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

53D SYSTEMS, INC.
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

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Cylinders and Holes
• Building a cylinder horizontally is faster; but building it
vertically eliminates Z stepping on the sides of the cylinder.
• Holes (or inside diameters of hollow cylinders) will also have a
better appearance when built in X/Y plane
• If the cylinder has another smaller cylinder attached to it, and is
lying down, make sure that the smaller cylinder is facing in an
upward orientation.
• If standing up, orient the smaller cylinder in the direction of the
roller.
Closed Boxes, Cylinders, and Shapes
Geometries that are closed on all but one side should be placed in the print area with the open side facing up. This reduces heat
buildup in the print cake and the part, making breakout easier and extending material life.
Nesting
You can nest smaller parts within larger ones to utilize more of the print area, as
long as the smaller parts can be removed after printing. If you nest parts, you
should maintain a minimum of 0.25 inches (6.35 mm) between the closest walls
of each part to the others. The part containing the nested parts should always be
facing with the open side up.
Triangular
Try to place the triangular shapes in the print so
that none of the three sides is perpendicular to
the direction of the roller motion, and so that the
base is not at the top in orientation. This offers less
resistance to the material as it ows across the print
bed (thus reducing the possibility of shifting) and will
result in a atter base.
Large blocky part
Thick cross-sections that have features with X/Y slices or Z depth greater than 12.7 mm (0.5 in.) are more likely to experience
distortion. Start these demanding parts later in the build (at greater Z), after other parts have already been built underneath
Rotating the part a few degrees about X and/or Y can help to mitigate this distortion. Rotation to 30° is shown to give good
results. Along with rotating around X and Y axes, rotating around the Z axis can also help reduce distortion
Refer to the Distortion section for more information.
Mating Surfaces
Parts that are to be printed in more than one piece, or parts that will have mating surfaces, should always be placed such that
the mating surfaces are printed in the same orientation. It is preferable that the mating surfaces be printed facing upward for
atness. If this is not possible, print the mating surfaces in the Z-axis. The least desirable-choice for orientation would be to
print the parts with the mating surfaces facing downward.
Preferred
Avoid
Roller Motion
Avoid
Preferred
Roller Motion
Orientation for cross sections

93D SYSTEMS, INC.
Cross-sections on a layer
Pay attention to the total cross-sectional area of the parts on
a layer. If there are multiple parts that contain heavy cross-
sections, make sure the parts are located so that the large cross-
sections happen on different layers. This will reduce the chance
of short feeds.
Although the process parameter default values in the Standard mode are optimized by 3D Systems, slight adjustments may be
needed to further optimize the process for specic powder blends and applications.
Part and Scale parameters - set for each individual part. Part parameters include laser power and scale for shrinkage.
The prole editors in the Build Prep software and in Sinter are used to adjust parameter values. You create a row in the table for
the initial value and for each Z height when the parameter should change. If you intend for a parameter to use the same value
throughout a build, its table should have only one row, with a Z height of 0.000 and the desired value. Prole Editors will show
Min, Max, and default values for parameter values.
Build set points, Parameter values - set independently for each stage by specifying a stage z value with an associated
parameter value. Build parameters include part heater set point and feed dose amount, etc.
Due to the material blend or application specic needs, it may be necessary to increase or decrease the part bed set point.
• If part cake at breakout is too soft overall, then increase the part heater set points by small increments (0.5 to 1.0
degrees)
• If part cake at breakout is too hard overall, then decrease the part heater set point by small increments (0.5 to 1.0
degrees)
This value is the rotation of the Feed Roller (located in the feed hopper). It controls the amount of the feed dose.
• The default values should release enough powder from the feed hopper so that when the traverse roller moves across the
part bed, there is sucient powder to cover the entire build area and deposit a small amount in the powder-return piston.
Observe the feed dose when preparing the printer for a print job.
◊ During the warmup and cooldown stage, a smaller feed dose is adequate.
◊ During build stage (during scanning), a larger feed dose is required to completely cover the scanned area.
• If the powder dose is too small, there is a possibility of short feeds. See Short Feeds in the glossary.
• If the powder dose is too large, the powder dose may not properly heat, and large amounts of powder will be pushed past
the return piston.
• Increase or decrease the Feed Powder amount in small increments of 0.01.
• If scanned area is very similar on each layer, the same feed amount can be used for entire build stage. If scanned area
varies signicantly from layer to layer, then use an amount that will work for the layers with the larger area, or prole the
feed amount.
• If the printer is not run for several days, it may take several layers while leveling powder for feed powder to dispense
properly.
• If Feed Hopper is emptied completely and then re-lled, allow at least two hours before starting a build so that powder
settles and feeds correctly.
Print Process Settings
Part Bed Heater Set Point
Feed Powder Amount
Note: On SLS 380, the IR camera balances the individual heater output during the build to maintain an even
temperature across the build area so there is no need to adjust individual heater output.

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• Clean Laser Window is place
• Coolant chiller is on and coolant temperature is 20°C
• Sock lter is in place and empty
• Compressed air is on
• MQC is in Full Cycle mode
• Adequate powder is in MQC (in blended bin) or that MQC will be able to blend more if needed
◊ Use 3D Sprint Material estimate to determine the amount of powder required
◊ As a rule of thumb - approximately 1 liter of DuraFormProX (PA or GF) powder is needed for every 8-10 mm (0.3-0.4
inches) of build height.
◊ The Feed Hopper holds approximately 18 liters; but as a normal practice, you should keep the hopper full by allowing
the MQC to send powder to the hopper as the powder level drops below upper proximity sensor.
• Heater Trays are in correct position
• If needed: move part piston to start position and home the roller
• Use Add Powder in Manual mode to create a level powder bed.
◊ Observe feed dose for consistency and uniformity
• Verify IR core temperature is 77°
◊ The temperature is displayed in the Status Window. If the print chamber doors are open (or any interlocks are not
made), the IR core heaters will not be on.
• Verify Laser Window N2 ow setting is 4 lpm
◊ If the print chamber doors are open (or any interlocks are not made), there will be no N2 ow.
If a DuraForm ProX PA print has been terminated, you will probably not be able to successfully restart it. The thermal conditions
necessary for DuraForm ProX PA material generally do not allow for successful restarts of terminated prints.
To operate the Material Quality Control (MQC) System, refer to the MQC 600 Single/Flex User Guide.
3D Systems suggests the following sifting techniques for DuraForm ProX PA material:
• Do not remove the print cake from the print chamber until the print bed temperature is approximately 85°C. Allow the print
cake to continue cooling to 50°C before trying to break out parts.
• Remove loose material from the print cake. Sift the loose/soft material using the MQC System; but discard the hard and
chunky material from the nal breakout and part cleaning.
• Sift the loose/soft material from the print cake between each print.
To operate the Material Quality Control (MQC) System, refer to the MQC 600 Single/Flex User Guide.
After a print, loose/soft material can be sifted and reused in another print. Consistent recycling procedures are important
in order to maintain consistent material properties. If recycling procedures are not followed, problems such as variable
shrinkages, part quality issues, and mechanical properties will be reduced.
The DuraForm ProX PA material is a very ne blend of small particles. As you run prints, the material is exposed to heat and
energy, and the particles tend to stick together, forming larger particles. You can offset this trend with sifting and blending.
Sifting removes undesirable particles, and blending adds new ones of proper size.
Verify Before Every Print
Restarting a Terminated Print
Sifting Material
Recycling Material
Note: If you suspect a problem with your IR sensor core temperature control, contact 3D Systems Field Service.
If feed dose is not uniform or consistent, see the Troubleshooting section of this guide.
Note: When collecting material from the print cake, use only the soft powder. Powder that is hard and must be
physically broken down should be discarded. Discard powder next to parts, in crevices, and any hard clumps
that do not break apart easily by hand.

113D SYSTEMS, INC.
Please see the MQC 600 Single/Flex User Guide. At any particular fresh powder ratio setting, the minimum volume of fresh and
used powder required to initiate a blend are displayed on the MQC home screen.
The default fresh powder ratio setting for DuraForm ProX PA material is 40%.
Material may build up on the roller and in other areas in the print chamber, as well as on the MQC System. Refer to the
procedures in your printer’s User Guide for the following cleaning information:
• Cleaning the SLS System between Prints
• Cleaning the Laser Window
• Cleaning the Blackbody section
• Cleaning the Overow Screen
• Cleaning the Sock Filter
Blending Fresh and Used Material
Cleaning up the SLS System

123D SYSTEMS, INC.
3POST-PROCESSING
This chapter covers various techniques for improving part surface nish after breakout and only highlights a limited number of
basic post-processing techniques. Many companies develop their own techniques based on their unique needs.
This chapter includes the following topics:
• Tools and Cleaning Media
• Cleaning Procedures
• Repairing and Joining Parts
• Power Sanding
• Wet Sanding Procedure
• Sealing and Inltrating Parts
• Sealing with a Water-Based Polyurethane
• Sealing with Imprex Superseal
TOOLS AND CLEANING MEDIA
The following is a typical list of tools and cleaning materials that you can use for post-processing:
• Hand-held les
• Round sanding tools
• Flat sanding tools
• Sandpaper (approximately 150 grit)
• Glass media blaster with a recommended bead size of 70 to 140 µm
• Cleaning cloth
• Pin vise with small drill bits
• Mini belt sander with 120 grit sandpaper belts
CLEANING PROCEDURES
Before performing any other post-processing technique, thoroughly clean the parts. To clean a DuraForm ProX PA Plastic part:
1. Remove the print cake from the print chamber.
Caution: 3D Systems recommends allowing the print cake to cool to room temperature before removing
parts from it.
2. Brush away all loose material to expose the part.
3. Use appropriate hand tools to remove all remaining material in corners and holes. Use a drill bit to clear holes.
NOTE: Do not recycle or blend this powder. It should be discarded.
4. Using a glass bead media blaster at 4.8 bar (70 psi), hold the part approximately 127 mm (5 inches) from the nozzle and
blast it.
NOTE: Holding the nozzle too close to the part can cause “burning” (surface discoloration and degradation).
For a better surface nish, continue with the “Wet Sanding Procedure”.
REPAIRING AND JOINING PARTS
3D Systems recommends cyanoacrylate (super) glues for repairing or joining parts made with DuraForm ProX PA Plastic
materials. Use an accelerator with the cyanoacrylate. As an alternative, you can use a thin epoxy (such as a 5-minute epoxy).
POWER SANDING
You can use a mini-belt sander (with 5/16-inch belt, 120 grit, medium speed) to remove layering on the side walls of parts
printed with DuraForm ProX PA Plastic materials.
WET SANDING PROCEDURE

133D SYSTEMS, INC.
Tools and Equipment Required
• Sand paper (220 to 1200 grit)
• Running water
• Cloth or paper towel for drying part
Complete the following steps to wet sand a part:
1. Dip the clean part in water.
2. Sand the surface until you achieve the desired nish. Start with 220 grit followed by 320 grit, 400 grit, 600 grit, and 1200
grit.
NOTE: After using 320 grit, be sure to change the water frequently.
SEALING AND INFILTRATING PARTS
Parts printed with DuraForm ProX PA Plastic materials can be sealed or inltrated with a variety of products, including primers,
paints, polyurethanes, cyanoacrylates (i.e. “super glues”), and epoxies.
The parts tend to be dense, so low viscosity products or products that can be thinned are easier to use and would be
advantageous to use to avoid altering a part’s dimensions.
For full inltration, 3D Systems recommends that you use a vacuum chamber to inltrate parts. If you only need a surface coat
of sealant, then brushing or dipping is sucient.
Caution: When working with inltrants, use solvent-resistant gloves in a well-ventilated area, and follow
proper safety precautions.
Some suggested products:
• Thermal-Cure Sealants: Godfrey & Wing Inc.
220 Campus Drive, Aurora, OH 44202
Phone: [phone]
Toll free: +1.800.241.2579 Fax: [phone]
http://www.godfreywing.com/vacuum-impregnation/sealants/types-of-gw-sealants
Part Number: 95-1000A + catalyst
• UCAR Vehicle 443 Acrylic Emulsion: A Union Carbide product.
Mix 72% emulsion with 28% water to create a 32% solid mixture. Dip the parts in this mixture for a surface coat. Use an
industrial oven at 70° C to dry parts afterwards.
• Cyanoacrylates: 3D Systems recommends Loctite 408. For cyanoacrylates, use of an industrial oven or vacuum chamber is
not recommended.
See also Repairing and Joining Parts.
SEALING WITH A WATER-BASED POLYURETHANE
You can use any water-based polyurethane sealant to inltrate and seal parts printed with DuraForm ProX PA Plastic materials.
Tools and Equipment Required:
• Metal pans deep enough to submerge parts
• Foam brush or applicator (optional)
• Industrial oven (optional)
• Vacuum Chamber (optional)
Procedure
1. Sand the part before sealing, if desired. See Wet Sanding Procedure.
2. Coat and inltrate the part with sealant using one of the following methods:
• Paint the sealant on with a foam brush.
• Immerse the parts in a container of sealant for ve minutes. If the parts oat, weigh them down or hold them down.
• To fully inltrate thick-walled parts (i.e. parts with walls more than 7.5 mm [0.3 inches] thick), place them in a container
of sealant in a vacuum chamber until air stops bubbling out of the sealant.

143D SYSTEMS, INC.
SEALING WITH THERMAL-CURE SEALANTS
Tools and Equipment Required:
• Foam brush or applicator
• Thermal Cure sealant
• Convection Oven capable of at least 100°C
• Vacuum Chamber (optional)
Procedure
1. Place the clean part on a tray to catch excess sealant.
2. Apply the sealant to one side of the part using the foam brush. Be sure the entire side is coated.
3. After the part face is coated, let the sealant sit on the part for 5 to 10 minutes to saturate the part surface.
4. Turn the part over and apply sealant to the back side of the part.
5. Set the oven to 100°C. Remove any excess sealant and place the part in the oven for 1 to 1.5 hours or longer for parts with
thick cross-sections.
6. Remove the part and apply a second coat of sealant, repeating steps 2 through 5.
3. Remove the part from the sealant and shake off the excess.
4. Use compressed air to blow excess sealant off of inside features and out of cavities.
• Air dry the part for 4 to 24 hours, depending on part density and size. You can speed drying by using an oven at low
heat (50°C).

153D SYSTEMS, INC.
4PROPERTIES AND HANDLING
This chapter contains general information about DuraForm ProX PA Plastic, its properties and how it should be handled. It
includes the following topics:
• Safety Data Sheets
• Material Handling
• Material Storage and Disposal
SAFETY DATA SHEET
3D Systems provides safety data sheets (SDSs) with safety and handling information for the DuraForm ProX PA Plastic material.
The document control number (DCN) for DuraForm ProX PA Plastic SDS is:
• DuraForm ProX PA Plastic: DCN 24168-S12-00-A
MATERIAL HANDLING
For complete information, refer to the Safety Data Sheet (SDS) for DuraForm ProX PA Plastic.
Observe the following:
• Avoid spilling material on the oor; and clean it up promptly if you do. Spilled material can cause oors to be very slippery.
NOTE: The operator must use an approved vacuum cleaner to clean up excess material. 3D Systems
recommends an ESD or explosion-proof model. Contact 3D Systems Customer Service for purchasing options.
• After vacuuming spilled material, use a wet mop to clean the oor. The powder is dicult to sweep up.
• Due to the small particle size of DuraForm ProX PA Plastic material, it is likely to become airborne during handling. For con-
ditions where exposure to dust is likely, 3D Systems recommends a NIOSH-approved dust respirator for dust appropriate
to the airborne concentration. Such conditions might include handling of material at the SLS system or the Material Quality
Control (MQC) System.
MATERIAL STORAGE AND DISPOSAL
This section contains storage information for DuraForm ProX PA Plastic, as well as disposal instructions.
General Storage Information
For information regarding the MQC System, refer to the MQC 600 Single/Flex User Guide.
To avoid contamination, spilling, dust clouds, or mixing different types of materials:
• Store used material in properly labeled containers. Be aware that they are subject to contamination, unless you seal them
in some manner.
• Do not mix one type of material with another.
Storing DuraForm ProX PA
If the material becomes contaminated, its processing characteristics may change. This can produce undesirable results in part
quality. The following storage guidelines suggest ways to minimize contamination and keep powder under optimum conditions:
• Store at a temperature of 40°C or less.
• Seal the container.
Material Disposal
When disposing of DuraForm ProX PA, follow any local ordinances and the guidelines in the Safety Data Sheet (SDS).

163D SYSTEMS, INC.
5TROUBLESHOOTING
This chapter is organized alphabetically by issue name. It contains the following topics:
• Introduction to Problem Solving
• Part Bed Temp/Set Point
• Distortion
◊ Lean
◊ Curling, visible during build
◊ Curling or warping not visible during build
° Bottom Distortion
• Bonus Z (Print-Through)
• Clumping
• Cracking of Print Bed
• Condensation
◊ Laser window
• Glazing, During Print
• Growth
• Melting, Print Bed
• Short Feeds
• Wash Out
• Weak Parts/Porosity
INTRODUCTION TO PROBLEM SOLVING
While optimizing prole parameters can eliminate many problems, it is often useful to monitor a print so you can establish the
process parameters.
There are two reasons to observe a print:
• Some parts may require attention and adjustment during the print.
• Your proling will become more accurate through observation. As your proling becomes more accurate, the need for
future observation will become less frequent.
Problem Description Format
You will nd the following information about each issue:
• Description: Explains the problem and provides a visual representation of it. The description includes such things as where
and when the problem might occur.
• Theory of Cause: Contains a brief explanation of what might have caused the problem.
• Visual Signs: Describes any observable information that may not be covered in the Description section.
• Consequences: Details what can happen to print quality if you do not correct the problem.
• Corrective Action: Describes what you can do to avoid or recover from the problem.
• Related Problems: Indicates whether this problem might interact with or be related to another problem.
Interaction of Variables
Many of the problems just described involve variables that interact with each other. For example, excessive print bed heat or
excessive laser power can cause growth. Insucient print bed heat can cause distortion. Insucient laser power can cause
weak parts. Refer to the sections titled Growth and Weak Parts/Porosity.

173D SYSTEMS, INC.
Part Bed Set Point is the desired temperature of powder surface in part build area. This optimum temperature may vary slightly
depending on the material blend and application.
The IR sensor provides feedback of actual part bed
temperature. The blackbody is used to calibrate the
IR sensor during the Oine IR Calibration. See printer
user guide for the Oine IR cal procedure. During
print jobs, automatic Real time calibration checks are
done to check for IR sensor remains in calibration.
• Part Bed temp too high results in hard part cake/hard break out/growth on parts. In extreme cases, the part cake will melt.
• Part Bed temp too low could result in curled parts. In extreme cases, parts curl up so much that the roller catches and jams.
• Why you might need to adjust Part Bed Set Point:
◊ Powder blend (#1 reason to adjust)
° Default part bed set point in each material should be good for recommended blend ratio for that material
° If part cake at breakout is too soft overall, then increase the part bed set point next build by small increment (0.5 to
1.0 degrees).
° If part cake at breakout is too hard overall, then decrease the part bed set point next build by small increment (0.5
to 1.0 degrees).
◊ Blackbody calibration is incorrect or blackbody is damaged.
Potential Print Problems
• Excessive laser energy will affect material outside the cross-section of the part and cause growth.
• Insucient laser energy does not fuse the part completely, which results in porous, weak parts.
• If the print bed temperature is too low, the parts will curl as the laser scans them.
• If the print bed temperature is too high, the parts will be dicult to remove from the surrounding material.
• If the feed material temperature is too low, the parts will be cooled too quickly when the material is rolled across the bed
and they will curl.
• If the feed material temperature is too high, the material will not be released from the feed hopper and chute correctly,
and the material will not roll correctly in front of the roller.
Before proceeding with troubleshooting, keep in mind the following information:
IR Sensor eld of view
BONUS Z
Description: Bonus Z occurs when the laser melts a part beyond the specied depth—
usually 0.1 mm (0.004 inches) on the rst few scans—and causes vertical growth in the Z
axis. The difference between growth and bonus Z is that growth may occur on any part
edge, while bonus Z occurs only on downward facing surfaces.