3d Printer Z Corp Spectrum Z510 3d Printer
Using a Z-Corp Spectrum Z-510®
Solid Object (Binder Jet) 3D Printer with Z-Print and Z-Edit Software
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By the end of this lesson, you should be able to:
The purpose of this lesson is to guide yous through the use of the ZCorp Spectrum Z-510 Color Solid Object Printer (Rapid Prototyper.) Information technology is meant to accompany an actual demonstration on this device. Practice not attempt to use the device without this sit-in.
In this folio, Color Solid Object Printing (CSOP) is a term used by the manufacturer of this 3D printer to refer to how it functions. (That manufacturer was Z-Corporation, which has since been purchased by 3D Systems.) A newer term that seems more descriptive for this procedure is “binder jetting.” This refers to the cosmos of a physical object through an condiment manufacturing mechanism that uses binder on a layer of powder to fuse the powder, and and so fuses a second layer on top of the first. Actually,
need not exist in color.
Caution: Do Non Steal Another’southward Intellectual Holding.
The rapid prototypers in this lab may non be used to “steal” the intellectual backdrop of others. Please only build objects that are not the intellectual property of others, unless y’all have the possessor’s written permission.
A1.Eye protection is required at all times by yous and anyone most you as y’all are working on this, including when yous are removing the model, depowdering it, and infiltrating it.
A2. If you wish, yous may wear protective gloves or a dust mask to minimize your contact with the pulverisation and binder chemicals.
A3. When you work with the pulverisation, please do so in a fashion that does non raise much dust.
A4. When y’all are done working with powder, be certain to accident your nose and launder your hands.
A5. Hot wax can be used to glaze models, only it can cause burns if you are non careful.
A6. Cyanoacrylate can exist unsafe; avoid pare contact or breathing fumes.
A7. None of the models produces on this device will always be “food-safe,” and therefore they must not be used for eating or drinking vessels or implements, nor should they be given to immature children who might put them, or pieces of them, into their mouths.
B. Get the
Apply Assignments, References, & Resource
B1. Please refer to references equally needed. These might include reference manuals for using the ZCorp Spectrum Z510 color solid object printer, ZPrint software, ZEdit software, solid object modeling software, and class assignments.
Create and Bank check an Object File
B2. Please use a computer that is not connected to the Z510 rapid prototyper to create a 3D object file. You lot may use solid object cosmos software such as Rhinoceros (pictured below), 3DS Max, AutoCAD, Lightwave, Maya, Google Sketchup, and Unigraphics, to proper noun a few. A digitizer can also be used to capture the surface geometry of an object in paw. However, exist sure your models do not violate copyright and trademark rights. In add-on, endeavour to create files that identify actual (closed) solids.
B3. If at that place are surfaces evident that do not seem to exist part of the solid, you lot may need to edit the object. You need a “watertight” model that is acceptable for 3D press.
B4. You will need to consign the file in an a format that can be read by the ZPrint software that communicates with the Z510. Rhinoceros has a built-in feature directly sending an object from Rhino to ZPrint; click File, Print 3D in Rhino. But since you are likely working on some estimator other than the ane that controls the Z510, consign your file in one of the post-obit formats (realizing that coloring may not exist preserved. In some instances, you would have mapped a graphic onto the surface of an object, merely that graphic might not show in ZPrint; one solution is to make sure the graphic file is in the same directory as your 3D object file. Another is to use ZEdit or ZEdit Pro to exercise the mapping.
ZPrint Import File Types:
.stl .ply .zcp .zpr .sfx .wrl .3ds
(For stl files, employ “binary” rather than “ASCII.”)
Load the File
B5. Transfer the digital object file you created elsewhere to the difficult drive of the computer decision-making the Z510. In that location should be a directory for your grade under D:\Classes\. Please make sure the filename is rather brusque and begins with your last name, and that it does not comprise any non-alphanumeric characters except an underscore, hyphen, or period.
B6. Open ZPrint. Load your file. Brand sure the correct pulverisation is selected.
The powder in the Z510 is zp151
and so change that setting if necessary in the pull downwards box (shown beneath). The units should be the correct ones for this site, given its size. You tin scale the object later.
Color the Part in ZEdit
B7. You lot can add color, colored text or graphic image maps to your digital object prior to prototyping it. To practice this, begin with your object selected in ZPrint (y’all’ll see a box around it indicating it is selected.) Start ZEdit past clicking Edit, Start ZEdit.
The reckoner controlling the Spectrum Z-510 has a licensed copy of Z-Edit Pro, which has many more features than the standard Z-Edit program. If no one is waiting to use that estimator, then utilise Z-Edit Pro with it. Otherwise, just utilize Z-Edit.
B8. Apply ZEdit to map a graphic image onto your file, to add text, or to change the color of a feature.
When using ZEdit, it might help to select the appropriate view. Yous tin also change the zoom level. Click on the foreground or background color to change information technology. Nether the “Edit and Annotate” title you’ll find icons to Select, Paint, Utilize Text, and Apply a Texture Map (i.east., map a graphic onto the object.) In the image below, the front view was showtime selected, and a yellow-brick map was practical with the map completely covering the size of the object.
B9. Return to ZPrint. You tin can either save the edited part first in ZEdit, or click File, Exit, and you will exist prompted if y’all want to update the part in ZPrint.
Scale and Orient the Object
B10. Back in ZPrint, If you run into odd coloring on the object, do not be alarmed. You should scale, rotate, and move the object, equally needed. Find these under the Transform menu item. Begin by Scaling your object to the appropriate size.
B11. Rotating tin can sometimes decrease build time, since it is the pinnacle of the overall build that determines the number of build layers.
B12. To move your object, you lot tin “Translate” information technology. However, if this is the only object to exist built, it is recommended that you use the “Justify” command and place your object at the Left, Back, Lesser of the build expanse.
B13. Click File, Save As and save the zpd file y’all are about to use. Please begin the filename with your last name, and identify it into the appropriate directory on the reckoner that controls the Z510.
Approximate the Build Time and Materials
B14. The actual amount of materials used in a build is only accurately determined subsequently the build, by looking for the advisable file under “C:/ZCorp Printer Records/Detailed Reports/ on the computer that controls the motorcar. Yet, y’all can and should estimated the amount of time, binder, and powder to be used prior to executing a job, and then afterward the job, locate that file to make up one’s mind the actual amounts used. To estimate the amount of fourth dimension and binder used, click File, Print Time Estimator. Note also the amount of colored and articulate binder estimated for this task. Finally, brand a note of the volume of the build. This is the powder volume.
B15. Toll out the apply of folder and pulverisation using the following factors; the costs listed for folder and pulverization are the ones charged by ZCorp (notation that at that place are virtually 16.387 cubic centimeters per cubic inch):
- Multiply the volume in cubic inches by $ 1.59 (because nosotros purchase it for $1,110 per 700 cu in)
- or the vol in cubic cm by $.10 (because we purchase information technology for $one,110 per eleven,500 cc)
- Multiply the ml of clear binder by $ 0.20 (considering nosotros purchase it for $772 per 3.8L)
- Multiply the ml of colored binder past $ 0.33 (because we buy information technology for $624 per 1.9L)
- Multiply the ounces of cyanoacrylate by $5.00 (because we purchase it for $fourscore per pint)
- Add the products.
By adding these iv numbers, you can make up one’s mind the raw cost of the powder, binders, and infiltrant, combined. These are the actual costs of these materials. However, due to the loss of materials, the costs of wash fluid, print heads, and other materials, the estimated product materials cost is greater.
The role called BallB, above, would utilize 99.8 ml of colored binder, 89 ml of clear binder, and 231.43 cubic centimeters of pulverisation. Assuming that an ounce of cyanoacrylate is also used, the cost comes to $78.88, not counting launder fluid, print heads, etc.
When you reduce the volume of an object to be built, the percent reduction is typically linear. That means that if yous reduce the volume to 25% or one/four, then you lot are reducing it in each of the 3 dimensions. A 4″ cube would be reduced to a 1″ cube. In a 4″ cube, there are 4x4x4 cubic inches, or 64 cubic inches. Thus, you would be reducing the volume to 1/64th
of the original, which is one / (ivthree) or 25%3. Even a small reduction in linear book can seem like a sizable reduction in book.
However, it is possible to reduce build book as well much, to the point where features are not distinct or where the objects lacks sufficient structural integrity. In these instances the build would be considered a failure, and all materials would exist a loss. Then decide wisely.
Too often, objects are designed every bit solid when they might have as easily been designed hollow. If you hollow out the interior of an object, be sure to include a hole through which the loose pulverisation can be
the Spectrum Z-510
Cleaning the Service Station
C1. Make sure the Z510 is set to Online.
C2. In ZPrint, select Service, Unpark.
C3. Slowly open the cover of the Z510 and so as to avert jostling the binder too much.
C4. Move the impress heads frontwards and left to betrayal the docking station.
C5. Apply distilled water and a towel to clean the stainless steel “spit plate” and dry out it.
C6. Employ distilled water and a towel and the safety parking caps and and then dry them.
C7. Utilize the specialized needle to make sure all six spray holes under the condom wiper are clear.
C8. On the computer, click that it is “okay to repark the heads.”
Preparing the Powder
C9. With the Z510 offline, lower the feed chamber and place the fine sifter into it.
C10. Using the fine sifter and trowel, place powder from the build chamber into the
feed bedchamber. Discard any lumps or colored bits. In that location should exist about one-quarter to ane-one-half inch of powder remaining in the build chamber.
C11. Remove the overflow bin and gently
place the powder through the fine sifter into the feed chamber. Place the cover back on the overflow bin and put it back into its slot.
C12. Scoop up the loose, clean powder from effectually the chambers into the sifter and down into the feed bedchamber. If you noticed any contaminates in either bedroom, remove them. Dust the sifter off and put it away.
C13. Remove the tamper from the door of the Z510. Press it downwardly onto the pulverization in the feed chamber. Movement it around a little, and press downward over again, rather hard, to compact the powder. Dump off the powder from the tamper into the feed chamber and put the tamper abroad.
C14. If you are concerned there might not be enough powder for your build, measure the powder in the feed chamber now with the dipstick.
C15. Raise the feed and build chambers, as needed, and use the screed to level off the pulverisation on both chambers. Remove the excess powder from the screed and put it abroad.
C16. Take a paper towel and neatly fold it in one-half, and then in half over again, so it covers the four fingers of your palm. Spray a few milliliters of isoprpyl booze onto the paper towel. Then pull the printhead nearer to y’all and wipe the bottom of all four printheads at the same time with the paper towel in your right hand, so that each of your 4 fingers exerts gentle force per unit area up through the moist paper towel confronting the printhead. When you lot pull it abroad, you should see areas where the cyan, magenta, and yellow binders bled onto the paper towel. If you did not, endeavor this once again.
C17. Close the Z510 hat.
Press the Spread push
on the Z510. The moves the heads and spreader to the left. Press it again, and the chamber heights adjust before the spreader moves to the right. If no powder was spread, it is because the chambers were too low. Try again: press Spread to move the spreader to the left. At present heighten both chambers until the powder in each looks similar information technology is most at the top of the sleeping room, and press Spread. Repeat this until the powder in each chamber is smooth and flat on top.
When you used the straightedge as a screed in Footstep C15, you leveled the powder, but did non bring information technology upwards to the proper pinnacle to begin the job.
Yous must also employ the Spread button as noted in Stride C17 until the feed and build chambers are both smoothen on top.
Failing to do this will likely upshot in a build that is missing its bottom layers.
C18. Cheque the levels of the waste fluid jug and wash fluid jug through the slots in the front end lower door. If you can’t see, open the front door (not the lid). Check to make certain at that place is sufficient clear launder fluid in the wash fluid container. Make certain there is sufficient room in the waste fluid container. Close the front door.
C19 Place the Z510 dorsum online.
D. Commencement the
D1. In ZPrint, select File, 3D Print. The software asks you if yous take completed some of the steps, above, so signal that you have. You should so see a screen that gives you lot the status for the build. If the temperature is too low, yous might have to wait for the build to start.
D2. On the machine log canvass, delight note the information related to this build. Indicate when y’all plan to return to remove your part. Delight realize that the person who starts the build should be the same one who removes the part, and that if your part is sitting in the machine when someone else needs to use it, yous are being a machine hog. There is besides a danger of your part getting broken if it is removed by someone who does not know what to expect when removing a part.
D3. Notice the first few layers. If there is an mistake, you should abort the job. Notwithstanding, it is essential that whatever contaminated powder is placed into the trash, rather than into the feed chamber.
E. Permit the Office to
for 1 Hour Prior to Removal.
When the build has finished, please realize that it is recommended the part dries (and strengthens) for an additional 60 minutes prior to removal.
E1. As if it were a delicate dinosaur bone, excavate your office from the build chamber. Identify the powder into the sifter in the feed chamber, and use dry out paintbrush to brush away the powder from near your object,
but exercise non actually let the castor touch the object. Carefully lift your object from the build chamber and dump out as much powder as you tin can without damaging your part. Place information technology on a clean, dry deli tray.
At the end of every chore, the post-obit should be done:
F1. Use the sifter and carefully identify the powder from the overflow bin into the feed chamber.
F2. Use the sifter and place all but 1/4″ of pulverization from the build chamber back into the feed chamber.
F3. Use brushes and spatulas to identify any powder inside the machine around the chambers dorsum into the feed bedroom.
F4.Tamp the powder in the feed chamber.
F5. Screed both the build sleeping room and the feed bedroom, but exercise non execute a spread. We volition all know that the feed chamber is empty and has 1/4″ of powder if we see the top has been screeded but not spread. Yet, if we see a smooth surface that has been spread, nosotros do not know if at that place is a model in the build chamber or how much powder is in that location.
F6. Use the special vacuum under the depowdering unit of measurement to clean upwardly any additional powder that is not in the chambers. Please note that this vacuum is to exist used only for clean powder. If the vacuum suction seems low, report this to a lab supervisor.
F7. Make certain your entry on the machine log is accurate and complete
Yard. Make up one’s mind and
Out the Actual Fabric Usage
G1. After the build job has finished, download the advisable txt file from the command figurer’southward directory: C:\ZCorp Printer Records\Detailed Reports\. In the example beneath, you will notice that I’ve highlighted in red where to find the amount of pulverisation (3.47 cubic inches), the amount of articulate binder (47.2559 ml), and the amounts of yellowish (25.6021 ml), magenta (25.5181 ml), and cyan (25.4586 ml) binders actually consumed.
Version: Version 7.10.3 – 7
Path: C:\ZPrint Samples\Nefertiti.zpr
Model: Nefertiti.zpr three.52 5.00 two.45 66.37
Estimation: 2 hours 23 mins
Started: 10/15/21 01:39 PM
Firmware Version: 3.210
Bleed Compensation OFF
Start layer: 0
Cease layer: 612
Full number of layers: 613
Printer: 192.168.1.2 : Spectrum 510
Base Pulverisation: ZP151
Powder Type: ZP151
Shell Saturation: 100% Binder/Book: 0.234
Core Saturation: 100% Binder/Volume: 0.117
Waste Available get-go: 0 mL
Final printed layer: 613
Binder usage for this job: 120.3 mL
Clear Binder usage:
4.seven % ( 2487340544 drops )
Yellow Folder usage:
2.half-dozen % ( 1347481088 drops )
Magenta Binder usage:
2.vi % ( 1343057408 drops )
Cyan Binder usage:
2.v % ( 1339928064 drops )
Waste product Available finish: 0 mL
Finished: 10/15/21 03:53 PM
Duration: two hours 13 mins
G2. Just as you did for the guess, cost out the actual use of binder and powder using the following factors (actual replacement cost values):
- Multiply the volume in cubic inches past $ 1.59
- or the vol in cubic cm by $.10
- Multiply the ml of articulate binder by $ 0.20
- Multiply the ml of colored folder by $ 0.33
- Multiply the ounces of cyanoacrylate by $5.00
- Add together the products
This is illustrated for the example in the tabular array below. Annotation that there are two figures. In a study, the entire tabular array shown beneath would be reported. Please see the instructor or lab supervisor to determine the actual charge to you, if any.
the Part and let it Finish Curing
H1. Make sure the vacuum is connected to the dorsum of the de-powdering unit.
H2. Remove everything from the meridian bedroom of the de-powdering unit and place your part on the tray into it. Shut the door.
Consider removing your lookout man so information technology does not get pulverisation in it.
H3. Attach the air castor to its hose.
H4. Inside the lower door, plough on the air compressor and the vacuum.
H5. Place your easily through the holes, and very gently accident the pulverisation out of your part. Do not intermission your function; the air pressure can sometimes exist strong enough to do this.
H6. When you are washed, blow the remaining of the powder downward the vacuum hole in the back left of the unit using the air brush.
H7. Plough off the vacuum and compressor. Replace the air brush into its container, and identify it dorsum into the de-powdering unit of measurement.
H8. Let the depowdered role to sit for 24 to 48 hours so that the powder and h2o in the part will continue to chemically combine (i.e., hydroset.)
H9. Place the part into the laboratory oven at 60�C overnight to drive off remaining water within the model and then that there will be more airspace that the infiltrate can occupy.
Infiltration is a finishing operation where a liquid is captivated in the surface of the part to increase its strength, hardness, durability, and color contrast. You tin can air dry the part, or dry information technology at 102 C in the laboratory oven until it stops losing mass. It is also possible to infiltrate the role without this extra drying, though that is not recommended.
Ever wear safety glasses when infiltrating parts. Take precautions to avoid burns with hot wax. Do not let cyanoacrylate to contact peel.
I1. Infiltrate the part and allow information technology dry. Do not allow it to become adhered to a workbench, work-surface, paper, or anything else, as you volition probable break your role removing information technology.
: Uncolored (white) objects may be infiltrated with a fine mist water spray, with a 2d or third application afterward about 10 minutes that become areas missed by the first application. Parts can likewise exist dipped in water. The surface will be rather rough, and if you tried this with a colored part, the color would run. Merely this is a fast technique, and has the lowest cost.
Epsom Salts Solution
: A solution of Magnesium Sulfate can be used to infiltrate parts that are colored. Application is with a fine spray, every bit mentioned above, for water. In that location is a little running of color, just not much, and parts are a fleck harder than prior to infiltration. They tend to be somewhat crude.
: Dipping in melted paraffin is some other method of infiltrating parts. This brings out the color without running, and makes a smooth surface. Part strength is moderate. Earlier heating the wax, be sure to drill relief holes.
: Also known as “super glue,” cyanoacrylate is a dangerous adhesive that imparts relative high strength to colored or white parts. Awarding is difficult, however, and tin can include dribbling or dipping. Some formulations of cyanoacrylate are quite volatile, and the fumes emitted can irritate the eyes and animate passages. This is likewise a very expensive infiltrant, with 16 fluid ounces costing $187.00. To apply cyanoacrylate, wear gloves and safe glasses. You can either carefully distill drops onto the object over the specially prepared platform for doing this, or immerse the object into a bathroom of cyanoacrylate. Please be very careful when pouring the infiltrant, dipping objects into it, and pouring it dorsum through a funnel into its containers.
: Other materials can be used as infiltrants. Epoxy is used in industry, though existence an “A B Organization,” whatever is mixed sets very presently and cannot be used later. Others have tried Minwax Woods Hardener, pigment, and a multifariousness of finishes and adhesives.
Appendix: Instructions and Notes for Laboratory Staff
S1. This machine is for use but by students assigned to classes in the AT 141 Rapid Prototyping Lab who were assigned by their instructors to use the Z510. If anyone else requests to use it, have them contact the lab administrator.
S2. Make certain the model is appropriate for this auto. If the features are too fine for the model to be handled without breaking, do not permit the user to build the model.
S3. At the beginning of every build, make sure the user cleans the spit plate, gently clears the half-dozen holes for washing the heads and cleans the surrounding rubber gasket, and cleans and the rubber parking station. Water is used for these, but it is very important that they are left very dry, since this powder would cling to any moisture on these surfaces and turn to a solid mass.
S4. For all-time results, I recommend taking a small slice of paper toweling and using alcohol to gently rub the four printheads, making sure that the three colored binders flowed a fleck in the procedure.
S5. Brand certain the user does not exceed the maximum size (price) of a build.
S6. Have the user fill out the machine log. Here, it is very of import that the user identifies precisely when they will return to remove their object, as it volition be in the mode of others who want to use the motorcar.
S7. Insist that after every build, the user empties the pulverisation from both the overflow bin and the build chamber into the feed sleeping accommodation using the sifter.
S8. Insist that when they are washed, a user leaves the machine with 1/4″ of powder in the feed chamber, and with both chambers screeded off using the straightedge. Exercise non accept them “spread” the bed considering this volition go far look as if there is a build in the bed.
S9. During times of heavy employ, clean machine well once each week. At the end of this, empty the powder from the vacuum under the depowdering station dorsum into the feed bedroom through the sifter.
S10. Record all errors and issues in the Staff sheet in the 3-band binder.
S11. Please clean this car, the area, and the computer workstation regularly. The pulverisation, binder, and infiltrants are all messy.
S12. If in that location is a printhead overtemp error message, endeavor to ready it by trying each of these in lodge: ane. clean the printhead with booze; 2. immerse the printhead in common cold, running water for a infinitesimal; three. use the printhead purge fixture and syringe, immersing the entire printhead in a container of cold water every bit you use the syringe to suck out the clog and a few ml of binder, which will be replaced with cold h2o. For this last step, it might assist to fill up the top of the syringe with h2o as well.