3D Systems Duraform ProX PA User manual

Duraform® ProX™ PA
Material Guide
Original Instructions

CONTENTS
1LEGAL NOTICES ........................................................................................1
COPYRIGHT AND CORPORATE IDENTITY................................................................1
LIMITATIONS OF WARRANTY AND LIABILITY .............................................................1
TRADEMARKS AND REGISTERED TRADEMARKS.........................................................1
2PRINTING PARTS WITH DURAFORM®PROX PA MATERIAL ...................................................2
SAFETY NOTICE: MATERIALS .........................................................................2
HOW THE DURAFORM ProX PA PROCESS WORKS........................................................2
Warm-Up Stage.....................................................................................3
Print Stage.........................................................................................3
As the Print Continues................................................................................3
Cool-down Stage....................................................................................4
Condensation in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRINT MODES FOR DuraForm ProX PA ..................................................................5
Offline IR Calibration .................................................................................5
Scale and Offset Print ................................................................................5
Calculating Scale/Offset Values ........................................................................5
DuraForm ProX PA Build Preparation Guidelines ..........................................................6
SLS 380 Build Volume................................................................................6
Part orientation and placement in the SLS build volume: .....................................................6
Part geometry and feature considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Small Features less than 1 mm will be affected by X, Y, and Z offset values.......................................7
Print Process Settings ................................................................................9
Part Bed Heater Set Point .............................................................................9
Feed Powder Amount ................................................................................9
Verify Before Every Print .............................................................................10
Restarting a Terminated Print .........................................................................10
Sifting Material.....................................................................................10
Recycling Material ..................................................................................10
Blending Fresh and Used Material .....................................................................11
Cleaning up the SLS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3POST-PROCESSING ....................................................................................12
TOOLS AND CLEANING MEDIA........................................................................12
CLEANING PROCEDURES............................................................................12
REPAIRING AND JOINING PARTS ......................................................................12
POWER SANDING...................................................................................12
WET SANDING PROCEDURE..........................................................................12
SEALING AND INFILTRATING PARTS ...................................................................13
Some suggested products: ...........................................................................13
SEALING WITH A WATER-BASED POLYURETHANE.......................................................13
Procedure ........................................................................................13
SEALING WITH THERMAL-CURE SEALANTS ............................................................14
Procedure ........................................................................................14

4PROPERTIES AND HANDLING ...........................................................................15
SAFETY DATA SHEET................................................................................15
MATERIAL HANDLING ...............................................................................15
MATERIAL STORAGE AND DISPOSAL ..................................................................15
General Storage Information ..........................................................................15
Material Disposal...................................................................................15
5TROUBLESHOOTING ...................................................................................16
INTRODUCTION TO PROBLEM SOLVING................................................................16
Problem Description Format ..........................................................................16
Interaction of Variables ..............................................................................16
BONUS Z .........................................................................................17
CLUMPING.........................................................................................18
CRACKING OF PRINT BED ...........................................................................18
CRYSTALS AND CONDENSATION......................................................................19
DISTORTION .......................................................................................19
Preventing Curl in Prints .............................................................................20
GLAZING, DURING PRINT ............................................................................20
GROWTH ..........................................................................................21
MELTING, PRINT BED................................................................................21
MISSED SCAN ......................................................................................21
ORANGE PEEL .....................................................................................22
SHORT FEEDS......................................................................................22
STRAY VECTORS ...................................................................................23
WASH OUT.........................................................................................23
WEAK PARTS/POROSITY.............................................................................23
6GLOSSARY............................................................................................24

13D SYSTEMS, INC.
1LEGAL NOTICES
COPYRIGHT AND CORPORATE IDENTITY
COPYRIGHT
© 2022 by 3D Systems, Inc. All rights reserved. This document is subject to change without notice. The 3D Systems logo is a
registered trademarks of 3D Systems, Inc. This document is copyrighted and contains proprietary information that is the property
of 3D Systems. The licensed user, in the name of whom this document is registered (the “Licensed User”) does not have the right
to copy, reproduce, or translate this document in any way or to any media without the prior written consent of 3D Systems. No
copies of the document may be sold or given to any person or other entity.
LIMITATIONS OF WARRANTY AND LIABILITY
This information is provided by 3D Systems for the convenience of its customers. It is believed to be reliable, but NO
REPRESENTATIONS, GUARANTEES OR WARRANTIES OF ANY KIND ARE MADE AS TO ITS ACCURACY, FITNESS FOR A PARTICULAR
USE OR THE RESULTS TO BE OBTAINED THEREFROM. The information is based in whole or in large part on laboratory work and
does not necessarily indicate performance in all conditions. Notwithstanding any information provided by 3D Systems or its
aliates, the customer remains fully responsible for determining which federal, state or local laws or regulations, or industry
practices are relevant to activities in which it engages, as well as assuring that those laws, regulations or standards are complied
with under actual operating conditions, and 3D Systems undertakes no responsibility in these areas.
IN NO EVENT WILL 3D SYSTEMS BE RESPONSIBLE FOR DAMAGES OF ANY NATURE, INCLUDING SPECIAL OR CONSEQUENTIAL
DAMAGES, RESULTING FROM THE USE OF OR RELIANCE UPON THIS INFORMATION. THE CUSTOMER ASSUMES ALL RISK RESULTING
FROM THE USE OF THIS INFORMATION.
Customers use of the materials that follow is an acknowledgment of its agreement to the foregoing. Any customer not wishing to
be bound should return this material to 3D Systems. Nothing contained herein is to be considered as permission, recommendation,
nor as an inducement to practice any patented invention without permission of the patent owner.
TRADEMARKS AND REGISTERED TRADEMARKS
DuraForm is a registered trademark and ProX is a trademark of 3D Systems, Inc.

23D SYSTEMS, INC.
2PRINTING PARTS WITH DURAFORM®PROX PA MATERIAL
DuraForm ProX PA is an engineered production plastic for use on 3D Systems’ ProX SLS systems. It is a general-purpose
material that is best-suited for printing parts with ne features and where smooth surface nish is desired. This guide describes
how to use your SLS system to print parts using 3D Systems’ proprietary DuraForm®ProX PA material. This chapter describes
the printing process. It includes the following topics:
• Safety Notice: Materials
• How the DuraForm ProX PA Plastic Process Works
• Build Modes for DuraForm ProX PA
• Preliminary Prints and Part Prints
• Setting Up a Print
• Part Placement and Orientation Guidelines
• Before Every Print
• Restarting a Terminated Print
• Sifting Material
• Recycling Material
• Cleaning Up the SLS System
SAFETY NOTICE: MATERIALS
DuraForm ProX PA has been designed for and tested in 3D Systems’ ProX SLS systems.
Material Safety Datasheets (SDS) may be found at: http://infocenter.3dsystems.com/production-printer-material/laser-
sintering-sls.
Caution: Using any material other than those certied by 3D Systems may cause health hazards and may
limit the warranty of the SLS system.
HOW THE DURAFORM PROX PA PROCESS WORKS
The DuraForm ProX PA material process has the following characteristics:
• The material is heated to slightly below its melting point.
• The material is processed in an inert, nitrogen-rich atmosphere (5.5% maximum oxygen).
After the initial nitrogen purge, there is make-up nitrogen gas owing at a constant rate through the print chamber during
the print process. There is also nitrogen gas owing across the laser window and the IR sensor head, and nitrogen gas is
used to transport material from the Feed Overow back to the Feed Hopper.
• The material’s melt transition allows it to be transformed from a solid to a low-viscosity liquid using a small amount of laser
energy.
• Printing with the material consists of 3 stages:
1. Warm-Up Stage
2. Print Stage
3. Cool-down Stage

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Feed Hopper Heater
Roller
Heat Heat
Warm-Up Stage
• The warm-up stage stabilizes the temperature in the print chamber, print bed, and feed hopper.
• This stage lasts approximately 60 minutes, during which the print bed piston indexes down in small increments (0.102 mm
(0.004 inches)) while the roller delivers material. During the warmup stage the part piston will index down approximately
13mm (0.51 inches)
• During this stage, the system gradually increases the print bed temperature to the necessary point (below the material’s
melting point).
• In the feed hopper, the material is gradually increased to the highest possible temperature at which the material still ows
freely. This limits the amount of thermal shock (cooling) caused by the feed material when it is rst delivered to the print
bed.
• During the nal 5mm of the warmup and during the entire Print (build) stage, the SLS 380 uses the IR camera to adjust the
output of the 8 individual print bed heaters to maintain a uniform temperature across the part bed.
Print Stage
• The print stage maintains the print bed and feed hopper temperatures.
• Laser energy is used to melt the material in each successive cross-section of the print.
As the Print Continues
• The print bed piston indexes down, the parts are covered and begin to slowly cool.
• The mass and geometry of the parts inuence the cooling rate. If the cooling rate is too high, the parts can develop post-
print curl or warp. If the cooling rate is too low, growth can occur.
• The part positioning in the print also inuences the cooling rate. The rst parts printed have the highest cooling rate.
First-order phase changes, such as solidication, occur isothermally; the top of these parts will not cool until the entire part
has solidied. This slows the cooling rate of parts subsequently built.
NOTE: To help slow the cooling rate, the SLS 380 uses a piston heater and cylinder heater.
Feed Hopper Heater
Roller
Heat Heat
Front cut-view of print chamber during the warm-up stage

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Cool-down Stage
• The cool-down stage allows the material, parts, and SLS system to cool suciently enough to safely remove the print cake
from the print chamber.
• Nitrogen is required for this process and the inert level in the chamber needs to be maintained.
• The length of this stage depends on how large the print is. A larger print will take longer to cool down. The cool-down stage
lasts approximately one-to-two hours inside the SLS 380
• When this stage ends, the material and the SLS system are still hot. The nal cool-down can take place in the system or the
print cake can be removed and allowed to cool-down on the MQC
• The print cake should be allowed to cool slowly to room temperature before removing the parts from the print cake. The
core of the print cake should be no warmer than 50°C.
• Removing the parts from the print cake too quickly could cause the parts to warp and/or discolor.
• Some part geometries are more susceptible to post-print warp than others.
Condensation in the Process
The DuraForm ProX PA contains a small amount of volatile material that vaporizes during processing. This material condenses
and sticks on cool surfaces in the SLS system print chamber.
• Heated nitrogen gas ow across the laser window helps reduce the condensing material from depositing on the laser win-
dow
• Heated nitrogen gas ow across the IR sensor head helps prevent condensation from forming on the IR sensor lenses.
Excessive condensation on the lenses will cause inaccurate readings of temperatures, leading to hard or melted material in
the print bed. The IR sensor should be inspected before each build and cleaned if necessary
NOTE: It is normal to see some slight condensation (or lm) on the laser window after a print, but excessive
condensation on the laser window can block laser power, causing weak or porous parts.
The laser window should be cleaned before each build. See your SLS printer’s user guide for cleaning procedures.
Clean laser windowDirty laser window

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PRINT MODES FOR DURAFORM PROX PA
DuraForm ProX PA is available in Standard Mode and Advanced Mode. Material conguration les for Standard and Advanced
modes are offered by 3D Systems. The process settings in the Standard mode are optimized by 3D Systems to help customers
get the best combination of mechanicals, part appearance (detail, surface nish) and DuraFormProX PA recyclability.
NOTE: 40% fresh powder to 60% recycled powder is the recommended MQC blend setting.
The standard mode has been designed for, and tested in, 3D Systems’ SLS 380 systems with 40% fresh powder to 60% recycled
DuraForm ProX PA on an MQC. Please refer to the Sifting Material section for more information on the MQC.
Expected mechanical properties and densities using 40% fresh to 60% recycled are found on 3D Systems Infocenter.
The Advanced mode offers more processing latitude for advanced users who may need to vary process settings for their
application.
NOTE: The material process parameter set points may vary slightly from machine to machine, due to
differences in material conditions and thermal sensors. As a result, the process parameters, more specically
the temperature set points, may need to be adjusted slightly from the defaults. An oine IR sensor
calibration is required before using a material for the rst time.
Scale and Offset Print
When you print parts with DuraForm ProX PA, you will perform at least one preliminary print to ne-tune the default
parameters you need to use when you print parts for use.
NOTE: Shrink and Beam offsets: The shrinkage of 100% fresh DuraForm ProX PA is slightly greater than that
of blended DuraForm ProX PA. You should expect to evaluate and adjust the scale values used to compensate
for shrink if the fresh powder ratio in the blend changes. Note that shrinkage may vary slightly based on part
geometry. Expect shrink rate close to 3.3% with 100% fresh powder. 3.1% is normal for 40% Fresh powder
blend
Either the eld engineer or the operator will print a preliminary build to verify the appropriate scale and offset parameters. It is
suggested that the following test print job be used.
Build Height is 35 mm, all parts are labeled. Total build
time is approximately 5 hours
PRELIMINARY PRINTS AND PART PRINTS
Before performing the rst print, you must perform an oine IR calibration. Refer to you printer’s User Guide for detailed
instructions.
Oine IR Calibration
1. Inspect and clean the Blackbody if needed.
2. Put the system in Manual Operations mode; close and lock the print chamber doors
3. Before performing the Oine Calibration, check to make sure DuraFormProXPA standard mode is selected.
4. Click the IR Calibration button.
Calculating Scale/Offset Values
Refer to the Help section in Build Prep software.

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DURAFORM PROX PA BUILD PREPARATION GUIDELINES
SLS 380 Build Volume
A small portion of the Z-stroke of the piston will be utilized by
the Warmup and Cooldown stages. Standard default values for
warmup and cooldown are shown at the right.
The Build stage height will vary based on part location.
The Warmup stage and the Cooldown stage will not be shown
graphically in the Print Job preparation software, only the Build
Stage is displayed.
• The optimum print area (inside dashed line, circled in red)
for parts is a 341 x 290mm (13.5 x 11.5 in.) rectangle.
• x0 y0 is located at the center of print area
• As piston indexes down from start position, Z increases
• The maximum z-height for parts is 440 mm (17.3 in.)
• X, Y, Z spacing will vary some based on part geometry,
◊ Thin wall parts can be placed within 1-2 mm of each
other.
◊ Larger, more-massive parts should be placed 3-5mm
apart.
The best orientation and placement of parts will depend on one or more factors, such as:
• Desired time for print job to complete
◊ Print job time is a function of total build height and time to scan the cross-section on each layer
◊ For most geometry, scan time has very small effect on total build time. Use the Sprint Estimate to view layer time and
scan time per layer. It is best to avoid extremely long or short scan times.
◊ Tall, full-stroke builds will take more time to print and more time to cool, both for the initial cooldown in machine and
for nal cooldown on the MQC. Actual cooldown time will vary based on part geometry, as well as Z-height, of the build.
• Part geometry/features - size/shape, important features, mechanical properties
• Amount of powder required - Powder required is largely a function of total build height. Use Sprint Estimate to see amount
of powder required
• DuraForm ProX PA powder blend - Improperly recycled material and/or Fresh blend ratios lower than the recommended
40% Fresh may require some adjustments in orientation, location, and process settings to ensure good part quality. These
adjustments will most likely increase build times
Part orientation and placement in the SLS build volume:

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Part geometry and feature considerations
Thin walls, small pegs, text, small protrusions, or cuts
X and Y Fill and Outline Offsets
Z-offset (Z compensation)
Small Features less than 1 mm will be a󰀨ected by X, Y, and Z o󰀨set values.
While parts will have good detail on both upward- and
downward-facing surfaces, generally the upward-facing
surface will have the best denition for text and small details.
Downward- facing surfaces exhibit a reduced, or softened, stair-
stepping effect.
Outline/Fill Laser beam offsets adjust the outline of a part to compensate for the laser beam diameter. This does not
compensate for regular shrinkage; rather, beam offset performs a topological offset, moving the skin of the part toward the
inside. Features like posts become smaller and features like holes become larger. Beam offset is performed on each slice of the
part as the scan les are created
The beam offset values are set using the following offset parameters: X Fill Offset, Y Fill Offset, X Outline Offset, and Y Outline
Offset. These parameters are set using the scale & offset editor of the respective build preparation software.
When the rst layer of a part or the layer of a part feature is scanned, the laser penetrates to the un-melted material below
the print boundary. Z-offset is used to compensate for this print-through (bonus Z). To compensate for this, downward-facing
surfaces are offset, moving the downward surface up. Thin features (less than layer thickness) oriented parallel to the Z plane
may not print.
Feature Strength
Orient features (such as snaps and pegs), which are subject to
bending stress, in the X/Y plane, so that layers run the length of
the features.
Surface Finish
Curved surfaces built in the Z direction may display stepping because of the layered process. Bead blasting and other post-
processing can minimize or eliminate the layer lines.
Note: Features smaller than twice the outline offset might not print. Use the View Slice option in 3D Sprint to
inspect the print slices. Rotating the part around Z by 45° might allow these small features to print.
Feature Denition
Posts built in Z direction
for feature denition
Posts built in X/Y plane for
strength of lengthwise layers