User Guide English Alaris30 3-D Printer System DRAFT 4 - July 11, 2010
DRAFT 4 - July 11, 2010
Copyright Copyright © 2010 Objet Geometries Ltd. All rights reserved. This documentation contains proprietary information of Objet Geometries Ltd. This information is supplied solely to assist authorized users of Alaris30 3‐D printing systems. No part of this document may be used for other purposes, and it may not be disclosed to other parties. The specifications on which this document is based are subject to change without notice.
Patents This product is covered by one or more of the following U.S. patents: 5,263,130 5,287,435 5,386,500 5,519,816 5,695,708 6,259,962 6,569,373 6,644,763 6,658,314 6,850,334 6,863,859 7,183,335 7,209,797 7,225,045 7,300,619 7,364,686 7,368,484 7,369,915 7,479,510 7,500,846 7,604,768 7,628,857 Objet Geometries Ltd. http://www.objet.com DOC‐24000 Revision A July 2010 iv DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Contents 1 About This Guide Using This Guide ............................................................................................................................... 1–2 For More Information........................................................................................................................ 1–2 Terms Used in This Guide................................................................................................................ 1–3 2 Safety Safety Features .....................
Alaris30 5 Using Objet Studio Opening Objet Studio........................................................................................................................ 5–2 Toolbars................................................................................................................................................. 5–2 Preparing Models for Production.................................................................................................... 5–3 Opening STL & SLC Files...................
User Guide 7 Operating & Maintaining the Alaris30 3‐D Printer Starting the Alaris30 Printer............................................................................................................. 7–2 Loading Model and Support Cartridges ........................................................................................ 7–3 Producing Models.............................................................................................................................. 7–5 Printer Interface Color Key..
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About This Guide Using This Guide................................................................................. 2 For More Information ......................................................................... 2 Terms Used in This Guide.................................................................. 3 DOC-24000 Rev.
About This Guide Using This Guide This user guide provides instructions for installing, operating and maintaining Alaris 3‐D printing systems. It explains how to use features, and provides practical examples to guide you as you use the system. This document is meant to be used with the Alaris30 3‐D printer, running software version 30.2.1, and with Objet Studio software version 8.5.9.
Alaris30 User Guide Terms Used in This Guide build tray In Objet Studio: The surface displayed on the screen that represents the actual build tray in the Alaris printer. In the Alaris printer: The surface upon which models are produced. cleaning fluid Cleanser for flushing model feed tubes and the printing block, used to completely remove model material from the system before loading another type of material in the printer. The cleaning fluid is supplied in model‐material cartridges.
About This Guide STL A file type used with Objet software. (For more information, see page 3‐3.) support material Material used for supporting the structure of models during production. 1–4 DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Safety Safety Features..................................................................................... 2 Symbols and Warning Labels ............................................................ 3 Safety Guidelines................................................................................. 4 Printer Installation ................................................................................ 4 Printer Operation ..................................................................................
Safety Safety Features Alaris 3‐D printers are designed to comply with CE and FCC standards. They are equipped with the following safety features: Cover interlock switch The power supplied to the UV lamp and the motion motors is turned off when the cover is opened. WARNING: Do not defeat (override) the interlock switch. Doing so could result in serious personal injury. If the interlock switch does not function correctly, do not use the printer, and contact your service provider.
Alaris30 User Guide Symbols and Warning Labels This following table lists the warning labels located on or in Alaris printers. Warning Symbol DOC-24000 Rev. A Meaning Location Comments Hazard (general) On the name plate on the back of the printer. Read the instructions in this document before operating the printer. Hot surface On the print‐head block. Risk of burns. Do not touch this surface after printing. High voltage Near the UV lamp connector. Near the power‐ supply enclosures.
Safety Safety Guidelines The following general guidelines, together with the instructions provided throughout this user guide, ensure user safety while operating and maintaining the Alaris system. If the system is not operated as specified, the userʹs safety may be compromised! Printer Installation ¾ Installation and removal of the Alaris printer should only be done by qualified service personnel. ¾ Connect the printer to the electric outlet using a power cord that is safety‐certified.
Alaris30 User Guide Model and Support Materials Model and support materials are made of chemical substances. Although precautions must be taken when handling these materials directly, all model and support materials used by the Alaris system are handled in sealed cartridges. Normally, operators of the Alaris printer should never be directly exposed to hazardous materials. In the unlikely event of a leak or spill, follow the instructions that are included with the printing‐material cartridge used.
Safety First Aid for Working with Printing Materials In general, try to avoid direct contact with uncured printing material. If skin or eyes come into contact with it, wash the area immediately and thoroughly with water, and follow these first‐aid instructions. Contact with Skin If uncured printing material comes in contact with skin, wash the affected area immediately and thoroughly with soap and cool water, then remove contaminated clothing.
Alaris30 User Guide Waste Disposal Fully cured printed models can be disposed of as ordinary office trash. However, special care is required when handling printer waste. ¾ When removing the waste container from the Alaris printer, wear neoprene or nitrile gloves. ¾ To prevent liquid waste from splashing into the eyes, wear safety goggles. ¾ Liquid waste from the Alaris printer is classified as hazardous industrial waste.
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Introducing the Alaris 3-D Printing System Work Configurations .......................................................................... 2 Source Files........................................................................................... 3 STL Files ................................................................................................. 3 SLC Files ................................................................................................. 3 Printing Materials..........................
Introducing the Alaris 3-D Printing System Figure 3-1: The Alaris30 3-D Printer Work Configurations The Alaris30 3‐D printing system can be set up as a single‐station system or as a multi‐station system. When connected to a local computer network, the system can serve multiple users. In such configurations, each user workstation (client) prepares files with Objet Studio software for production.
Alaris30 User Guide The Objet software arranges the jobs it receives according to their priorities, model‐material type, and other factors. In multi‐workstation configurations, the operator of the server—typically the production administrator—has total control over the jobs sent to the 3‐D printer, and can prioritize and delete jobs, review job history and reprint a job, and so on.
Introducing the Alaris 3-D Printing System Printing Materials Alaris printers produce models by jetting thin layers of printing materials on the build tray, until the complete model is formed.
Alaris30 User Guide Shelf Life Materials used for producing models have a limited shelf life. The expiry date on the label is valid when properly stored in an undamaged, unopened cartridge. Always rotate your stock, so that the cartridge with the earliest date is used first. Exposure to Light If printing materials are not in their sealed cartridges, make sure to shield them from sunlight and other sources of UV radiation, such as fluorescent and mercury‐vapor lights.
Introducing the Alaris 3-D Printing System Work Environment Extreme heat and humidity conditions can adversely affect the operation of the Alaris 3‐D printer. Therefore, it is recommended that you use ventilation or air‐conditioning systems, if necessary, to keep the work area within the following ranges: • 18°–25° C (64°–77° F) • 30%–70% relative humidity Workstation Requirements The minimum requirements for computer components used with Objet 3‐D printer software are listed in the following table.
Alaris30 User Guide Preparing Files for Use with Alaris 3-D Printing Systems Before using files with Alaris 3‐D printing systems, you must convert them in your CAD program to either STL files or SLC files. (For an explanation of these file formats, see “Source Files” on page 3‐3.) After converting the model files, it is recommended that you check them for defects in an STL‐repair application (such as Magics, by Materialise) before opening them in Objet Studio and producing the model.
Introducing the Alaris 3-D Printing System Objet Software Objet software for the Alaris 3‐D printing system consists of two applications: • Objet Studio • Job Manager Objet Studio With Objet Studio, you prepare source files for production in Alaris 3‐D printers. Objet Studio offers you a wide variety of file‐preparation options, but always consists of the following basic procedure: 1. Inserting one or more objects on the build tray 2. Positioning the object(s) on the tray 3.
Installing Objet Software How to Install Software for the Alaris 3‐D Printing System......... 2 DOC-24000 Rev.
Installing Objet Software How to Install Software for the Alaris 3-D Printing System The Objet Studio setup wizard guides you when installing the Objet software. During installation, you must choose to install either the server (“host”) application or the client application. To install Objet software: 1. Insert the Objet Studio CD into the disk drive. 2. Right‐click the Start button and select Explore (or use any other method for displaying files on the computer). 3.
Alaris30 User Guide 4. Click Next to begin installation. Figure 4-2: Objet Setup—Select Components screen 5. When the Select Components screen appears, select one of the installation options, then click Next. • Select Objet Studio only for client workstations • Select Objet Studio and Job Manager for the server (host) station and for a standalone station—that is, the computer directly connected to the Alaris printer. Figure 4-3: Objet Setup—Choose Destination Location screen 6.
Installing Objet Software Figure 4-4: Objet Setup—Select Program Folder screen 7. In the Select Program Folder screen, verify the pre‐selected folder in which the Objet Studio icons will be installed. • To install the icons in another program folder, select it. • To continue, click Next. Installation begins and the Setup Status screen appears, showing the progress of the installation process. Figure 4-5: Objet Setup—Setup Status screen 4–4 DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Alaris30 User Guide When the Objet program installation is complete, the final InstallShield Wizard screen appears. Figure 4-6: Objet Setup—final wizard screen To complete the software installation, you must restart the computer. You can do so now or at another time. 8. Select either “Yes…” or “No…” and click Finish. Make sure to remove the CD from the disk drive before restarting the computer.
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Using Objet Studio Opening Objet Studio ......................................................................... 2 Toolbars .................................................................................................. 2 Preparing Models for Production ..................................................... 3 Opening STL & SLC Files .................................................................... 3 Copying and Pasting Objects ..............................................................
Using Objet Studio Opening Objet Studio After you install Objet Studio, a launch icon appears on the Windows desktop. Open the application by double‐clicking this icon, or by selecting Objet Studio from the Start > Programs menu. Objet Studio opens, displaying an empty build tray. Figure 5-1: Objet Studio opening screen Toolbars The icons shown in this chapter are available only when relevant toolbars are displayed.
Alaris30 User Guide Preparing Models for Production To produce models, you must open one or more files in Objet Studio and position the objects on the build tray. You can place objects on the build tray in two ways: • by inserting individual stl or slc files • by pasting objects that you copied to the Windows clipboard If you know what type of model material will be used to produce the models, make sure it is selected from the material drop‐down menu.
Using Objet Studio If the Preview check box is selected, the object is displayed in the dialog box, as shown in figure 5‐4. 5. Select any of the following options, as required: • Units—Choose millimeters or inches for the object’s units of measure. • Number of copies—Choose how many copies of this object to place on the build tray. • Arrange models—Select this check box to automatically position objects on the build tray for efficient model building.
Alaris30 User Guide Copying and Pasting Objects If you need to duplicate objects on the build tray, you can, of course, insert the same object from its file more than once. An easier way, however, is to copy and paste the object. You can copy objects from the build tray or the hierarchy pane. The objects copied remain in the Windows clipboard until you paste them onto the build tray.
Using Objet Studio Arranging the Objet Studio Screen The default screen layout displays the perspective view of the build tray and the tray hierarchy pane, which lists the elements placed on the tray (see figure 5‐5 on page 5‐4). You can view models from different angles by changing the screen layout. To change the Objet Studio screen layout: ¾ From the View menu, select Layout, then the desired number of build‐ tray views.
Alaris30 User Guide Figure 5-9: 4-view screen layout Figure 5-10: 1-view screen layout You can change the perspective of the active viewing pane by clicking any of the nine viewing icons. Figure 5-11: Viewing-pane perspective icons DOC-24000 Rev.
Using Objet Studio Positioning Objects on the Build Tray To produce models efficiently and with the required finish, it is important to carefully position objects on the build tray. Objet Studio features the automatic positioning of objects. However, you should check to make sure that the objects are orientated logically for your needs, according the considerations explained in “Model Orientation” on page 5‐10.
Alaris30 User Guide Figure 5-13: Tray before objects are properly arranged Figure 5-14: Tray after objects have been automatically arranged Because of the unique characteristics of each type of modeling material, it is recommended that you select the material before inserting objects on the tray with automatic positioning or running Automatic Placement. Manual Positioning DOC-24000 Rev.
Using Objet Studio Model Orientation The orientation of models on the build tray affects how quickly and efficiently they will be produced by the 3‐D printer, where and how much support material is used, and whether or not model parts will have a gloss finish. Therefore, you should consider a variety of factors when deciding how to place models on the tray, using the following positioning rules. X-Y-Z Rule This rule considers a modelʹs outer dimensions.
Alaris30 User Guide Manipulating Objects on the Build Tray Object Position on the Z-Axis When you use automatic positioning to arrange objects on the build tray (see “Automatic Positioning” on page 5‐8), the objects are positioned directly on the tray. If you do not insert objects with automatic positioning, they often appear either above or below the tray. In practice, the Alaris system prints all models on the build tray on a onemillimeter bed of support material.
Using Objet Studio Repositioning Objects You can select and manipulate objects on the build tray after selecting the following icons or menu options. Icon Menu Option (none) Purpose What to do For selecting an object. Click the object on the build tray. Object > For selecting and moving Click the object to select it. Translate an object with the mouse. Drag the object to a new location while holding down the mouse button. Object > Rotate For selecting and rotating Click the object to select it.
Alaris30 User Guide Figure 5-16: Object properties dialog box, Transform tab You can make precise changes to an object on the build tray by selecting the object (either on the tray or in the tray hierarchy pane), changing its values in the dialog box, and clicking Change Units. Note: You can only change the height of the objects on the build tray if this is allowed by the Objet Studio settings (see “Object Position on the Z-Axis” on page 5-11.
Using Objet Studio Valid Object Placement To ensure that models do not overlap when you position them on the build tray, you can select the Dynamic Checking icon from the Tools toolbar. When selected, Objet Studio only allows the positioning of objects if they do not interfere with other objects on the tray. Note that the space occupied by an object includes the “bounding box” surrounding it (see figure 5‐24 on page 5‐19).
Alaris30 User Guide The dialog box displays the current grid settings. 2. As required, make changes to the settings, and select or clear the check boxes. 3. Click Apply or OK. Changing an Object’s Orientation There are several methods for changing the orientation of objects on the build tray. To rotate an object: ¾ Select the object and use the Rotate icon or Object menu options (see “Repositioning Objects” on page 5‐12).
Using Objet Studio Freezing an Object’s Orientation If you manipulate an object on the build tray, you can freeze its orientation so that it does not change when you perform Automatic Placement (see “Automatic Positioning” on page 5‐8). To freeze an object’s orientation: 1. Select a model on the build tray. 2. In the Options tab of the object properties dialog box, click Advanced. The Advanced Properties dialog box opens. Figure 5-20:Advanced Properties dialog box 3.
Alaris30 User Guide Default Object Properties You can set several default properties for objects placed on the build tray: • locking of object orientation on the tray For an explanation of this feature, see Freezing an Object’s Orientation on page 5‐16. • surface finish for printed models For an explanation of this feature, see Surface Finish on page 5‐16. • support strength used during printing For an explanation of this feature, see Choosing the Support Strength on page 5‐26.
Using Objet Studio Display Options From the View menu, you can change the way objects are displayed on the screen. The default method for displaying models on the build tray is as solid (“shaded”) objects. Figure 5-22: Tray and model displayed in shaded view The other display options are wire frame and points. To display the build tray in wire frame view: ¾ Select View > WireFrame or click the WireFrame icon .
Alaris30 User Guide Figure 5-24: Model displayed with bounding box To display the area around objects needed for support material (to produce a matte finish): ¾ Select View > Display Thickening Box. Figure 5-25: Model displayed with thickening box Display Colors You can customize some of the colors used for displaying Objet Studio screens and for displaying objects on the build tray. To change the colors displayed in Objet Studio screens: 1. From the Tools menu, select Define Colors. 2.
Using Objet Studio To set the color indication of objects displayed on the build tray: 1. In the Define Colors dialog box, select one of the options. • Show color according to material. • Show color according to building style. 2. Click OK. Note: This selection has the same effect as toggling the object-colordisplay switch.
Alaris30 User Guide Tray Viewing Options The Objet Studio toolbars contain several icons for changing the appearance of the display screen, enabling you to view the tray and objects in different magnifications and from various perspectives. Note: You must display the relevant toolbar(s) to access many of the icons described below (see “Toolbars” on page 5-2). Icon DOC-24000 Rev. A Tool Tip Name Purpose Zoom Full Reverts to normal view after using various zoom options. (The same as .
Using Objet Studio Icon 5–22 Tool Tip Name Purpose Pan Left Each mouse click moves the build tray to the left in the viewing pane by one step. Pan Right Each mouse click moves the build tray to the right in the active viewing pane by one step. Pan Up Each mouse click moves the build tray up in the active viewing pane by one step. Pan Down Each mouse click moves the build tray down in the active viewing pane by one step. Advance Forward The same as .
Alaris30 User Guide Handling Completed Trays After you have properly placed all objects on the build tray, you save the tray as an objtf file, which is sent to the 3‐D printer for production. But before saving the tray, you can check that there would be no problem producing it. You can also calculate how much material would be consumed during production and how much time this would take.
Using Objet Studio Production Estimates Objet Studio enables you to calculate the time and material resources needed for producing trays before sending them to the Alaris printer. The time it takes Objet Studio to make this calculation depends on the number of objects on the tray and their complexity. Calculating the production estimate for a full tray could take up to 15 minutes, depending on your computer’s specifications.
Alaris30 User Guide Figure 5-32: Tray validation warning To cancel the Build command so you can correct the problem, click No. To print the models as they are positioned on the tray, click Yes. Figure 5-33: Constraints Settings dialog box, with color codes for problematic model positioning The tray file is sent to Job Manager. Objet Studio closes and Job Manager opens, so you can monitor the progress of your trays—before, during, and after printing.
Using Objet Studio Additional Objet Studio Features Dividing Objects You can use the Split Object feature to produce objects larger than the build tray by dividing the model into separate parts. With this feature, you produce only a specific section of a model. To split an object: 1. Select the object. 2. From the Object menu, select Split. 3. In the Split Object dialog box, enter the values to determine how Objet Studio will divide the object.
Alaris30 User Guide The Advanced Properties dialog box opens. Figure 5-35:Advanced Properties dialog box—Grid Style selection 3. In the Grid Style section, choose the support strength suitable for the selected model: • Heavy—for large models needing much support. • Lite—for delicate models needing little support. • Default—for models needing average support (most models). Note: You can select a different support strength for each model on the build tray. 4. Click Apply.
Using Objet Studio To inspect, change or cancel the Smartcast/Hollow setting: 1. Select a model on the build tray. 2. Access the Advanced Properties dialog box, as above. 3. If you change or cancel the Smartcast/Hollow setting, click Apply. You can set Smartcast/Hollow as a default property for all models placed on the build tray. See “Default Object Properties” on page 17.
Alaris30 User Guide Printing the Screen Display on Paper You can print the view displayed in the active pane on a regular (paper) printer. Before printing, you can configure how the tray will be printed on the page, and you can display a screen preview of the printed page. To access the paper printing controls: ¾ From the File menu, select— Page Setup… Page Preview… Print You can also print a paper copy of the tray by using the standard Windows keyboard shortcut for printing: Ctrl+P.
Using Objet Studio To open an objzf file: 1. From the File menu, select Import Packed Job… 2. In the Open dialog box, display the appropriate folder and select the file. 3. In the Browse for Folder dialog box, display the folder in which you want Objet Studio to expand the compressed file, and click OK. The objtf file and associated stl files are expanded and placed in the selected folder, and the tray is displayed in Objet Studio.
Alaris30 User Guide Save Tray As… In addition to saving the tray as an objtf file, for producing it with an Alaris 3‐D printer, you can save a group of objects positioned on the tray as an stl file. You can then use this file as any other stl file, both in Objet Studio and in other applications. You can also display this and other stl files as “floating” objects, without the build tray. This is useful for inspecting objects from every angle. To save the build tray as an stl object: 1.
Using Objet Studio Configuring the GL Driver The OpenGL driver displays 3‐D graphics on your screen. There is normally no reason to adjust its settings. If you suspect a problem with the way Objet Studio displays objects, you can use the OpenGL Driver Configuration tool to check and configure the driver settings. To access the OpenGL Driver Configuration dialog box: 1. From the Tools menu, select Options. 2.
Alaris30 User Guide To perform a test of the driver configuration and enter the suggested pixel format ID: 1. Select Choose Format. 2. Click Test. Objet Studio returns the recommended pixel format ID. Figure 5-45:Recommended pixel format ID 3. Click OK. 4. In the OpenGL Driver Configuration dialog box (figure 5‐44), select Pixel Format ID and enter this number. 5. Click Apply. 6. Display the other pixel format tab, and repeat this procedure. DOC-24000 Rev.
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Using Job Manager Client Job Manager.............................................................................. 2 Job Manager Screen .............................................................................. 3 Job Manager Operations ...................................................................... 4 Configuring User Alerts....................................................................... 5 Server Job Manager .............................................................................
Using Job Manager The Job Manager application is different for client workstations and for the computer connected directly to the 3‐D printer. • Job Manager installed on client computers displays the queue and status only for jobs sent to the 3‐D printer server from that computer, and allows the user to edit only these jobs. If there are several Alaris printers on the local network, client computers can connect to any of them, but only one at a time.
Alaris30 User Guide Job Manager Screen On a client computer, Job Manager displays the queue of jobs sent by that computer to the printer server. Print Queue Print History Figure 6-2: Client Job Manager screen Information for each of the queued jobs is displayed, including the job status: DOC-24000 Rev. A Status Meaning Waiting Printing of this job has not started. Building Printing of this job is in progress.
Using Job Manager Job Manager Operations Even after sending a build tray to the 3‐D printer, you can inspect the tray— and make changes to it, if necessary—as long as it is still in the print queue. To inspect the build tray: 1. Select the job. 2. Click the Edit Job icon or open the Job menu and select Edit. Objet Studio opens, displaying the build tray. To make changes to it, see “Making changes to a Job” on page 6‐10.
Alaris30 User Guide Figure 6-3: Printer status screen Configuring User Alerts Job Manager can alert you and others to the status of the jobs sent to the server for printing. The following events can be reported: • The level of model or support material is low. • The job was interrupted. • The job was completed successfully. To send e‐mail and SMS messages, make sure that e‐mail software supporting MAPI is installed on the printer’s server computer.
Using Job Manager 2. For e‐mail and SMS alerts, click Add Recipient in the respective sections. 3. To choose the events reported to you by Job Manager, click Details in the relevant sections. Figure 6-5: Event selection for alerts 4. Select the desired events for sending alerts and click OK. The parameters for “Low level of material” alerts are set on the printer’s server computer. 6–6 DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Alaris30 User Guide Server Job Manager When you open the server Objet Studio / Job Manager program for the first time, or if the program is not connected to an Objet 3‐D printer, you are prompted to connect to a printer. If you click Yes in the dialog box, the Setting Network Connection dialog box opens (see figure 6‐6). To connect to a printer, the printer must be on and connected to the local network. You can switch the server connection to another printer at any time.
Using Job Manager Job Manager Screen On a server computer, Job Manager displays the queue of jobs sent to it by all client computers. In addition, it lists details of the last 15 jobs sent to the printer, and information about the job currently being printed. Print Queue Current Job Info Print History Figure 6-7: Server Job Manager screen Print Queue Information for each of the queued jobs is displayed, including the job status: 6–8 Status Meaning Waiting Printing of this job has not started.
Alaris30 User Guide Job History The History section of the Job Manager screen lists details of the last 15 jobs sent for printing, showing the job’s final status. A job can be returned from the History section to the print queue in order to print the tray again. To move a job from History to the print queue: 1. Select the job in the History section. 2. Click the Resume icon . The job moves from the History section to the end of the print queue.
Using Job Manager Icon Making changes to a Job Menu Option Purpose Job > Restart Job For a stopped job in the print queue: Starts printing the selected job from the beginning. For a selected job in the History section: Moves the job to the print queue and changes its status to Waiting. Job > Stop... Instructs the 3‐D printer to stop printing after curing the currently printed slice.
Alaris30 User Guide User Alerts Job Manager can alert you and others to the status of the jobs sent to the server for printing. This is especially useful during long printing jobs, when the operator is away from the 3‐D printer. The following events can be reported: • The level of model or support material is low. • The job was interrupted. • The job was completed successfully. For details on how to configure alert messages, see “Configuring User Alerts” on page 6‐5.
Using Job Manager Material warning icon Figure 6-9: Insufficient material warning When the time set in the dialog box triggers the remote alert message, the warning icon changes color—from a yellow to a red background. Sending the Tray to the 3-D printer for Production 6–12 If there is a job in the print queue, it is sent automatically to the Alaris printer—as long as it is on, there is a connection to the printer, and the printer is on line.
Operating & Maintaining the Alaris30 3-D Printer Starting the Alaris30 Printer .............................................................. 2 Loading Model and Support Cartridges.......................................... 3 Producing Models ............................................................................... 5 Printer Interface Color Key.................................................................. 7 Printing Indicators .......................................................................
Operating & Maintaining the Alaris30 3-D Printer Printer cover Printing-materials & waste compartment Figure 7-1: The Alaris30 3-D Printer Starting the Alaris30 Printer CAUTION! • Do not attempt to operate the Alaris printer before being trained by an Objet customer-support representative. • Observe all safety warnings and follow the safety guidelines described in chapter 2. 1. Turn on the main power switch, located at the back of the Alaris printer.
Alaris30 User Guide The Alaris printer interface screen opens (see figure 7‐3). All monitoring and controlling of the Alaris printer is done from this interface. Printer mode Current activity Display toggle button Online/offline button Pause button Stop button Support material cartridges Model material cartridges Figure 7-3: Alaris30 interface Alaris installations utilize one monitor for displaying both the computer running Objet Studio / Job Manager and the computer installed inside the printer.
Operating & Maintaining the Alaris30 3-D Printer Figure 7-4: Printing-materials drawer You should feel some resistance, as a needle pierces the cartridge. 4. Check the Alaris printer interface to make sure that the new cartridge is detected and that its weight is displayed (see figure 7‐3). 5. Close the printing‐materials drawer. Tips about replacing cartridges: • You can replace material cartridges either before or during printing.
Alaris30 User Guide Producing Models Before beginning to produce models, it is recommended that you clean the print heads (see “Cleaning the Print Heads” on page 7‐21). To prepare the Alaris printer for producing models: 1. Make sure that the build tray in the Alaris printer is empty and clean. If not, remove old material with the scraper, and clean the tray thoroughly with cleaning fluid. CAUTION: Use protective gloves when cleaning the build tray, and be careful of the sharp edges of the scraper blade.
Operating & Maintaining the Alaris30 3-D Printer On the Alaris printer interface, the printer mode changes from Idle to Pre‐ print, as the printer’s components prepare themselves for production: • The print block is heated. • If more than 48 hours have passed since the last print job, the printing materials in the print heads are flushed and replaced, to ensure quality printing. (This step adds 7 to 14 minutes to the Pre‐print cycle, and it is displayed in the printer interface.
Alaris30 User Guide Block temp. behind print heads Temp. of support head System vacuum level UV lamp state Waste weight Chamber temp. Temp. of model head Block temp.
Operating & Maintaining the Alaris30 3-D Printer Printing Indicators The printer interface screen changes when you send a print job from Job Manager to the printer, and the printer is on line (see figure 7‐8): • The mode changes from Pre‐print to Printing. • The specific activity being performed is shown in the “current activity” field. • Current job‐printing information is displayed. • The printing progress bar is displayed. • The Stop and Pause buttons are enabled.
Alaris30 User Guide Resuming Production After Printing has Stopped If the printing process is interrupted for any reason, Job Manager stops sending slices to the Alaris printer. To continue printing the model: 1. Switch the printer to online mode by clicking the red button at the bottom of the Alaris printer interface (see figure 7‐3 on page 7‐3). The button changes from red to green (see figure 7‐7 on page 7‐7). 2.
Operating & Maintaining the Alaris30 3-D Printer If you cannot continue printing: 1. Cancel the print job in Job Manager. 2. Remove the partially printed model from the build tray. 3. Send the job to the Alaris printer again. You can stop and later resume printing from either the Alaris printer interface or the Job Manager interface, since both applications are updated when you use these commands.
Alaris30 User Guide 4. In the Compartment Selection screen, select the cartridge(s) you want to replace, and click Next. Figure 7-11: Compartment Selection screen 5. From the drop‐down menu, choose the material you want to install, and click Next. Figure 7-12: Material Selection screen Note: This selection automatically affects the default material setting in Objet Studio. DOC-24000 Rev.
Operating & Maintaining the Alaris30 3-D Printer 6. In the Flushing Options screen, choose the appropriate cycle for the model material you want to install. Figure 7-13: Flushing Options screen • Economy. During this cycle, which takes about 25 minutes, the pump purges the model material from the print block, then flushes the system with the new material.
Alaris30 User Guide 8. To continue, click Next. 9. When prompted by the wizard screen, remove the material cartridges. Select the check box to confirm that you have done so, and click Next. Figure 7-15: Remove Cartridge confirmation screen 10. When prompted, load the new cartridge(s) and close the drawer. Confirm this in the wizard screen and click Next. After identifying the new cartridge(s), the Alaris printer begins filling the print heads with the new material.
Operating & Maintaining the Alaris30 3-D Printer Keeping the Alaris Printer in Idle Mode Between printing jobs, the Alaris30 printer can be kept on for up to one week. If the printer will not be used for more than a week, use the shutdown wizard to automatically perform the procedures that must be done before turning off the printer (see “Shutting Down the Alaris Printer,” below).
Alaris30 User Guide Shutting Down the Alaris Printer You only need to shut down the Alaris printer if it will not be used for a week or more. Otherwise, the printer can remain on, in Idle mode. To properly shut down, the printer needs to perform several processes. Do not attempt to shut down the printer by simply closing the computer interface (the printer‐control application), and never disconnect power to the printer before completing this wizard.
Operating & Maintaining the Alaris30 3-D Printer 3. In the next screen, indicate whether or not the tray is empty and click Next. Figure 7-18: Tray status screen The shutdown procedure begins. Figure 7-19: Shutdown progress screen The shutdown procedure may take up to 10 minutes while the following tasks are performed: a. The print block returns to its starting point on all axes. b. The print heads are heated. c. The print heads are cleared of any remaining material.
Alaris30 User Guide 4. When completely shutting down the Alaris printer and turning the power off, select Yes and click Next. 5. After the printer computer shuts down, turn off the main power switch (at the back of the printer) (see figure 7‐2 on page 7‐2). Material Flush/Fill Wizard You use this wizard to prepare the printer for a shutdown of more than one week, and to restore the printer to working condition.
Operating & Maintaining the Alaris30 3-D Printer 4. Load the required cartridges, close the cartridge drawer, and confirm this in the wizard screen. Figure 7-22: Cartridge confirmation screen—before shutdown Figure 7-23: Cartridge confirmation screen—before printing 5. In the next wizard screen, confirm that the printer cover is closed, and click Next. The wizard runs the material‐flushing cycles. Figure 7-24: Flushing cycles in progress 7–18 DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Alaris30 User Guide 6. If cleaning‐fluid cartridges are loaded in the printer, the wizard prompts you to remove them. Confirm this in the wizard screen, and click Next. Figure 7-25: Final wizard screen Note: After preparing the printer for an extended shutdown period with this wizard, run the Shutdown Wizard to complete the shutdown process. DOC-24000 Rev.
Operating & Maintaining the Alaris30 3-D Printer Maintaining the Alaris Printer The performance of routine maintenance tasks is essential for getting satisfactory results from Alaris 3‐D printers. Perform the tasks at specified intervals for optimum performance. Routine Maintenance Schedule 7–20 Frequency Task For More Information After every print job Clean the print heads. Clean the build tray and the surrounding area. See “Cleaning the Print Heads” on page 7‐21.
Alaris30 User Guide Cleaning the Print Heads Periodic inspection and cleaning of the orifice plates on the bottom of the print block ensures that the print nozzles are not clogged. A wizard guides you through the procedure, and adjusts components of the Alaris printer to enable you to perform it. To maintain your Alaris printer in optimum condition, clean the print heads after every print job, when you remove the model from the build tray. This procedure takes about 20 minutes.
Operating & Maintaining the Alaris30 3-D Printer WARNING: The print head orifice plates (bottom surface) may be hot. Do not touch them with your bare hands, and proceed with caution. 6. Place the mirror on the build tray. 7. Put on the gloves. 8. Soak the cleaning cloth with the cleaning fluid. 9. Clean the orifice plates, with a back‐and‐forth motion (see figure 7‐28). Use the mirror to make sure that you have removed all of the residue material.
Alaris30 User Guide Pattern Test The pattern test is the basic verification of the printer’s ability to produce quality models, since it demonstrates the condition of the nozzles in the print heads. Make sure, therefore, that you perform this test weekly, and whenever you suspect a printing problem. To perform the pattern test: 1. Make sure that the build tray is empty. 2. Prepare a sheet of pink paper, approximately 21 × 14 centimeters in size (8.5 × 5.5 inches)—half of the standard A‐4 or Letter size.
Operating & Maintaining the Alaris30 3-D Printer Too many missing lines, especially if they are in the same area, indicates that the quality of printing when producing models will be poor. If this is the case, see “Improving Print Quality,” below. Note: Acceptable model quality is subjective, and depends on the type and scale (size) of the models produced.
Alaris30 User Guide 2. Start the Wiper Cleaning wizard from the Options menu of the printer interface. Figure 7-33: Starting the Wiper Cleaning wizard 3. Close the printer cover, and click Next in the wizard screen. 4. Make sure that the build tray is empty, and close the printer cover. Confirm this in the wizard screen. Figure 7-34: Wiper Cleaning procedure—step 4 5. Click Next. DOC-24000 Rev.
Operating & Maintaining the Alaris30 3-D Printer 6. When the following screen appears, open the cover. Figure 7-35: Wiper Cleaning wizard during steps 7–10 7. Put on the cleaning gloves. 8. Using a generous amount of cleaning fluid and the cleaning cloth, remove any material remaining on the wiper and the surrounding area. 9. Inspect the wiper. If the wiper is scratched, torn or worn, or if you cannot clean it completely, replace it.
Alaris30 User Guide 12. Select the confirmation check boxes in the wizard screen and click Next. Figure 7-37: Wiper Cleaning procedure—final confirmation screen 13. Click Done to close the wizard. Cleaning and Replacing the Roller Waste Collector You should remove the roller waste collector once a month to clean it and to inspect the condition of the scraper. The unit should be replaced every six months, or when the roller knife is worn or damaged. To remove the roller waste collector: 1.
Operating & Maintaining the Alaris30 3-D Printer 3. When the following screen appears, open the cover. Figure 7-39: Wizard screen that appears when you can begin the procedure WARNING: The print head orifice plates (bottom surface) may be hot. Do not touch them with your bare hands, and proceed with caution. 4. Loosen the two side screws securing the UV lamp assembly, and remove the assembly. Securing screws Figure 7-40: UV-lamp-assembly securing screws 5.
Alaris30 User Guide 6. Pull the bottom of the locking pin, and turn it counter‐clockwise, to raise the drain‐tube bracket from the roller waste collector. Drain-tube bracket Roller waste collector Roller-waste-collector screws Figure 7-42: Raising the drain-tube bracket 7. Support the roller waste collector with your hand under it, and use a 3 mm Allen key to loosen the screws. 8. Pull out the roller waste collector, taking care not to touch or damage the scraper.
Operating & Maintaining the Alaris30 3-D Printer Aligning the Print Heads You should check the alignment of the print heads— • once a month • if model quality is not acceptable even after cleaning the orifice plate on the bottom of the print block (see “Cleaning the Print Heads” on page 7‐21) The head‐alignment procedure takes about 20 minutes. To check the alignment of the print heads: 1. Prepare— • a transparency sheet, at least 10 × 16 centimeters in size (4.5 × 6.
Alaris30 User Guide 7. In the wizard screen, select the check box to confirm that the transparency sheet is on the build tray, and click Next. The Alaris printer prints the head alignment test on the transparency. 8. When the following screen appears, remove the transparency. Figure 7-46: Head Alignment wizard—steps 8–10 The transparency sheet is printed with sets of vertical lines in two rows, each showing the results from a different print head.
Operating & Maintaining the Alaris30 3-D Printer The first in a series of alignment screens appears. Figure 7-48: Head alignment screen 11. In the head‐alignment screen, select the number that indicates which lines align in the upper and lower rows. Note: Because the alignment of the middle lines is optimum, the number “8” is selected, by default, in the wizard screen. This does not change the head alignment. If you select other numbers, the wizard adjusts the head alignment, accordingly. 12. Click Next.
Alaris30 User Guide 14. In the final wizard screen, choose to either repeat the head alignment procedure or close the wizard. • If the most closely aligned vertical lines for a print head were at either extreme, choose Yes to run the head‐alignment wizard again, then click Next. The transparency test will show if the heads are now properly aligned, and—if not—the wizard will allow you to “fine tune” the alignment.
Operating & Maintaining the Alaris30 3-D Printer Replacing Print Heads The condition of the print heads directly affects the quality of printed models. You need to replace a print head if one or more of the following symptoms occurs: • There are noticeable grooves in the surface of printed models. • The pattern test reveals that more than four consecutive nozzles—or a total of more than 12 nozzles—are not functioning.
Alaris30 User Guide To replace a print head: 1. Prepare— • • • • • replacement print head(s) isopropanol (IPA—isopropyl alcohol) or ethanol (ethyl alcohol) disposable safety gloves (included in the head replacement kit) an Objet‐supplied cleaning cloth or equivalent the scale supplied by Objet for use in the Weight Test Note: Make sure that you have these items before running the Head Replacement wizard. 2.
Operating & Maintaining the Alaris30 3-D Printer When the print block is completely drained, the wizard wipes the heads. Then, the following warning screen appears. Figure 7-53: Head Replacement warning screen 6. Click Next if you are ready to continue. 7. Open the Single Head Replacement kit, and remove the safety gloves and the instructions. 8. Put on the safety gloves. 9. When the following screen is displayed, open the Alaris printer cover.
Alaris30 User Guide Removing the Defective Head To replace the model print head, you must first remove the support print head. Support Print Head ¾ If you do not need to replace the model print head, continue with “Support Print Head” on page 39. DOC-24000 Rev.
Operating & Maintaining the Alaris30 3-D Printer Model Print Head Installing the New Head 7–38 Model Print Head Important: Remove the protective tape from the surface of the new print head. DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Alaris30 User Guide Support Print Head Important: Remove the protective tape from the surface of the new print head. 10. In the Head(s) Replacement screen (see figure 7‐54 on page 7‐36), select the check box to confirm that you have replaced the head(s), and click Next. DOC-24000 Rev.
Operating & Maintaining the Alaris30 3-D Printer 11. Confirm that the heads are level and even by selecting the check box in the following wizard screen, and click Next. Figure 7-55: Installation-check screen 12. In the next wizard screen, select the check box to confirm that you have removed all tools and objects from the printer. Figure 7-56: Cleared-tray confirmation screen 13. Close the printer cover. The wizard continues by filling the heads, then heating and purging them.
Alaris30 User Guide Installation Problems If the printer detects that there is a problem after you install print heads, relevant warning screens appear. • If the print head you installed is not new—that is, it was previously removed from a printer—a message appears. Figure 7-57: Used print head message To continue with the installation of this print head, click Yes. To remove this print head and install a new one, click No.
Operating & Maintaining the Alaris30 3-D Printer • If the replacement head was not factory‐calibrated, the following warning screen appears. Figure 7-59: Invalid-data warning screen If this happens: a. Remove the head and replace it with another one. b. In the wizard screen, select the check box to confirm that you have installed another print head, and click Next. c. Contact your authorized Objet Customer Support center about the unformatted head.
Alaris30 User Guide Weight Calibration After the successful installation of print heads, the wizard begins the weight test, in which each head prints a sample. This test takes 15–25 minutes. Figure 7-61: Weight test progress screen 14. Carefully remove the samples for each head, keeping track of the head that printed them. Support Print Head Model Print Head Figure 7-62: Samples printed on the Alaris printer build tray 15.
Operating & Maintaining the Alaris30 3-D Printer After the Alaris printer calibrates itself, the last wizard screen appears. Figure 7-64: Final Head Replacement screen 17. After replacing print heads, you should check the head alignment before using the Alaris printer to produce models. • Select Yes and click Done to open the Head Alignment wizard (see “Aligning the Print Heads” on page 30). • Select No and click Done to align the heads at another time. 18. In the final wizard screen, click Done.
Alaris30 User Guide Calibrating the Load Cells Load cells are sensors that measure the weight of the printing cartridges and the waste container in the printer. It is important that you periodically check that the weight measurements are accurate, both for convenience and to prevent unnecessary waste of printing materials. It is recommended that you calibrate the load cells once a month, with the Load Cell Calibration wizard. To calibrate load cells: 1. Start the Load Cell Calibration wizard.
Operating & Maintaining the Alaris30 3-D Printer 4. In the next wizard screen, observe the numbers and wait until the level is relatively stable—two units above or below the average level shown. Figure 7-67: Load cell calibration screen 5. Select the Weight is stable check box, and click Next. If you need to calibrate more than one load cell, the next calibration screen appears. Repeat steps 4 and 5 until all of the load cells are calibrated. 6. Click Done in the final wizard screen.
Alaris30 User Guide Replacing the Odor Filter The Alaris30 printer has an activated‐carbon filter for removing odors from printing materials. The filter should be replaced regularly (about once a year, as necessary) to keep your working environment pleasant. This is normally done during the yearly preventive‐maintenance service visit. To replace the odor filter: 1. Locate the filter drawer at the rear of the printer and pull it open. Odor filter drawer Figure 7-69: Rear of the Alaris30 printer 2.
Operating & Maintaining the Alaris30 3-D Printer Replacing the UV Lamp The UV lamp used for curing models has a long, but limited, working life. The Objet service engineer tests its effectiveness during regular maintenance checks, and replaces it, if necessary. If, for any reason, you need to replace the UV lamp, follow these instructions: 1. Make sure the Alaris printer is in offline mode. Figure 7-71: Offline mode indicator (red) The online/offline button the printer interface should be red.
Alaris30 User Guide 4. Disconnect the UV lamp cable and the fan cable. UV-lamp connector UV-fan connector Figure 7-73: Disconnecting the UV lamp assembly 5. Loosen the two side screws securing the UV lamp assembly to the printer. Securing screws Figure 7-74: UV-lamp-assembly 6. Remove the assembly, and place it on a flat surface. DOC-24000 Rev.
Operating & Maintaining the Alaris30 3-D Printer 7. Loosen the screws securing the UV lamp cover and remove the cover. Cover screws Figure 7-75: UV-lamp-cover screws 8. Loosen the two screws securing the UV reflector. Reflector screws Figure 7‐76: UV‐reflector screws 9. Remove the UV reflector by raising it slightly, then pulling it out of the housing at an angle, from the bottom. Figure 7-77: Removing the UV reflector from the UV assembly 7–50 DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Alaris30 User Guide 10. Inspect the new lamp reflector, and make sure that a black strip is attached to the inside of it. If not, install one—on the side of the reflector opposite (not next to) the print block. Note: Extra black strips are included in the printer Start-up Kit. If necessary, you can remove the black strip from the old reflector and install it in the new reflector (as long as the black paint has not faded). 11. Discard the old reflector and lamp.
Operating & Maintaining the Alaris30 3-D Printer 18. In the wizard screen, confirm that you have replaced the lamp and that the black strip is attached, then click Next. Figure 7-80: Installation confirmation screen The wizard operates the lamp to test if it is installed correctly. If the lamp does not light, the wizard prompts you to check the power connections and to re‐install the lamp. Figure 7-81: Final wizard screen 7–52 DRAFT 4 - July 11, 2010 DOC-24000 Rev.
Alaris30 User Guide Replacing the Waste Container The waste container contains partially cured polymeric material produced during normal operation and maintenance of the Alaris printer. For safety and environmental reasons, this material is kept in a special leak‐proof, disposable container. The container has a capacity of two kilograms of waste material—usually enough for several weeks of printer use. The printer software displays a warning message when the container weighs 1.
Operating & Maintaining the Alaris30 3-D Printer To replace the waste container: 1. Open the materials drawer. 2. Remove the fireproof cover from the waste container. Figure 7-83: Removing the waste-container cover 3. Unscrew the cap securing the waste drain tube. 4. Carefully lift out the waste container to remove it from the printer. 5. Close the full container with a sealing cap. 6. Place the new waste container in the materials drawer, and attach the drain tube to it.
Alaris30 User Guide 8. Place the fireproof cover over the waste container, making sure that the drain tube is free and not bent. Figure 7-85: Fireproof cover installed over the waste container Note: Operating the printer without the waste-container cover results in an inaccurate measurement of the waste weight, which will cause waste to overflow into the printer. 9. Close the materials drawer. Dispose of the full waste container in accordance with environmental and safety requirements.
Operating & Maintaining the Alaris30 3-D Printer Backing-Up and Restoring Printer Settings Printer modes and configuration settings are stored in files on the printer computer. You can back up these files, and restore them, if necessary, using desktop icons. Figure 7-86: Backup and restore desktop icons ReInitiate Wizard 7–56 One of the wizards listed in the Options menu is ReInitiate. You normally do not have to run this wizard.
Handling Printed Models Removing Models After Printing...................................................... 2 Removing the Support Material........................................................ 2 Storing Models..................................................................................... 3 DOC-24000 Rev.
Handling Printed Models Removing Models After Printing After printing models, you should allow them to cool as much as possible before handling them. If additional models do not have to be produced on the Alaris printer, it is best to let the printed models cool in the printer, with the cover closed, as long as possible. If the Alaris printer must be used to produce additional models as soon as possible: 1. Let the printed models cool on the build tray for at least 10 minutes. 2.
Alaris30 User Guide Figure 8-1: Objet WaterJet Cleaning Unit To clean a model using this device, you place it in the chamber, and you manipulate it and the jet using the built‐in, waterproof sleeves. A pump turns ordinary tap water into a high‐pressure jet, and a wiper keeps the window clear. Use caution when cleaning delicate models with high-pressure water systems.
Handling Printed Models 8–4 DRAFT 4 - July 11, 2010 DOC-24000 Rev.
