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Spectrum z510 3d printer


spectrum z510 software problems - 3D Printers - Talk Manufacturing

CharlesRiverMkr

#1

I recently acquired a z510 and have finally gotten it all cleaned up and unclogged.

I’ve done a few prints with it but more often than not, when I tell zprint to print, windows stops the program and tells me there is a problem.

I’m running zprint 7.10 that I downloaded. I’m not sure if it’s a problem with the program or another problem.

I have tried it on various machines with similar results. I’ve tried it on Windows 10 & XP

on actual machines and in virtualization.

Has anyone experienced this? Does anyone know where I could get another copy of the zprint software to try?

Thanks!

designanything3

#2

3D systems has the software on their site. I am using 7.10 on a windrows 7 and xp machine. Try dl the software from 3D systems and try to reinstall

CharlesRiverMkr

#3

Thanks. I found it on their site. I had to search for it. It isn’t listed there anymore.

i think the problem was related to trying to use custom powders. I think it’s crashing when I try to set the saturation to high.

Move had a few successful prints in the last couple days.

Running on xp though. I think I’ll try to switch back to a modern OS next.

Thanks!

designanything3

#4

It will defiantly crash if you have edited the build recipe incorrectly. Try to make sure that is deeres and then reinstall. That has happened to me when I was trying to get tricky.

CharlesRiverMkr

#5

I wasn’t even editing the recipes directly, I was just deriving a powder from a stock one and increasing the binder percentage.

I turns out I didn’t need to, hydroperm is printing well at pretty normal saturation levels.

Thanks!

jan3dp

#6

Hi Charles, I have zPrint 7.10.3 install files if you need it, I can sendt it to you. We have used this version thru the whole progress from XP - to 7 and now Win10.

I bougth a Z-510 Spectrum new in 2006, but its been parked the last year. Mostly print plugs and molds with it, and when I now started it up to print some sand moulds it failes booting.

My problem occurred to be an error coming up at booting saying comm error on headcard, flags = 1f , but in the boot sequence it stops and says 0601 Diskette Error . (I have hooked up av vga screen and a keyboard to the machine)

After buying and installing a complete new headcard from 3DS, it still stops with the same error.

Thing is, I think the “hard drive” could be damaged, or the boot file corrupted. The hard drive on this machines are a 40 pin IDE flash of massively 32MB

I can not find any of my former contacts from z-corp, and a reply from 3DS about a fresh boot file or a new IDE flash with boot config have not shown up.

I have now ordered in an “of the shelf” 40 pin IDE 32MB flash unit, and was hoping that some one could be willing to copy the file from their 40pin IDE flash on a working machine, and share the file with me…

Jan

CharlesRiverMkr

#7

Hello,

thanks for the offer. I found the software on the 3ds website.

I would be happy to image the drive and send the file to you. I have been meaning to make a backup of it anyway.

I should be able to do it tomorrow.

You can email me at [email protected]

designanything3

#8

I would love to get a copy too if possible. I can give you my ftp info so we can share with other 510 users. It would be great to keep in contact with you both. It’s great to meet other 510 users. I would love to share info, material recipes etc and finishing processes that work well.

[email protected]

jan3dp

#9

Cheers Charles ! Splendid

Things have been busy, but when I have a mirror of your flash disc I will use time to get the 510 up to speed again

Sent you an email for the file transfer.

Jan

CharlesRiverMkr

#10

It’s great to have some other 510 users to talk to. I might have to set up a new Wiki with recipe info. I’m having good success with homemade binder right now and hydroperm and am hoping to try a few new powder recipes.

I’ll try to image the boot drive today.

designanything3

#11

That would be great. I just purchased some hydroperm and hydrostone. Would love to hear what is working. I also purchased melodextrin and some other things. I didn’t find a good source for pva powder as an option to try. What binder are you using?

CharlesRiverMkr

#12

The binder I’m currently using is this:

Minus the potassium sulfate & proxel gxl as I didn’t have those ingredients at the time.

Distilled Water: 93.45% volume (3537 ml)’
**’**Surfynol 465: 0.5% volume (18.92 ml)’
**’**Glycerol: 6% volume (227.12 ml)’
**’**Potassium Sulfate: 0.2% weight (7.5 mg)’
**’**Proxel GXL: 0.05% volume (1.89 ml)

It seems like the potassium sulfate is there as an accelerant for the plaster. The proxel GXL is an antimicrobial.

I purchased the surfynol (2,4,7,9-TETRAMETHYL-5-DECYNE-4,7-DIOL ET) from Sigma-Aldrich.

I have some dry clay on the way and I have some maltodextrin and PVA powder. I think my first attempt will be with sugar instead of PVA though as it’s cheaper and it only needs to hold together until it’s fired.

I got replacement printheads from here: https://www.discountinkllc.com/products/hp-11-black-print-head?variant=9816827653

They aren’t genuine HP heads but they seem to be working fine for now and they are certainly cheaper.

I’ve also been playing with trying to revive the heads that came in the machine but cleaning them in an ultrasonic cleaner and flushing some binder through them with a kit from ink owl (http://www.inkowl.com/index.php?p=product&q=hp+11&product=5668)

CharlesRiverMkr

#13

I didn’t think it would be such a pain to image this drive, I don’t have much equipment around anymore for IDE drives.

The one computer I could plug it in to isn’t recognizing it correctly once it boots to linux.

I think I’ll try to grab an IDE->SATA adapter tonight to give a try.

designanything3

#14

Was the surfynol a pain to order? I just tried to register but they want an existing sigma… Act.

CharlesRiverMkr

#15

It wasn’t too difficult. I think I just had to set up a new account and give them my EIN. So, if you don’t have an EIN, they might not be too helpful. They also warned me that they wouldn’t be able to ship hazardous materials to my home address, luckily, the surfactant wasn’t hazardous.

I did also run a water/alcohol binder with a tiny bit of dishwashing soap in it, it seemed to work ok but I think the straight water binder works better with the hydroperm.

designanything3

#16

Hey Jan

to to get rid of the diskette error you need to boot to the bios setup. I think it’s the delete key. It should say it on the screen during boot. Then to disable go to the boot options and go down to floppy drive and disable it. Then it won’t check for it any more and should boot past that.

designanything3

#17

So I think I found a source for pva thats a bit cheaper… they want to have me order about 88 pounds cost is just under 10 delivered. It is 1788 grade and about 300 mesh they said

DisFanJen

#18

Wow!

I finally found some people talking about the Z510.

Anyhoo, sorry to send this off on a bit of a tangent but as there’s already a captive audience of 510 users.

I’m trying to revive our school’s Z510 and have hit a stumbling block. It boots, and seems ok, I can send a job to it but then it randomly throws an overheat error on either head 2 or 3.

I’ve replaced the heads for both of these but no luck.

Not sure if there’s anything else I can do and there is zero budget for repairs (like I said, school, we got the thing when our budget was flush a few years ago but even then they bought it 2nd hand).

So any ideas, hacks, etc? I’d really like to get this going again.

designanything3

#19

A few things to try and figure out the source of the problem… Old or contaminated binder can be a source of overheating heads. Flush the lines and leave bleached water in them overnight. Make sure the filters are clean and you can pull fluid easily through the lines. If it’s hard to pull that can cause heads to go out also.

Clean the shiz out of the pogo pins with alcohol and make sure the ribbon cable is seated well. Are you using oem heads or knockoff?

CharlesRiverMkr

#20

My machine had lots of dried up binder in the lines. I pulled a lot of clean distilled water through until it ran mostly clear. I also ended up blowing the lines out with compressed air at the connector inside the printer. There was a lot of gunk.

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Using a Z-Corp Spectrum Z-510 Solid Object (Binder Jet) Printer with Z-Print and Z-Edit Software

Using a Z-Corp Spectrum Z-510® Solid Object (Binder Jet) 3D Printer with Z-Print and Z-Edit Software

This page was updated on 10/26/2021 and is located at: techweb. bsu.edu/jcflowers1/rlo/z510.htm
Objectives:

By the end of this lesson, you should be able to:

1. Safely use the Z-Corp Z-510 rapid prototyper and software to create product prototypes.

2. Determine the estimated and actual materials cost for a model built with the Z-510 prototyper.

 

Introduction

The purpose of this lesson is to guide you through the use of the ZCorp Spectrum Z-510 Color Solid Object Printer (Rapid Prototyper.) It is meant to accompany an actual demonstration on this device. Do not attempt to use the device without this demonstration.

In this page, 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 process is "binder jetting." This refers to the creation of a physical object through an additive manufacturing mechanism that uses binder on a layer of powder to fuse the powder, and then fuses a second layer on top of the first. Actually, binder jetting (Barnatt, n.d.) need not be in color.

Caution: Do Not Steal Another's Intellectual Property.

The rapid prototypers in this lab may not be used to "steal" the intellectual properties of others. Please only build objects that are not the intellectual property of others, unless you have the owner's written permission.

A. Safety

A1. Eye protection is required at all times by you and anyone near you as you are working on this, including when you are removing the model, depowdering it, and infiltrating it.

A2. If you wish, you may wear protective gloves or a dust mask to minimize your contact with the powder and binder chemicals.

A3. When you work with the powder, please do so in a way that does not raise much dust.

A4. When you are done working with powder, be sure to blow your nose and wash your hands.

A5. Hot wax can be used to coat models, but it can cause burns if you are not careful.

A6. Cyanoacrylate can be dangerous; avoid skin contact or breathing fumes.

A7. None of the models produces on this device will ever be "food-safe," and therefore they must not be used for eating or drinking vessels or implements, nor should they be given to young children who might put them, or pieces of them, into their mouths.

B. Get the File Ready

Use Assignments, References, & Resources

B1. Please refer to references as 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 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 may use solid object creation software such as Rhinoceros (pictured below), 3DS Max, AutoCAD, Lightwave, Maya, Google Sketchup, and Unigraphics, to name a few. A digitizer can also be used to capture the surface geometry of an object in hand. However, be sure your models do not violate copyright and trademark rights. In addition, try to create files that identify actual (closed) solids.

B3. If there are surfaces evident that do not seem to be part of the solid, you may need to edit the object. You need a "watertight" model that is acceptable for 3D printing.

B4. You will need to export 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 computer other than the one that controls the Z510, export your file in one of the following formats (realizing that coloring may not be preserved. In some instances, you would have mapped a graphic onto the surface of an object, but 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 do the mapping.

ZPrint Import File Types: .stl .ply .zcp .zpr .sfx .wrl .3ds

(For stl files, use "binary" rather than "ASCII.")

Load the File

B5. Transfer the digital object file you created elsewhere to the hard drive of the computer controlling the Z510. There should be a directory for your class under D:\Classes\. Please make sure the filename is rather short and begins with your last name, and that it does not contain any non-alphanumeric characters except an underscore, hyphen, or period.

B6. Open ZPrint. Load your file. Make sure the correct powder is selected. The powder in the Z510 is zp151 so change that setting if necessary in the pull down box (shown below). The units should be the correct ones for this site, given its size. You can scale the object later.

Color the Part in ZEdit

B7. You can add color, colored text or graphic image maps to your digital object prior to prototyping it. To do this, begin with your object selected in ZPrint (you'll see a box around it indicating it is selected.) Start ZEdit by clicking Edit, Start ZEdit.

Note

The computer 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 computer, then use Z-Edit Pro with it. Otherwise, just use Z-Edit.

B8. Use 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. You can also change the zoom level. Click on the foreground or background color to change it. Under the "Edit and Annotate" title you'll find icons to Select, Paint, Apply Text, and Apply a Texture Map (i. e., map a graphic onto the object.) In the image below, the front view was first selected, and a yellow-brick map was applied with the map completely covering the size of the object.

B9. Return to ZPrint. You can either save the edited part first in ZEdit, or click File, Exit, and you will be prompted if you want to update the part in ZPrint.

Scale and Orient the Object

B10. Back in ZPrint, If you see odd coloring on the object, do not be alarmed. You should scale, rotate, and move the object, as needed. Find these under the Transform menu item. Begin by Scaling your object to the appropriate size.

B11. Rotating can sometimes decrease build time, since it is the height of the overall build that determines the number of build layers.

B12. To move your object, you can "Translate" it. However, if this is the only object to be built, it is recommended that you use the "Justify" command and place your object at the Left, Back, Bottom of the build area.

B13. Click File, Save As and save the zpd file you are about to use. Please begin the filename with your last name, and place it into the appropriate directory on the computer that controls the Z510.

Estimate the Build Time and Materials Cost

B14. The actual amount of materials used in a build is only accurately determined after the build, by looking for the appropriate file under "C:/ZCorp Printer Records/Detailed Reports/ on the computer that controls the machine. However, you can and should estimated the amount of time, binder, and powder to be used prior to executing a job, and then after the job, locate that file to determine the actual amounts used. To estimate the amount of time and binder used, click File, Print Time Estimator. Note also the amount of colored and clear binder estimated for this job. Finally, make a note of the volume of the build. This is the powder volume.

B15. Cost out the use of binder and powder using the following factors; the costs listed for binder and powder are the ones charged by ZCorp (note that there are about 16.387 cubic centimeters per cubic inch):

  • Multiply the volume in cubic inches by $ 1.59 (because we purchase it for $1,110 per 700 cu in)
    • or the vol in cubic cm by $.10 (because we purchase it for $1,110 per 11,500 cc)
  • Multiply the ml of clear binder by $ 0.20 (because we purchase it for $772 per 3.8L)
  • Multiply the ml of colored binder by $ 0.33 (because we purchase it for $624 per 1.9L)
  • Multiply the ounces of cyanoacrylate by $5.00 (because we purchase it for $80 per pint)
  • Add the products.

By adding these four numbers, you can determine 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 part called BallB, above, would use 99.8 ml of colored binder, 89 ml of clear binder, and 231.43 cubic centimeters of powder. Assuming that an ounce of cyanoacrylate is also used, the cost comes to $78.88, not counting wash fluid, print heads, etc.

Note

When you reduce the volume of an object to be built, the percent reduction is typically linear. That means that if you reduce the volume to 25% or 1/4, then you are reducing it in each of the three 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 1 / (43) or 25%3. Even a small reduction in linear volume can seem like a sizable reduction in volume.

However, it is possible to reduce build volume too 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 be a loss. So decide wisely.

Too often, objects are designed as 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 powder can be emptied.

C. Prepare 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 so as to avoid jostling the binder too much.

C4. Move the print heads forward and left to expose the docking station.

C5. Use distilled water and a towel to clean the stainless steel "spit plate" and dry it.

C6. Use distilled water and a towel and the rubber parking caps and then dry them.

C7. Use the specialized needle to make sure all six spray holes under the rubber 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 chamber. Discard any lumps or colored bits. There should be about one-quarter to 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 around the chambers into the sifter and down into the feed chamber. If you noticed any contaminates in either chamber, remove them. Dust the sifter off and put it away.

C13. Remove the tamper from the door of the Z510. Press it down onto the powder in the feed chamber. Move it around a little, and press down again, rather hard, to compact the powder. Dump off the powder from the tamper into the feed chamber and put the tamper away.

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 powder on both chambers. Remove the excess powder from the screed and put it away.

C16. Take a paper towel and neatly fold it in half, then in half again, so it covers the four fingers of your palm. Spray a few milliliters of isoprpyl alcohol onto the paper towel. Then pull the printhead nearer to you 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 four fingers exerts gentle pressure up through the moist paper towel against the printhead. When you pull it away, you should see areas where the cyan, magenta, and yellow binders bled onto the paper towel. If you did not, try this again.

C17. Close the Z510 lid. Press the Spread button 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. Now raise both chambers until the powder in each looks like it is nearly at the top of the chamber, and press Spread. Repeat this until the powder in each chamber is smooth and flat on top.

Note

When you used the straightedge as a screed in Step C15, you leveled the powder, but did not bring it up to the proper height to begin the job. You must also use the Spread button as noted in Step C17 until the feed and build chambers are both smooth on top. Failing to do this will likely result in a build that is missing its bottom layers.

C18. Check the levels of the waste fluid jug and wash fluid jug through the slots in the front lower door. If you can't see, open the front door (not the lid). Check to make sure there is sufficient clear wash fluid in the wash fluid container. Make sure there is sufficient room in the waste fluid container. Close the front door.

C19 Place the Z510 back online.

D. Start the Build

D1. In ZPrint, select File, 3D Print. The software asks you if you have completed some of the steps, above, so indicate that you have. You should then see a screen that gives you the status for the build. If the temperature is too low, you might have to wait for the build to start.

D2. On the machine log sheet, please note the information related to this build. Indicate when you plan to return to remove your part. Please 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, you are being a machine hog. There is also 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. Observe the first few layers. If there is an error, you should abort the job. However, it is essential that any contaminated powder is placed into the trash, rather than into the feed chamber.

E. Allow the Part to Dry 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 part from the build chamber. Place the powder into the sifter in the feed chamber, and use dry paintbrush to brush away the powder from near your object, but do not actually let the brush touch the object. Carefully lift your object from the build chamber and dump out as much powder as you can without damaging your part. Place it on a clean, dry cafeteria tray.

F. Clean up

At the end of every job, the following should be done:

F1. Use the sifter and carefully place the powder from the overflow bin into the feed chamber.

F2. Use the sifter and place all but 1/4" of powder from the build chamber back into the feed chamber.

F3. Use brushes and spatulas to place any powder inside the machine around the chambers back into the feed chamber.

F4.Tamp the powder in the feed chamber.

F5. Screed both the build chamber and the feed chamber, but do not execute a spread. We will 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. However, if we see a smooth surface that has been spread, we do not know if there is a model in the build chamber or how much powder is there.

F6. Use the special vacuum under the depowdering unit to clean up any additional powder that is not in the chambers. Please note that this vacuum is to be used only for clean powder. If the vacuum suction seems low, report this to a lab supervisor.

F7. Make sure your entry on the machine log is accurate and complete

G. Determine and Cost Out the Actual Material Usage

G1. After the build job has finished, download the appropriate txt file from the control computer's directory:  C:\ZCorp Printer Records\Detailed Reports\. In the example below, you will notice that I've highlighted in red where to find the amount of powder (3.47 cubic inches), the amount of clear binder (47.2559 ml), and the amounts of yellow (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 3.52 5.00 2.45 66.37 3.47

COLOR MODE
Estimation: 2 hours 23 mins

Started: 10/15/21 01:39 PM
Firmware Version: 3.210
Bleed Compensation OFF
Start layer: 0
End layer: 612
Total number of layers: 613
Printer: 192.168.1.2 : Spectrum 510
Base Powder: ZP151
Powder Type: ZP151
Shell Saturation: 100% Binder/Volume: 0.234
Core Saturation: 100% Binder/Volume: 0.117
Waste Available start: 0 mL
____
Last printed layer: 613
Binder usage for this job: 120.3 mL
____
Clear Binder usage: 47.2595 mL 4.7 % ( 2487340544 drops )
Yellow Binder usage: 25.6021 mL 2.6 % ( 1347481088 drops )
Magenta Binder usage: 25.5181 mL 2.6 % ( 1343057408 drops )
Cyan Binder usage: 25. 4586 mL 2.5 % ( 1339928064 drops )
Waste Available end: 0 mL

Finished: 10/15/21 03:53 PM
Duration: 2 hours 13 mins

G2. Just as you did for the estimate, cost out the actual use of binder and powder using the following factors (actual replacement cost values):

  • Multiply the volume in cubic inches by $ 1.59
    • or the vol in cubic cm by $.10
  • Multiply the ml of clear binder by $ 0.20
  • Multiply the ml of colored binder by $ 0.33
  • Multiply the ounces of cyanoacrylate by $5.00
  • Add the products

This is illustrated for the example in the table below. Note that there are two figures. In a report, the entire table shown below would be reported. Please see the instructor or lab supervisor to determine the actual charge to you, if any.

  Unit Used Unit Cost Cost
Powder cu in 3.47 $1.59 $5.52
Clear ml 47.2959 $0.20 $9.46
Yellow ml 25.6021 $0.33 $8. 45
Magenta ml 25.5181 $0.33 $8.42
Cyan ml 25.4586 $0.33 $8.40
Infiltrant oz 1 $5.00 $5.00
Estimated Materials Cost   $45.25

H. De-powder the Part and let it Finish Curing

h2. Make sure the vacuum is connected to the back of the de-powdering unit.

h3. Remove everything from the top chamber of the de-powdering unit and place your part on the tray into it. Close the door.

Note

Consider removing your watch so it does not get powder in it.

h4. Attach the air brush to its hose.

h5. Inside the lower door, turn on the air compressor and the vacuum.

 

H5. Place your hands through the holes, and very gently blow the powder out of your part. Do not break your part; the air pressure can sometimes be strong enough to do this.

H6. When you are done, blow the remaining of the powder down the vacuum hole in the back left of the unit using the air brush.

H7. Turn off the vacuum and compressor. Replace the air brush into its container, and place it back into the de-powdering unit.

H8. Let the depowdered part to sit for 24 to 48 hours so that the powder and water in the part will continue to chemically combine (i.e., hydroset.)

H9. Place the part into the laboratory oven at 60C overnight to drive off remaining water within the model so that there will be more airspace that the infiltrate can occupy.

I. Infiltrate the Part

Infiltration is a finishing operation where a liquid is absorbed in the surface of the part to increase its strength, hardness, durability, and color contrast. You can air dry the part, or dry it at 102 C in the laboratory oven until it stops losing mass. It is also possible to infiltrate the part without this extra drying, though that is not recommended.

Caution

Always wear safety glasses when infiltrating parts. Take precautions to avoid burns with hot wax. Do not allow cyanoacrylate to contact skin.

I1. Infiltrate the part and let it dry. Do not allow it to become adhered to a workbench, work-surface, paper, or anything else, as you will likely break your part removing it.

Infiltrants

Water: Uncolored (white) objects may be infiltrated with a fine mist water spray, with a second or third application after about 10 minutes that get areas missed by the first application. Parts can also be dipped in water. The surface will be rather rough, and if you tried this with a colored part, the color would run. But 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, as mentioned above, for water. There is a little running of color, but not much, and parts are a bit harder than prior to infiltration. They tend to be somewhat rough.

Wax: Dipping in melted paraffin is another method of infiltrating parts. This brings out the color without running, and makes a smooth surface. Part strength is moderate. Before heating the wax, be sure to drill relief holes.

  

Cyanoacrylate: Also known as "super glue," cyanoacrylate is a dangerous adhesive that imparts relative high strength to colored or white parts. Application is difficult, however, and can include dribbling or dipping. Some formulations of cyanoacrylate are quite volatile, and the fumes emitted can irritate the eyes and breathing passages. This is also a very expensive infiltrant, with 16 fluid ounces costing $187.00. To apply cyanoacrylate, wear gloves and safety glasses. You can either carefully dribble drops onto the object over the specially prepared platform for doing this, or immerse the object into a bath of cyanoacrylate. Please be very careful when pouring the infiltrant, dipping objects into it, and pouring it back through a funnel into its containers.

Other Materials: Other materials can be used as infiltrants. Epoxy is used in industry, though being an "A B System," whatever is mixed sets very soon and cannot be used later. Others have tried Minwax Wood Hardener, paint, and a variety of finishes and adhesives. 

Appendix: Instructions and Notes for Laboratory Staff

S1. This machine is for use only 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 sure the model is appropriate for this machine. If the features are too fine for the model to be handled without breaking, do not allow the user to build the model.

S3. At the beginning of every build, make sure the user cleans the spit plate, gently clears the six 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 best results, I recommend taking a small piece of paper toweling and using alcohol to gently rub the four printheads, making sure that the three colored binders flowed a bit in the process.

S5. Make sure the user does not exceed the maximum size (cost) of a build.

S6. Have the user fill out the machine log. Here, it is very important that the user identifies precisely when they will return to remove their object, as it will be in the way of others who want to use the machine.

S7. Insist that after every build, the user empties the powder from both the overflow bin and the build chamber into the feed chamber using the sifter.

S8. Insist that when they are done, a user leaves the machine with 1/4" of powder in the feed chamber, and with both chambers screeded off using the straightedge. Do not have them "spread" the bed because this will make it look as if there is a build in the bed.

S9. During times of heavy use, clean machine well once each week. At the end of this, empty the powder from the vacuum under the depowdering station back into the feed chamber through the sifter.

S10. Record all errors and problems in the Staff sheet in the 3-ring binder.

S11. Please clean this machine, the area, and the computer workstation regularly. The powder, binder, and infiltrants are all messy.

S12. If there is a printhead overtemp error message, try to fix it by trying each of these in order: 1. clean the printhead with alcohol; 2. immerse the printhead in cold, running water for a minute; 3. use the printhead purge fixture and syringe, immersing the entire printhead in a container of cold water as you use the syringe to suck out the clog and a few ml of binder, which will be replaced with cold water. For this last step, it might help to fill the top of the syringe with water as well.

References

Barnatt, C. (n.d.). Explaining The Future: 3D Printing. Retrieved from http://explainingthefuture.com/3dprinting.html 

"Using a Z-Corp Spectrum Z-510 Solid Object Printer with Z-Print and Z-Edit Software"
All information is subject to change without notification.
© Jim Flowers
Ball State University

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Spectrum Z510

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The benchmark for speed, color, affordability and ease of use

The ProJet x60 Series 3D printers meet a wide range of customer needs from higher education to the most demanding manufacturers. In addition, 3D Systems provides 3D printing materials suitable for various applications.


Print technology

3D printing technology is based on the principle of layer-by-layer 2D printing. The inkjet print head dispenses a water-based liquid adhesive that sticks the powder together to form layers of the future model. The glue, which is fed into each print head in turn, is distributed according to the set program and hardens immediately after application. When one layer is completed, the printer checks its thickness and proceeds to work on the next. At the end of the printing (growing) process, the model is removed from the powder. The powder not used in the process of building a model is used to print the following models.

The software cuts the CAD file into thousands of thin layers.

The real prototype is built one layer at a time.

The inkjet printhead applies adhesive to the powder to set the layer.

The cycle then repeats.

3D Modeling Principle

Materials

ProJet x60 3D Printer models made from high quality zp151 composite material can be sanded, drilled, sectioned, painted and electroplated.

The zp151 composite material offers a range of end properties for the task at hand, from impregnating parts with epoxy for heavy-duty functional prototypes to a simple Epsom salt treatment process, making concept models fast, safe and very affordable. zp151 is ideal for architecture and construction, industrial CAD systems and education. zp151 has the following advantages:

  • the most durable models;
  • best resolution;
  • even brighter white;
  • high color rendering;
  • low unit cost.
    • Spectrum Z510

    Spectrum Z510

    ProJet 160

    ProJet 260C

    ProJet 360

    Photo of

    Model formation speed

    2-3 coats per minute

    3. 5 coats per minute

    Multicolour, number of colors

    -

    64

    -

    Maximum size of the formed model, mm

    254x356x203

    236x185x127

    203x254x203

    Resolution, dpi

    600x540

    300x450

    Layer thickness, mm

    0. 089-0.203

    0.1

    0.089-0.102

    Network connection

    Ethernet 10/100

    TCP/IP 100/10 base T

    Print file format

    DESIGNprint/ZPrint; import of 3DS, STL, VRML, PLY

    formats

    STL, VRML, PLY, 3DS, ZPR

    Equipment dimensions, cm

    107x79x127

    74x79x140

    122x79x140

    Equipment weight, kg

    204

    165

    179

    Description

    The most affordable and high quality monochrome 3D models

    Affordable and high quality multicolor 3D models

    The first single color automated 3D printer, the most affordable

    Automation

    Yes

    -

    Materials used

    High quality composite materials

    High Strength Composite

    Number of printheads

    1

    2

    1

    Number of nozzles

    304

    604

    304

    Power Requirements

    208-240V, 4. 0A

    230V, 6.2A

    Compatible with

    workstations

    Windows 7, Windows XP Professional, and Windows Vista

    Windows XP Professional and Windows Vista Business/Ultimate

    Compliance with

    CE, CSA

    Special requirements

    No

    Specification continued

    ProJet 460 Plus

    ProJet 660Pro

    ProJet 860Pro

    Photo of

    Model formation speed

    2-4 coats per minute

    5-15 mm/h

    Multicolour, number of colors

    2. 8 million

    6 million

    Maximum size of the formed model, mm

    203x254x203

    254x381x203

    508x381x229

    Resolution, dpi

    300x450

    600x540

    600x540 dpi

    Layer thickness, mm

    0.089-0.102

    Network connection

    TCP/IP 100/10 base T

    Print file format

    STL, VRML, PLY, 3DS, ZPR

    STL, VRML, PLY, FBX, 3DS, ZPR

    Equipment dimensions, cm

    112x79x140

    188x74x145

    119x116x162

    Equipment weight, kg

    193

    340

    363

    Description

    Most affordable color printer, easy to use, great for the office

    Excellent color reproduction, easy to use, very large model volume, office friendly

    Largest model building chamber, excellent color reproduction, easy to use

    Automation

    Yes

    Materials used

    High Strength Composite

    Number of printheads

    1

    2

    5

    Number of nozzles

    304

    604

    1520

    Power Requirements

    230V, 6. 2A

    100-240V, 50-60Hz, 15-7.5A

    100...240V, 15...7.5A

    Compatibility with workstations

    Windows XP Professional and Windows Vista Business/Ultimate

    Windows® 7, Windows Vista® Business/Ultimate

    Compliance with

    CE, CSA

    Special requirements

    No

    Compressed air

    Back to section

    Architectural 3D printing

    0

    3D digital modeling (BIM) is used today by half of the architectural companies in the world, and few argue that the advent of BIM has made a real revolution. Architects have finally got a trouble-free way to quickly, clearly, visually and accurately convey their ideas to the customer.
    It's time to master the innovative technology of the presentation of the physical model. The physical model is much more complete than the picture on the monitor, allowing the customer to understand and feel the architectural design. The architect also needs both models: a 3D digital model is required to analyze the components of the project, and a physical model is required to effectively assess the details and scale. More importantly, the physical model allows architects to speak in a language understandable to the customer, even the most distant from architecture. The client, on the other hand, gets the opportunity to evaluate the project on an emotional level, to perceive it taking into account all the subtleties.
    The art of hand-crafting architectural models certainly deserves all respect, but it is so time-consuming that the creation of such a model in itself becomes a separate project. First, the architectural drawings are handed over to the model maker, who embodies the overall concept in the material. This takes two to four weeks. If the project has successfully passed the approval, the layout is finalized without significant changes. If not, the architect has to make changes to the project and submit a new version of the model to the customer for approval. It happens that the process of manufacturing a physical layout stretches for months, disrupts deadlines and jeopardizes the fate of the entire project.
    In the rapidly changing world of digital modeling, relying on hand-made approximations is old-fashioned and far too expensive. But what if the production of the layout were faster, cheaper and more accurate? Just imagine the possibilities! The same 3D model could be directly used in the workflow... Z Corporation's 3D printers make these dreams come true.

    Visualization
    When Z Corporation's first 3D printer, capable of printing 3D physical models, hit the market, it brought with it a host of new possibilities. No longer constrained by the high cost and size of prototyping machines, designers were suddenly able to afford to routinely use visual 3D mockups early in a project.
    Morphosis, a Tom Mine Architecture Award-winning company accustomed to working only with cutting-edge technology, was among the first to adopt 3D printing. Morphosis CIO Marty Doscher talks about the company's headquarters in Eugene, Oregon: "We have two 3D printers here, and any project goes straight to 3D from day one."
    Tom may do a couple of sketches on paper, but the rest of the work is done in 3D and there are a lot of 3D prints all over it.

    Defending ideas, winning in business
    “The human brain works in three dimensions, not two,” explains the owner of the architectural bureau iKix, R. “Partha” Parthasarathy. “Architects and contractors have relied on 2D drawings for centuries. But no matter how accurate these drawings are, there is always a danger that the customer will interpret them incorrectly.
    As an example, he cites a recent story with a residential complex with hundreds of buildings. The client was quite pleased with the drawings, but as soon as he saw the 3D layout, he was immediately worried about the too dense placement of buildings. To dilute this heap, the architect had to place a swimming pool and a fitness room in the center of the complex. One can only guess what the belated solution to this problem would have cost the customer - say, when half of the complex would have been built ... The presence of a 3D layout saved the architect a lot of time, and the customer saved the huge costs of changes in the complex already under construction ...
    Jerde Partnership purchased ZPrinter 310 Plus printers and now uses them in the development of any project - from a skyscraper to a kiosk. The ability to 3D print in the office allows you to make models very quickly, and, in addition, create models that would simply be impractical to do manually.
    Just a week after purchase, the ZPrinter 310 Plus helped win the Jerde Partnership's San Diego Coastal Landscape project. The detailed physics model showed how the Jerde project enhances the contours of the landscape while maintaining its overall style. Al Waas, deputy vice president and chief designer of the project, says that creating the same layout by hand would require a week of effort from an entire team of specialists. And with the help of the ZPrinter 310 Plus, the layout was printed in just half a day. “The more detailed the project, the more complex it is, the more benefits 3D printing provides,” Vaas notes. And he adds that the use of 3D printers gives an approximately twofold increase in productivity.

    How does it work?
    Z Corporation 3D printers work with BIM file formats to create 3D physical layouts from composite powdered plaster.
    A model obtained from software such as Autodesk Revit or Autodesk 3ds Max is cut by Z Corp into thousands of horizontal layers. The printer's print head then makes thousands of passes through the powder, leaving a liquid binder at the intersection points. Where this substance comes into contact with the powder, it quickly hardens. Thus, printing at a vertical speed of about one inch per hour, the printer deposits the material layer by layer and creates a finished layout from powdered plaster.
    Z Corp's 3D printers are unique in that they are the only ones that can make models in color. No other technology for creating 3D layouts offers such a possibility. In addition, graphics and photographs can be applied to the model to further enhance the resemblance to the original.
    Z Corp software allows you to go beyond the size of the plot area. The layout of the building can be divided into parts, and ZEdit Pro will automatically add studs and holes to them for subsequent assembly almost flush.

    Savings
    While a handmade mock-up can cost several thousand dollars, the cost of the same mock-up printed on a Z Corporation 3D printer is only $2-$3 per cubic inch.
    “For medium to large projects, the cost of making a mock-up pays off almost immediately,” says Scott Harmon, vice president of product development at Z Corporation. – The device itself often pays off very quickly: if, for example, at the very early stage of the project, thanks to the model, it was possible to detect a serious error or the company became the winner of the tender, presenting its project in the most advantageous light. While 3D building layouts are relatively new, the majority of our clients are architects, who get value from the printer from day one.”

    Speed ​​and scalability
    Where it took weeks to produce a medium-sized layout, a 3D printer can do it in less than 12 hours. Z Corporation inkjet 3D printers do not smoke, produce a minimum of waste, and the material remaining unused during the printing process is suitable for further use. Printers print at resolutions up to 600 dpi, scrupulously reproducing the smallest surface details.
    The Z Corp line includes the ZPrinter 310 Plus black and white printer and three color devices: the ZPrinter 450, the Spectrum Z510 and the high-resolution ZPrinter 650.
    “Other manufacturers' presses don't allow multiple layouts to be created at the same time: it's impossible to print models one on top of the other,” says Scott Harmon. “Z Corp printers allow you to print as many layouts as they physically fit in the build area, thanks to a thin layer of powder between them.”

    Not so long ago, the Realization Group was once again convinced of the advantages of mass printing on Z Corp printers. When its office in Coral Gables, Florida, ordered 100 copies of a mockup for marketing purposes, Realization Group was able to complete the order in just two days, thanks solely to its ability to print multiple copies at the same time with no loss in accuracy, quality, or reliability.
    Along with the benefits of speed and affordability, a 3D printer is of particular value to aspiring architects. The use of 3D printing at an early stage of design allows you to quickly gain valuable experience, protecting both the architect and customers from costly mistakes caused precisely by a lack of experience.
    Thanks to Z Corporation's 3D printers, which produce architectural models much cheaper and faster than by hand, 3D printing can now be applied early in the design process, making the entire process more efficient. Just as BIM digital modeling makes designing cheaper and more efficient, 3D mockups created at the design stage of a project help to better understand its concept, avoid mistakes and provide business opportunities that were previously only dreamed of.

    Building a house: 3D printing as the engine of the project
    Throughout twenty years of work in the field of computer-aided design, R. "Parta" Parthasarati meets a new client with the same question: "What problem can we solve for you?"
    Regular the answer is: “Fast time to market for our product.”
    In the case of architecture, Parthasarathy found that the two main reasons for delays came down to a lack of theoretical development of the project and poor communication.Two years ago, he discovered 3D printing, a completely new technology, significantly reduces design time. It makes it possible to produce an accurate 3D physical model of a building and make it an essential part of every designer's work.Partha saw this as a great opportunity to improve communication among all those involved in the project, increase efficiency and eliminate costly errors.Thus iKix was born (www.ikix .in) is India's first archit service bureau textured 3D printing.
    Previously, all construction models were made by hand. Since this process is time consuming and expensive, architects only make the layout at the final stage of the project, just before the public presentation.
    "iKix prints a 3D layout in an average of six to 10 days, which is much faster than the month it takes to make a similar layout by hand," Parta says. for golf and more - we can produce in six weeks versus five months of manual work. Time and financial savings become even more noticeable when plans change and the layout has to be adjusted on the fly.”
    iKix uses the color Spectrum Z510 from Z Corp. The capabilities of this printer allow the architect and project manager to quickly obtain multiple copies of the layout - one each for the architect, client, general contractor, subcontractor and civil authorities. “A 3D printer is more than just a prototyping machine,” Parta says. – It really became one of the developer's tools. 3D printing is a breakthrough that I believe will determine the future of technical information exchange for the next two hundred years. Each project must be presented in 3D, and soon it will be so. I sincerely believe that all architects will work in 3D. iKix clients come here to implement more and more new projects in three-dimensional layouts. The benefits are undeniable."
    Parta believes that infrastructure objects also need physical layouts. For example, when the authorities decided to build a highway interchange, it is necessary to plan traffic in all modes of its operation. The presence of a physical 3D model simplifies the solution of this problem.

    Visibility: Civilian 3D Printing
    Scandinavian consulting company Ramboll Group's (www.ramboll.com) has a track record of restored landmarks, amazing bridges, excellent roads and sustainable utilities. However, each new tender requires not only bright ideas, but also their bright presentation - this is the only way to count on success. This is one of the reasons why Ramboll adopted 3D printing technology.
    Ramboll operates in a highly competitive international marketplace offering a full range of consulting services in the areas of infrastructure, telecommunications, architecture, healthcare, oil and gas, energy, environmental protection, information technology and management.
    Ramboll is justifiably proud of the already realized design findings, but prospective customers are more interested in suggestions for possible future orders. The company is looking for ways to best represent its ideas, and in this area, the possibilities of 3D printing cannot be overestimated.
    From the very beginning, Ramboll's absolute requirement was color printing. This predetermined the choice: Ramboll purchased a Z Corporation Spectrum Z510 3D printer, the only high-resolution color printer to date. The
    Spectrum Z510 quickly generates 3D architectural and engineering mock-ups - in less time and typically at a fraction of the cost of traditional manual methods. Due to the clear color detailing, layouts better convey the ideas of the project. And the ability of the Spectrum Z510 to apply textures to the surface makes the layouts realistic and spectacular, which is especially important for infrastructure projects. For example, Ramboll engineers can apply a brickwork texture to the surface of the wall, and a bird's-eye photo of it on a landscape model.
    New features greatly improved Ramboll's chances. Shortly after acquiring the Spectrum Z510, the company won a tender to design a major bridge at its home in Denmark.
    The layout faithfully displayed special V-shaped stops that took up less space and required less material than their classic counterparts. He perfectly conveyed the zest of the concept.
    “This is just one example where color 3D printing has won a tender,” says Jita Monshizadeh, CAD designer for Ramboll's transportation and infrastructure division. “And we already have many such examples. 3D printing, like nothing else, helps the customer to feel the uniqueness of our projects, not to miss any of the ideas embedded in them. We create presentations that represent the capabilities of Ramboll in high definition and color. The color, clarity and textures – right down to the pattern of the stonework on the wall – all really make a lasting impression.”
    In addition, 3D printing saves Ramboll money. For example, recently, when a company needed a mock-up of a 12-story apartment building, it was calculated that it would cost three times less to print a color model on a 3D printer than ordering it by hand.
    “Printing a color physical model is almost effortless, as long as the scale is right,” continues Jita Monshizadeh. - If the project is made in a 3D design program, this is quite enough to form a 3D model. Sometimes the model needs to be slightly optimized to scale it to the resolution of the printer, but this is usually not difficult. Problems rather arise in the manual production of a layout - when, for example, one single small detail takes a lot of time! In other words, 3D printing encourages creativity and spatial thinking. At different stages of the project, you can easily make printouts of the layout and compare them. ”

    Highlight: using 3D mockups in presentations
    For Robin Lockhart, Associate Manager and Head of Operations at OBM International (www.obmi.com), design projects that typically involved many hours of discussion and required many trial and error decisions and mistakes, have now become a catalyst that sets the overall dynamics.
    The thing is that not so long ago the company integrated 3D printing into its production processes.
    One of the very important projects is the construction of the new headquarters of OBM International in the city of Coral Gables. Using a 3D printer purchased from Z Corporation, “I made a mock-up of a four-seat workbench with components broken down so that they can then be assembled in different configurations,” says Robin Lockhart. – The design team came up with solutions that can be combined by swapping components. This saved us from unnecessary debate, saved a lot of time and effort, and most importantly allowed us to quickly and dynamically come to the desired solution. In addition, the search process itself turned out to be extremely exciting.
    OBM International acquired a Z Corp Spectrum Z510 3D printer in December 2007. “Now we use the Z Corp Spectrum Z510 with all the options, including the automatic cleaning module for powder residue. In essence, we have here the entire set of devices for working with layouts, which gradually developed around the main printer.
    Lockhart commented that 3D printing had the best impact on the nature of OBM International's business: “Our level of understanding with the customer is amazing. The general mood of the presentation instantly changes for the better as soon as we present the layout to the customer. Clients are now able to discuss in a way they understand well, the model consistently makes a good first impression, and clients are grateful.”
    Previously, OBM International used traditional 2D drawings, color projections and videos for presentations. Designers used tracing paper, hand sketches, CAD, 3D visualization and modeling. “All this was in our arsenal and all this imposes certain restrictions. When we make a presentation for a customer who is not fully familiar with the nuances of this format, the information content is reduced, and this can negatively affect the decision made.” According to Robin Lockhart, OBM International also makes 3D models for its own needs: for the purpose of critical analysis and evaluation of the project.
    “Our document workflow is focused on the ubiquity of physical layouts,” says Lockhart. – With the increasing use of the 3D printer, we can hope that the quality of our projects will only improve. In addition, this device really became the highlight of all our architectural presentations.”

    Export from Autodesk Revit
    The increasing use of 3D printing in architectural design has led to a tool that allows users to upload STL files imported from Autodesk Revit directly to Z Corp.'s 3D printer. Not so long ago, Autodesk announced the release of a new STL Exporter utility for the Autodesk Revit 2009 platform.(BIM). In the past, converting Revit files to STL format required third-party software.
    This development highlights Autodesk's confidence in 3D printing and its growing adoption as the process becomes more cost effective and efficient.
    “Physical 3D models are becoming an integral part of the design process, offering visual insight into the design and improving the relationship between designer and customer,” says Emile Kfoury, Senior Line Manager at Autodesk AEC Solutions. – 3D mock-ups are essential for our customers throughout the entire life cycle of a product, but above all when looking for a conceptual solution.

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