6 1 3 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.
Z406 System User Manual Z Corporation 2. Polypropylene Scraper: When gross depowdering a bulky part, such as the engine block, the user may choose to carve powder away from the part instead of moving it away with either the vacuum or their hands. 3. Soft Horsehair Brush: This brush has very soft bristles and assists the user with the gross depowdering process. Brushing powder away from the part is a useful technique prior to the vacuuming step. 4.
Z Corporation Z406 System User Manual 6. Soft Acid Brush: This part can also be used to remove caked powder from hard to reach areas and the soft bristles make this brush perfect for delicate features.
Z406 System User Manual Z Corporation 5 INFILTRATING THE PART INFILTRANT MATERIAL SYSTEM APPLICATION Z-MaxTM Epoxy Starch and Plaster System Spray or Brush Z-BondTM Cyanoacrylate Starch and Plaster System Spray, Brush, Drizzle Z-Snap Epoxy zp250 Material System Spray, Brush, Drizzle Wax Starch and Plaster System Spray or Dip For an updated list, please visit the Z Corp. Users Website at www.zcorp-users.
Z Corporation Z406 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).
Z406 System User Manual 5.1.2 Z Corporation 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, no-odor, nonblooming 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.
Z Corporation 5.1.3 Z406 System User Manual USING Z-SNAPTM 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 zp250 parts see Section 9.2, Using zp250 Powder.
Z406 System User Manual 5.1.4 Z Corporation USING PARAPLAST X-TRA WAX Paraplast X-Tra is a low viscosity, general purpose, infiltration wax formulated to melt at very low temperatures (122°F or 50°C) and strengthen both starch and plaster parts. This material cures rapidly and enhances the vibrancy of color parts. PARAPLAST is available in a case of eight 2.2 lb. (1 kilogram) bag of chips. Paraplast X-Tra Wax can be used in both the ZW3 and ZW4 Waxers.
Z Corporation Z406 System User Manual 6 APPLICATIONS In this section, you will learn various ways to maximize the versatility of your Z Corporation 3D Printer through the implementation of advanced part processing techniques. Please visit the User Group Website at www.zcorp-users.com 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@zcorp.com.
Z406 System User Manual 6.1 Z Corporation GLUING MULTI-PIECE PARTS Instructions: 1. Remove, depowder, and dry parts out of printer as described in Section 4, Post Processing the Part. 2. Sand seams prior to gluing and check fit of any assemblies. Sanding small parts or parts with curved surfaces can be made easier with a small, air-powered glass air etching/sanding kit. 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.
Z Corporation 6.2 Z406 System User Manual 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.
Z406 System User Manual Z Corporation 6.3 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.
Z Corporation 6.4 Z406 System User Manual ELECTROPLATING Parts printed on the Z406 3D Printer 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.
Z406 System User Manual Z Corporation 6.5 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.
Z Corporation Z406 System User Manual 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 30°C. The film dissolves and only the ink image remains floating on the water. Activating: The ink is sprayed that it becomes adhesive. After ink must sit for 3 minutes. with an activating material so spraying with activator, the Transferring: The parts are dipped into the water through the layer of liquefied ink.
Z406 System User Manual Z Corporation Presenting: The finished parts can now be used. The surface can be very durable and scratch resistant – depending on the top coat used, so the finish will stand up to many functional applications. Typical Site Requirements (from www.dips-n-pieces.
Z Corporation 6.6 Z406 System User Manual 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 Corp.
Z406 System User Manual Z Corporation 2. When using wax patterns assembled on wax runners, the tree assembly should go though an autoclave process for 10 minutes before being put in the firing oven. The autoclave should be 380oF (193oC) and 130 psi (9 bars). The pattern should then be put 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. 3. Z Corp.
Z Corporation 6.7 Z406 System User Manual FLEXIBLE PARTS Material • Por-A-Mold 2030 Preparation • • • • • Read and understand the Material Safety Data Sheet, as well as any directions. zp15e parts should be used. Be sure the parts are completely dry. Wear impervious rubber gloves, glasses, and a lab coat. Use adequate ventilation when mixing and applying the material. Instructions 1. Material should be mixed well at an exact 1:1 ratio. 2. Apply generously. For thin parts, use a brush or syringe.
Z406 System User Manual 6.8 Z Corporation 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 used.
Z Corporation Z406 System User Manual The instructions below are specific to molds produced on Z Corporation Printers. It is assumed that the user currently owns a thermoforming system and is familiar with using molds created from other techniques for creating thermoformed parts. The process for making molds is straightforward. Good design of the molds will be the first and most important step in the process. Design Considerations 1. Material – Plaster 2.
Z406 System User Manual 6.9 Z Corporation 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 draft1, complex parting lines2 and undercuts3 are not factors in building effective molds as they are when using hard tooling.
Z Corporation Z406 System User Manual Process Overview Î Î Printed Part Mold Setup Î Î Mold with Cavity Box Î Pour Silicone Make Parting Line Î 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.
Z406 System User Manual Z Corporation 4. Sand the filler with 220-grit sand paper. The finish at this point should be completely smooth with no surface defects. 5. Prime the part with a sprayable / sandable primer. Z Corporation recommends Plasti-kote® Sandable Primer for 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.
Z Corporation Z406 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 free5.
Z406 System User Manual Z Corporation Preparing and Pouring the Silicone Mold Preparing the silicone is relatively easy but must be performed properly to ensure a good mold. Pay close attention to the mix ratio of the two components of the silicones. Be sure to prepare a large enough volume to completely encase the pattern.
Z Corporation Z406 System User Manual 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.
Z406 System User Manual Z Corporation 7 MAINTENANCE Maintenance Action: 1. Change Print Heads Frequency: Every 30 Billion Pixels (each print head in monochrome mode), 15 Billion Pixels (each print head in color mode), or when needed 2. Flush Binder If not used regularly 3. Grease the Fast Axis Bearings 30 Million inches of fast-axis travel or 1 year since last service 4. Oil the Snowplows Before every build 5.
Z Corporation 7.1 Z406 System User Manual 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.
Z406 System User Manual 5. To remove the print head, lift the blue handle and pull up gently. Repeat for all four print heads. PLEASE NOTE: All print heads should be changed at the same time to ensure proper print head alignment. 6. Remove the print head from the packaging. Remove plastic covering from print head contacts. 7. Insert the new print head and push down firmly on top to make sure print heads is seated properly in the carriage. 8. Close the carriage cover.
Z Corporation Z406 System User Manual 7.2 ALIGNING THE PRINT HEADS PLEASE NOTE: After every print head change, you must perform the alignment procedure. The software will prompt you to align the print heads. 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 paper and the plate. 2.
Z406 System User Manual Z Corporation 5. Click on ‘Print Test Pattern’ in the alignment dialog box. It will take a minute to initialize the printer, send the pattern, and print. 6. For each print head to be aligned, there are two numbers to be chosen. To do this, look at the alignment pattern and decide which pattern looks best. In this pattern, a properly aligned set has four longer lines with three shorter lines centered between them.
Z Corporation Z406 System User Manual 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 right The three short lines are interleaved with the long lines. Examples of problem reticules: Slow axis too low Good slow axis reticule. Slow axis too high The three short lines are interleaved with the long lines.
Z406 System User Manual 7. Choose ‘Edit Alignment’ alignment dialog box. Z Corporation in the Technical Tips – If you have printed problem reticules, and are not able to choose the best aligned pattern, choose ‘Set Defaults’ under the Edit Alignment option and continue alignment procedure. 8.
Z Corporation Z406 System User Manual 10. Remove the paper off 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. 11. Repeat steps 2-10 on a clean sheet of alignment paper until all alignment reticles line up at 0. 12. Look at target drawings to confirm alignment of print heads. All bull's eyes are centered. All targets are evenly spaced. 13.
Z406 System User Manual 14. Unpark the gantry to expose the service station. 15. Clean the service station of any HP ink residue as described in Section 2.2.2, Cleaning the Service Station. Clean the deck and fast axis rails. Oil the fast axis rails. Technical Tips – The first 50 layers of your part will have a tint of black HP ink. You may place a flat brick, such as the 406purge.stl, under Samples\Test Parts, under your part to purge all black ink before printing your part. www.zcorp-users.
Z Corporation 7.3 Z406 System User Manual COLOR ALIGNMENT PLEASE NOTE: You will only need to color align the print heads if your standard alignment did not align your print heads properly. 1. Make sure you have run through the standard alignment, purged the print heads, and changed the binder supply to color mode. 2. Spread powder onto the build piston. 3. Choose ‘Color Alignment’ under the 406Service menu. 4. Choose to print the ‘Pattern’ to print two layers. 5.
Z406 System User Manual Z Corporation 6. Look at the left and right edges of the squares. Look for the least color fringing on the sides. For each color choose the corresponding square in the dialog box. In this case, the ‘0’ square would be chosen among the blue squares. Click ‘OK’ to go on to the vertical alignment selection. 7. Look at the top and bottom edges of the squares with the least color fringing. For each color choose the corresponding square in the dialog box. Then click ‘OK’. 8.
Z Corporation 7.4 Z406 System User Manual FLUSHING THE BINDER 1. If the machine is not in daily use, binder should be flushed bi-weekly for one minute. This may be done by choosing the ‘Flush Binder’ option under the ‘Service’ menu in the ZPrint Software. 2. The LCD will display ‘Flushing Binder’ 3. When finished, press the ‘Online’ button. PLEASE NOTE: If machine will not be in use for more than a month, replace liquid in binder bottles with distilled water and flush the fluid system for five minutes.
Z406 System User Manual 7.6 Z Corporation GREASING THE SLOW AXIS Apply grease (supplied in the tool kit) to the two grease fittings located on the slow axis rails located in the back of the printer. For instructions on how to assemble the grease gun, please refer to the manufacturer’s instructions on the packaging. The software will alert you as to when to grease the fast axis if the Maintenance Reminders feature is enabled. 1. Turn off and unplug the Z406 3D Printer.
Z Corporation 7.7 Z406 System User Manual OILING THE SNOWPLOWS Two snowplows are located between the roller on the gantry. Snowplows needs to be oiled before every build. To oil snowplows, squeeze a few drops of oil into the wicks on the snowplow. Snowplows need to be oiled once a week. Wick 7.8 CLEAN UNDER THE GANTRY Powder will adhere to the bottom surface of the gantry due to moisture accumulation. This may cause poor surface finish and dragging of powder over the build area.
Z406 System User Manual Z Corporation 6. Press ‘OK’ on the software dialog box to repark. 7.9 GREASING THE PISTON SCREWS 1. Lower both the feed and build pistons all the way down. 2. Turn off and unplug the printer. 3. Remove the overflow bucket and locate the two piston screws. 4. Take grease supplied in the toolkit and apply grease onto entire the length of both feed and build piston screws. 5. Take a paper towel and lightly wipe the feed and build piston screws in order to distribute grease. 6.
Z Corporation Z406 System User Manual 7.10 REPLACING THE SCRAPER BLADE The plastic scraper blade will eventually become worn and will need replacement. To replace, follow the instructions outlined below. 1. Remove the scraper cover. 2. Unscrew the scraper blade holder using an Allen wrench sized 3/32. 3. Remove the scraper blade holder.
Z406 System User Manual 4. Loosen the scraper blade by pushing the blade so that it no longer adheres to the side of the scraper blade holder. 5. Remove the scraper blade. 6. Remove adhesive cover from the new scraper blade. 7. Place scraper blade into scraper blade holder. www.zcorp-users.
Z Corporation Z406 System User Manual 8. Using the Allen wrench tool, push scraper blade against the wall to ensure adhesion to wall. 9. Replace and reattach the scraper. 10. Replace the scraper cover.
Z406 System User Manual 8 CHANGING THE BINDER SUPPLY Changing the binder supply allows you to change between monochrome and color mode. To change binder supplies, choose the ‘Change Binder Supply’ option under the 406Service Menu. The software will inform you when the printer is finished changing binder supplies. www.zcorp-users.
Z Corporation Z406 System User Manual 9 CHANGING MATERIAL SYSTEM IF USING ZCAST POWDER Before using ZCast powder, a hardware upgrade (Z406 ZCast Kit, part number 06215) is needed to prevent damage to your Printer. The hardware change includes new snowplows. A build plate is also included to help remove parts from the build envelope. Please ensure that these hardware changes have been made before proceeding.
Z406 System User Manual Z Corporation 3. Remove the powder from the overflow bin and empty into a sealed container. 4. To prevent any material contamination, vacuum any remaining powder in the overflow bin. 5. Change binder solution (color and clear binder) if necessary. www.zcorp-users.
Z Corporation Z406 System User Manual 6. Set up the printer as described in Section 2.2.1, Filling the Feed Box with Powder. Change Powder Type 7. Open or import your file into the ZPrint Software using version 6.0 or higher. 8. Open up the 3D Print Setup dialog box. 9. Change powder type in ZPrint Software.
Z406 System User Manual Z Corporation Recommended Saturation Values 10. Override or approve all powder parameters. 11. Then proceed to printing your part. www.zcorp-users.
Z Corporation Z406 System User Manual 12. Change printer mode from color to monochrome or monochrome to color if needed. 13. If you changed binder solution, flush binder for two minutes by choosing the ‘Flush Binder’ option under the Service menu. 14. Then purge the print heads. 15. For ZCast Powder users, remove scraper assembly if you are changing over to ZCast powder. Or reattach scraper assembly if using plaster or starch material. Use the 3/32 Allen wrench tool that accompanied the Z406 ZCast Kit.
Z406 System User Manual 9.1 USING ZCAST POWDER 9.1.1 GENERAL INFORMATION Z Corporation 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.
Z Corporation Z406 System User Manual For more information, please refer to Section 8, Changing Material Systems. Deck Adjustment Place the removable build plate onto the build piston and adjust the build height as described below: Place the build plate on top of the build piston. Use the build up button to raise the piston all the way to the top. Use a straight edge to view the clearance between the build plate and the top deck.
Z406 System User Manual 9.1.3 Z Corporation LOADING ZCAST INTO THE Z406 3D PRINTER 1. Fill the piston completely with ZCast powder being sure to keep the casting powder “fluffy”. Use the tamper to level off the top of the feed piston but do not compress the powder. 2. Spread over the build bed and print.
Z Corporation 06312 9.1.7 Z406 System User Manual zb56 binder clear binder 1 gallon RECYCLING Similar to plaster and starch, ZCast can be recycled. Recycle only powder that is unprinted and free of moisture as bonded or printed material will degrade printing performance. 9.1.8 STORAGE ZCast powder should be stored in a cool, dry environment. See container labels for additional information. 9.1.9 DISPOSAL ZCast powder is a non-toxic substance.
Z406 System User Manual 9.2.2 • • Z Corporation SOFTWARE SETUP ZPrint Software version 6.2 or higher should be used when printing with zp250 powder. To check the version of ZPrint Software currently installed select “About Z Corporation Software” from the Help Menu. If ZPrint version 6.2 or higher is not installed contact the Z Corporation Service Department for an upgrade at service@zcorp.com.
Z Corporation 102 Z406 System User Manual • 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’. • 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.
Z406 System User Manual • 9.2.3 Z Corporation Go to the “3D Print Setup” window under the File Menu and select zp250 powder as the powder type. PART REMOVAL AND POST PROCESSING 1. When printing parts that can be manually handled, allow the part and fixture to dry in the build bed for at least 2 hours before removing. If printing parts that cannot be manually handled, please refer to the Infiltration Addendum of this set of instructions. Parts built deeper than 2 inches (50.
Z Corporation Z406 System User Manual 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. 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.
Z406 System User Manual Z Corporation 6. Let the part sit for 30 minutes at room temperature to allow excess Z-Snap epoxy to drain or wick into the fixture. Z-Max parts should sit at ambient for 1 hour prior to the oven cure. 7. 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. If using Z-Max, parts should be oven cured for an additional 2 hours at 160°F (71°C). 8.
Z Corporation Z406 System User Manual 10 TROUBLESHOOTING 10.1 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 6.1, Changing the Print Heads. 10.
Z406 System User Manual Z Corporation 10.5 MY STARCH-BASED PARTS ARE UNUSUALLY “CAKEY” • Is the saturation too high? If your parts (especially bulky parts) are unusually difficult to depowder, too much moisture has moved from the part into the immediately surrounding powder. The first is that you may have the saturation levels set too high for this type of part. Using a lower maximum setting will fix this problem.
Z Corporation Z406 System User Manual 10.8 AIR ENTERED THE FLUID LINES When removing binder by disconnecting airlines from binder bottles or if binder runs out while printing air may enter the fluid lines. Air in the fluid lines will result in the early print head mortality. To remove air from the fluid lines follow the following instructions: 1. Select the ‘Bleed Air’ function under the 406Service menu. 2. Insert the syringe into the septum and let the syringe fill until there are no more air bubbles.
Z406 System User Manual Z Corporation 10.9 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 Head ROM errors) or when it is dirty. To clean the pogo pins, follow the instructions below: 1. Use the alcohol swabs which can be ordered from Z Corporation (part number 12073). 2.
Z Corporation Z406 System User Manual 11 Z406 SYSTEM DETAILS 11.1 DESCRIPTION OF REAR I/O PANEL Power Input Keyboard Diagnostic Connector Ethernet Connector Circuit Breaker Diagnostic Video Connector Serial Input Connection Serial Port Connection: This is an RS-232 serial port for data transfer to and from the ZPrint software. The Z406 System uses 115k baud and has the same pin out as a standard PC compatible computer.
Z406 System User Manual Z Corporation 12 SYMBOLS USED The following symbols are used on the Z406 3D Printer: This is the international symbol for ‘standby power’. It is used on the Z406 3D Printer power switch. The Z406 3D Printer is partially powered as soon as you plug it in. 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’. It indicates the need to consult your manual for further information.
Z Corporation Z406 System User Manual 12.1 SYSTEM SPECIFICATIONS Z406 3D Printer Dimensions: 40” x 31” x 44” high (102cm x 79cm x 112cm high) Z406 3D Printer Weight: 470 lbs. (210 kg) Power Requirements and Operating Conditions at Site of Installation: • Power Requirements: 100-240, 4 amps • Operating Conditions: 68 to 85ºF, 20 to 60% Relative Humidity, non-condensing. Lithium Battery: Internal to the Z406 3D Printer is a lithium coin cell type battery.
Z406 System User Manual Z Corporation 12.2 MATERIAL STORAGE PRECAUTIONS Carefully read the Material Safety Data Sheets (MSDS) before using any Z Corporation materials. Material Storage Usage Powder Store powder on pallets in a cool, dry, ventilated area away from sources of heat, moisture, and incompatible materials. Keep containers tightly closed. Use of powder in environments with more than 30% relative humidity will affect powder performance.
Z Corporation Z406 System User Manual 1008 Head cover is open 1009 Head %d fire voltage stuck 1010 Invalid head temperature 1100 SYSTEM: On boot up – possible bad INI variable 1207 THREAD %d: Problem occurred while trying to reboot. Cycle the power and try again. 1800 PACKETS: layer is too big Corrupted communications or Desktop software problem.
Z406 System User Manual Z Corporation 2304 MOVER: axis %d timed out completing move 2305 MOVER: axis %d didn't settle 2400 REZERO: axis %d can't find end of travel 2501 SHAKER: bad layer number 2600 HEAD: bad ROM format 2700 DRAWSPAN: bad bit number 2701 DRAWSPAN: bad print mode 2800 TIGERCOM: serial write timeout 2801 TIGERCOM: serial read timeout 3000 SEQUENCER: bad FIFO size Hardware problems.
Z Corporation 116 Z406 System User Manual 4602 CARWASH: carwash is stuck 4603 CARWASH: can't finish squirt 4700 BINDER: weak pressure from pump %d – Leak, bad pump, or out of binder with indicated fluid line – 0 = clear; 1 = yellow; 2 = magenta; 3 = cyan.
Z406 System User Manual Z Corporation 13 INDEX 3 Color Alignment, 82 Control Panel, 18 3D Print, 33 D A Aligning the Print Heads.
Z Corporation Z406 System User Manual Multi-pieced parts, 55 O Oiling the Snowplows, 86 Online, 28 Open File, 29 P Painting, 56 Part infiltration, 49 Part Orientation, 30 Circular Features, 30 Hollow Area, 30 Opening, 30 Overhangs, 30 Part Removal, 34 Piston Screws Greasing, 87 Polyester Resin, 57 Post Processing, 34 Tools, 46 Powder Anisotropic Scaling Values, 32 Saturation Values, 33 Settings, 32 Powder Settings, 32 Print Heads Align, 76 Purge, 80 Printing the Build, 33 R Removing finished parts, 34
Appendix I ® ZCast 501 Direct Metal Casting DESIGN GUIDE September 2004 09521 ZCast® Design Guide Rev E
Appendix I Table of Contents 1 Introduction ................................................................................. 4 2 General Safety............................................................................ 5 2.1 2.2 2.3 3 Safety Precautions ............................................................................................................ 5 Safety Symbols .................................................................................................................
Appendix I Seal – ......................................................................................................................................... 31 Clamp......................................................................................................................................... 32 Pour............................................................................................................................................ 32 8 Pouring Metal.........................................
Appendix I 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.
Appendix I 2 General Safety This manual has safety information and instructions to help users reduce or eliminate the risk of accidents and personal injuries. This section briefly explains hazards associated with fabrication of metal parts using the ZCast process. 2.1 Safety Precautions The making of molds and casting of metal parts using the ZCast process involves steps, such as mold baking and handling molten metal, that have particular safety hazards.
Appendix I 2.3 Safety Instructions Read and follow this safety information to reduce or eliminate the risk of accidents and personal injuries. GENERAL SAFETY WARNING Do not allow untrained individuals to design or handle ZCast molds during manufacturing. Only trained individuals with sand casting design and foundry experience should design and handle the ZCast molds. WARNING Do not bake ZCast molds in unvented ovens. Irritating and toxic fumes are formed at elevated temperatures during oven baking.
Appendix I WARNING Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten metal causing personal injury during metal casting. Venting paths in the mold must be arranged and directed away from the metal path to avoid entrapment of gases. WARNING Do not cast molten metal in molds with multiple sections without using core paste or adhesive. Molten metal can leak from the mold and cause personal injury.
Appendix I PREPARING AND BAKING MOLDS WARNING Bake ZCast molds until all moisture is removed before metal casting. Residual moisture in the mold can cause the mold to unexpectedly fail, releasing entrapped gases and molten metal and causing serious personal injury. WARNING Do not bake ZCast molds in unvented ovens. Irritating and toxic fumes are formed at elevated temperatures during oven baking. Ovens must be vented to the outside.
Appendix I FINISHING CAUTION 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. CAUTION 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.
Appendix I 3 ZCast Advantages Today, metal casting molds are commonly created by first producing a machined pattern (or pattern set) that is then used to create the molds. Instead of utilizing this costly and often time consuming process, the ZCast process utilizes 3D printing to create the molds and mold inserts directly from CAD data. With the ZCast process, Z Corp.
Appendix I 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®100 series materials.
Appendix I 4 Locating a Foundry Whether you are an experienced mold designer with a foundry in-house, or a design engineer who has never designed a mold, the first step in the ZCast process is to run a trial with your foundry. 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, the first choice would be to find a foundry with experience in sand casting.
Appendix I 5 Designing with ZCast – Mold Design ZCast powder offers flexibility and simplicity in mold design. Because of its simplicity, the engineer or designer can spend more time focusing on the design of the part rather than on the design of the mold. 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.
Appendix I 5.2 Selecting a Design Method This first step in designing a mold is to decide which design method best suits the desired casting. These are the three basic methods. 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.
Appendix I Figure 4: Shell Method – ZCast components of a shell mold (left). Assembled mold with ZCast components packed in foundry sand. Note that the risers, runners and sprue have been formed in the foundry sand (right). 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.
Appendix I a c b d e 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.
Appendix I 9. Add mating features to help align the mold components. These can be simple holes pegged with dowel pins, or mating positive and negative features built into the model. 10. Add venting to the mold cavity and to the cores. 11. 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.
Appendix I 5.3.3 Combination Method The combination method is slightly more process oriented and is not represented in the context of this document. Users familiar with the conventional sand casting process that incorporates the use of a pattern will find this technique to be desirable using ZCast. The primary advantage of the Combination method is that a significant number of components can be manufactured using this technique. A tutorial can be provided upon request to your Z Corp.
Appendix I 6 Design Techniques with ZCast Patterns 6.1 Direct Gating Conventional methods of runner design are based on having a flat pattern that must be drawn out of a sand mold. This forces the runners and gates out sideways resulting in a mold that covers a larger area. 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 allows for a simple, compact design which can easily be printed. 6.
Appendix I 6.4 Stiffening Ribs Increase the strength of your mold with the addition of stiffening ribs. You can use the Make Fixture2 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.
Appendix I into the metal. When gas passes through the metal as it cools, it can be trapped, forming pockets called porosity. To avoid this, the cores can be hollowed with the hollow sections vented through the core print to the outside of the mold. It is important to keep the venting path away from the metal path. WARNING Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten metal causing personal injury during metal casting.
Appendix I 6.5.2 Venting the Mold Vented molds facilitate the safe passage of gas generated as a result of molten metal coming into direct contact with the ZCast material. The design and adequacy of the mold vents is a contributing factor that strongly influences whether quality castings are made or the mold possibly fails releasing molten metal. Therefore, when designing mold vents, careful consideration is placed on their overall design, capacity, placement, and number.
Appendix I Suggested Solutions: • For the majority of the molds, there should be least a 0.5 in (13 mm) wall thickness between the metal and the outside of the mold. CAUTION • Mold wall thicknesses of less than 0.5 inches (13 mm) may allow 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.
Appendix I Make sure that geometries are properly shelled. Almost all molds are capable of having ‘sacrificial’ outer surfaces that can be removed to allow for even baking and proper gas dispersion during the pouring process (see below). Make certain that if the mold has a core that the core is properly vented to the atmosphere to allow unimpeded release of gas. For situations where large surface area to volume ratio geometries are present (i.e.
Appendix I Creating a runner bar, for example, across the heat sink fins would help to facilitate proper filling; however mold vents must still be provided for adequate exhausting of any gas. 6.6 Parting Lines The process for creating a mold in CAD software typically involves taking an object (the casting) and subtracting it from a larger, encompassing object (the mold). The mold must then be split along a generated surface or a plane.
Appendix I CAUTION Parting lines near core vents may leak molten metal into the vents. The vents may not function properly and cause the unexpected release of molten metal and personal injury. 6.7 Depowderability – Fixed vs. Removable Cores Part depowdering refers to the removal of loose, unprinted powder from the mold cavities following the printing process.
Appendix I radius to the bottom edges of core prints where they sit in the cope or drag; this provides space for loose powder to collect safely away from metal flow. A foundry will typically seal parting surfaces with core paste. A bead of this material is placed around the outer edges of the mating surfaces of the mold and across the core prints to prevent leakage. 6.
Appendix I 6.11 Pouring Sleeves & Risers A pouring sleeve is a tapered cylinder made of a refractory material with a ceramic filter at the base. The filter is removable, so the pouring cup can be used as a riser as well. There is no requirement to use sleeves, but the convenience is an advantage. 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.
Appendix I • For mating parts (such as a cope and drag of the same mold), try to always print them in the same orientation in the build. 6.13.1 Machine Settings Use the following optimized print settings for printing ZCast 501 powder with zb®56 binder: Saturation Settings Shell 1.2 Core 0.3 Layer Thickness 0.005” Bleed Compensation Settings ZPrinter® 310 Z®406 Z®810 X 0.016 0.019 0.014 Y 0.015 0.019 0.014 Z 0.010 0.016 0.012 Table 1 6.
Appendix I a d b e c f Figure 13: a,b,c: Horizontal filter orientation – Metal rises up through filters (maximum are achieved with horizontal placement.
Appendix I 7 Mold Preparation After the mold is designed and printed in a Z Corp. 3D Printer, there are only a few necessary steps before you are ready to pour metal: Mold Wash – Mold wash is used in traditional sand casting to improve the surface finish of the castings. 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.
Appendix I Clamp – Carefully close the mold with the cores in place. Clamp with C – clamps or similar and orient in the proper direction for pouring. Attach pouring cups and risers if necessary (use core paste to glue in place). CAUTION Attachment of risers and cups without core paste may result 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. Pour – The mold is now ready for metal.
Appendix I 8 Pouring Metal 8.1 Metal Types The current product offering is ZCast 501 powder and is designed for low temperature, nonferrous 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.
Appendix I 9 Material Handling 9.1 Storage Though ZCast powder has no special storage requirements; it should be stored in a cool, dry environment. See container labels for additional information. 9.2 Disposal ZCast powder is a non-toxic substance. Please consult the Material Data Safety Sheet for product details. Dispose of ZCast powder according to local and state regulations. 9.3 Powder Recycling Unprinted ZCast material can be recycled. Z Corp.
Appendix I 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 can be unclamped and broken apart. Breaking a mold can usually be done with a hammer or other blunt object.
Appendix I 11 Foundry Consumables You can purchase foundry consumables through a wide offering of vendors. This includes items such as core wash, pouring sleeves, filters, core paste, etc. Prominent foundry consumables that are commonly used are: Ceramic filters – These disposable items are inserted into either the pouring sleeve, or they are often placed in the drag in a cavity in line with the runner channel. Core paste – This liquid material is a refractory that is used to seal the mold halves together.
Appendix I 11.1 Sand Casting Glossary Cope 11.1.1 Cope and Drag Molds are typically made up of two halves encapsulating the outer surfaces of the casting. The two parts are called the cope and drag; the cope being the “top” section and the drag being the “bottom.” 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. Drag Figure 15: Cope and drag – manifold 11.1.
Appendix I Core prints (light areas) 11.1.4 Pouring Cup The pouring cup, as the name implies, is where the molten metal is poured into the mold. The pouring cup can take many different forms, each to optimize the feeding of metal into the mold and minimize the amount of turbulence produced in the metal stream. Pouring Cup Sprue Figure 18: Core prints – pockets where cores lock in place (drag of manifold from Figure 15) Well 11.1.5 Sprue Figure 19: Pouring cup, sprue and well.
Appendix I 11.1.8 Ingates The metal enters the mold cavity through the ingates. Ingates typically feed thicker sections of the casting, which subsequently, feed thinner 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.
