3D Systems ProX SLS 6100 User manual

3D Systems, Inc.
ProX® SLS 6100
3D Printer
User Guide
Original Instructions

3D Systems, Inc. ip/n 76-D020 Rev. A
CONTENTS
1INTRODUCTION ........................................................................................1
About This Guide......................................................................................1
What’s Inside? ..........................................................................................1
Introduction to the ProX® SLS 6100 ........................................................................1
Safety Guidelines and Instructions.........................................................................1
Printing Parts with the ProX® SLS 6100.....................................................................1
ProX® SLS SLS 6100 System Operations.....................................................................1
Machine Operations......................................................................................1
2INTRODUCTION TO THE PROX® SLS 6100..................................................................2
Auxiliary SLS Equipment ...............................................................................3
Nitrogen Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Bead Blaster (Optional) ..................................................................................3
ProX® SLS 6100 System Components ....................................................................4
ProX® SLS 6100 User Interface............................................................................4
Part Transfer Cart Assembly ..............................................................................6
ProX® SLS 6100 Stack Lights ..............................................................................6
3SAFETY GUIDELINES & INSTRUCTIONS ....................................................................7
General Guidelines ....................................................................................7
Training and Instructions ..............................................................................7
Machine Handling ....................................................................................7
Material Handling.....................................................................................7
Laser ................................................................................................7
Alarms and Warnings..................................................................................7
Safety Symbols and Definitions .........................................................................8
First Aid Section – What to do ..........................................................................9
Burns ..................................................................................................9
Reporting Laser Radiation Exposure .......................................................................9
Electrocution ...........................................................................................9
SLS Equipment Safety Features ........................................................................10
Safety Interlocks .......................................................................................10
SLS System Response if an Interlock Fails ..................................................................10
Limited Access and Barrier Shielding......................................................................10
Other Active Safety Features .............................................................................11
Electrical Safety......................................................................................11
Emissions .............................................................................................11
Material Disposal.......................................................................................11
Laser Safety .........................................................................................12
Laser Safety Classifications ..............................................................................12
Laser Safety Labels on the SLS system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Material Safety ......................................................................................13
Material Ignition Information ............................................................................13
Finding Material Safety Information ......................................................................13
Material Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Material Handling Precautions ...........................................................................14
Safe Material Handling Guidelines ........................................................................14

3D Systems, Inc. ii p/n 76-D020 Rev. A
Nitrogen/Oxygen Safety ..............................................................................15
Oxygen Deprivation Effects and Symptoms ................................................................15
4PRINTING PARTS WITH THE PROX® SLS 6100 .............................................................16
ProX® MQC System Preparation .......................................................................16
ProX® SLS 6100 Start-Up Sequence.....................................................................16
PrepaRING A PRINT JOB USING 3D SPRINT ..............................................................17
Position Parts in the virtual build volume ..................................................................18
Modify Build and Part Parameter Values for the Print Job (optional) ...........................................18
Quality Check (optional) .................................................................................19
Build Time & Material Estimate ..........................................................................19
Pre/Post Build Checklist ..............................................................................20
Print Job Prep ..........................................................................................20
Daily/Every Print........................................................................................20
3D Sprint build packet preparation .......................................................................20
Build Parameters: Print bed heaters ......................................................................20
Before Starting the build:................................................................................21
Build Removal .........................................................................................21
5PROX® SLS 6100 SYSTEM OPERATIONS ...................................................................22
ProX® SLS 6100 Start-Up Sequence.....................................................................22
3D Sprint and Sinter Applications ......................................................................22
Messages in the Sinter Application .......................................................................22
About the Message List Window..........................................................................22
Restarting a Terminated Build. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Viewing a Build In Progress ..............................................................................23
Viewing Options on the Toolbar ..........................................................................23
Options on the Viewer Menu.............................................................................23
Pausing a Build ........................................................................................24
Modifying a Build in Progress ............................................................................24
Modifying Part and Build Profiles .........................................................................24
Adding and Deleting Parts and Other Changes .............................................................25
Running a Prime Cycle ..................................................................................25
Manual Operations...................................................................................26
Homing the Part Piston and Roller........................................................................26
To Home the Part Piston ................................................................................26
To Home the Roller .....................................................................................26
Adding and Leveling Powder.............................................................................26
To Add and Level Powder................................................................................26
To Use the Add Powder Layer Dialog Box ..................................................................26
Change the settings for each parameter in the Add Powder Layer dialog box to the settings you want, then click the
Add Layer button. ......................................................................................26
The following parameters are available to set in the Add Powder Layer dialog: .................................27
Add Powder Layer Parameters ...........................................................................27
Calibrating the IR Sensor ................................................................................27
To Perform Manual IR Calibration ........................................................................27
Removing the Print Cake from the Print Chamber .......................................................28
Where to Cool Down the Print Cake .......................................................................28

3D Systems, Inc. iii p/n 76-D020 Rev. A
Unloading the Print Cake After a Print.....................................................................28
Breaking Out Parts...................................................................................30
Part Finishing After Breakout ............................................................................30
6MAINTENANCE PROCEDURES ...........................................................................31
Maintenance Procedure Precautions ...................................................................31
Maintenance Kit .....................................................................................31
Print Chamber Maintenance ..........................................................................31
Replacing Light Bulbs in the Process Chamber .............................................................31
Cleaning the Print Chamber .............................................................................31
To Clean the Print Chamber..............................................................................32
Tools and Supplies .....................................................................................34
Cleaning the Laser Window ..............................................................................34
Replacing the Laser Window .............................................................................37
Cleaning the IR Sensor (Inspect first and olny clean if necessary) .............................................37
Cleaning the Black Body.................................................................................37
Cleaning the Exhaust Port ...............................................................................37
Cleaning and Replacing Filters ........................................................................38
ProX SLS 6100 Filters....................................................................................38
Exhaust Processing Module Filters........................................................................38
Electrical Enclosure Filter ................................................................................39
Replacing Electrical Enclosure Filter.......................................................................39
Transporter Filter (“Sock” Filter) ..........................................................................39
Cleaning or Replacing the Transport Filter .................................................................39
7USER MAINTENANCE CHECKLIST ........................................................................40
Daily/Every Print.....................................................................................40
Weekly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Monthly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Every 3 months ......................................................................................41
Every 6 months ......................................................................................41
AS NEEDED ..........................................................................................41
MQC – User Maintenance .............................................................................41
3D Preventative Maintenance – Annual.................................................................41
8EC DECLARATION OF CONFORMITY ......................................................................42

3D Systems, Inc. 1p/n 76-D020 Rev. A
Thank you for purchasing the 3D Systems ProX® SLS 6100 (Selective Laser Sintering) 3D Printer, auxiliary SLS equipment,
and 3D Systems materials! Before you start printing parts with your process facility, please read this guide carefully to enjoy
optimum process performance and longer equipment service life.
ABOUT THIS GUIDE
This guide describes how to operate and maintain your ProX® SLS 6100 3D Printer, and auxiliary equipment used for the SLS
process. For part printing instructions, refer to the Material Guide for your specic material. The SLS Single MQC System Use
Guide can be found here.
What’s Inside?
This guide includes the sections summarized below:
Introduction to the ProX® SLS 6100
This section describes basic components and concepts of your SLS system.
Safety Guidelines and Instructions
The Safety section tells you what you need to know to avoid injury or equipment damage. Read this section before you switch
on power to any SLS equipment or handle any material.
Printing Parts with the ProX® SLS 6100
This section gives you an outline of the entire part printing process.
ProX® SLS SLS 6100 System Operations
This section describes the printer and provides operating instructions for manual control of the machine.
Machine Operations
This section provides an overview of Material Quality Center (MQC) operation, refer to SLS Single Use MQC System operations
or SLS Dual Use MQC System operations for your specic MQC.
OTHER DOCUMENTS
Refer to the following manuals for additional information:
3D Sprint Quick Start Guide
This guide takes you through the 3D Sprint SLS workow for setting up your rst print with the new ProX SLS 6100
Material Guides
Each material used with the ProX® SLS 6100 system has its own manual which details the part printing and processing
procedures specic to that material.
ProX® SLS 6100 Facility Guide
Details the necessary requirements to install your ProX® SLS 6100 3D Printer, SLS Single Use MQC System, and auxiliary
equipment can be found here.
1INTRODUCTION

3D Systems, Inc. 2p/n 76-D020 Rev. A
The ProX® SLS 6100, the new cutting-edge Selective Laser Sintering (SLS)
production 3D printer from 3D Systems, takes SLS toughness, part quality and
manufacturing economics to the next level. Designed for smooth integration with
your manufacturing workow, the ProX® SLS 6100 produces parts for a variety of
end-use and functional prototyping applications in aerospace, medical, industrial
design and more. Use the ProX® SLS 6100 and DuraForm® plastic materials to
produce parts with superior mechanical properties, resolution, surface nish and
edge denition compared to other processes.
Ensure repeatable, consistent, tool-free manufacturing and produce durable
functional parts faster with this mid-size production 3D printer. Additionally,
the ProX® SLS 6100 is equipped with mature production automation, mobile
production control and material recycling functions, so it pays you back faster.
ProX SLS 6100 AT A GLANCE
F
B
A
D
E
C
Stacklight: Indicates the state of the
system.
Print Chamber Area: There are two doors
in front of the Print Chamber—the outer
locking door, and the inner print chamber
door. The parts are printed inside the Print
Chamber.
E-Stop: The Emergency Stop button is a
safety mechanism used to shut off the
machine in an emergency situation in which
it cannot be shut down in the usual
manner.
User Interface (UI): The user controls the
system using a monitor, keyboard and
pointing device.
LED Interface Lights and Controls: There
are three LED lights which give the user
visual feedback regarding the system. The
two buttons allow the user to control the
chamber lights and enable the system.
There is one standard USB port beneath
them.
User and Service Access Panels: There are
two types of panels on the sides and back
of the machine—user access and service
access. The user access panels are hinged
doors. The service access panels are lift-off
panels.
A
B
C
D
E
F
2INTRODUCTION TO THE PROX® SLS 6100

3D Systems, Inc. 3p/n 76-D020 Rev. A
AUXILIARY SLS EQUIPMENT
There are several auxiliary components which can accompany the ProX® SLS 6100 system. The Nitrogen Generator and Bead
Blaster (optional) are shown below.
Bead Blaster (Optional)
If you plan to use DuraForm SLS material, 3D Systems
recommends you install a pneumatic abrasive blast
cabinet (“bead blaster”) in the part nishing area
separate from the ProX® 6100 SLS 3D Printer process
station room.
Nitrogen Generator
3D Systems manufactures a High-Performance Nitrogen
Generator — Part Number 104011-02. The generator is ideal for
SLS applications.
3D Systems
Nitrogen
Generator
Compressed
air inlet
O2exhaust
N2outlet
N2exit

3D Systems, Inc. 4p/n 76-D020 Rev. A
ProX® SLS 6100 SYSTEM COMPONENTS
ProX® SLS 6100 User Interface
The User Interface, located on the front panel of the printer, consists of a monitor and the system status LED indicators. An
E-Stop is located above the touchscreen.
B
C
A
User Interface: The user controls the system using a keyboard
and pointing device located below the monitor.
Emergency Stop: This switch, located above the monitor,
immediately disables all hazardous machine functions or renders
them safe. However, some surfaces may remain hot and care
should be taken when handling them. After being pressed, it
remains in the closed state until it is manually returned to the
open state
Buttons, Indicators, USB Ports:
Chamber Lights: This button turns the chamber lighting on or
off
LED Indicators: The LED indicators under the monitor indicate
the system’s power and safety status. Each indicator operates as
follows:
• “Laser”Blue LED
-ON, Solid
»Laser is enabled.
-OFF
»Laser is not enabled.
• “Control” Green LED
-ON, Solid
»System is on and its controller has initialized.
»The system is in RUN mode.
-OFF
»System is OFF or its controller is still initializing.
• “System” Amber LED
-ON, Solid
»All E-stop buttons are reset, and system power is
enabled.
-OFF
»An E-stop button is pressed or system power is not
enabled.
System Enable: This button re-enables the system following an
emergency stop, which occurs after the emergency stop switch
returns to the open state.
USB: There is one standard auxiliary USB port connected to the
control PC. It is located under the LED Indicators.
A
B
C

3D Systems, Inc. 5p/n 76-D020 Rev. A
Electrical Cabinet
Computer: A computer which handles much of
the functionality of the user interface and printer
is located inside the electrical cabinet. It is part
of a wider system of electronic components
(Field-Programmable Gate Arrays, Digital Signal
Processors, etc.) which control the hardware of
the system.
Main Power
Disconnect
Power Supply: This module distributes all the AC
power that the system needs. Circuits for the various
subsystems are located in this module.
Main Power Disconnect: The main power
disconnect, located on the rear side of the
system on the right panel door, enables you to
turn on and off all power to the system. Do NOT
position the equipment so that it is dicult to
operate this device. There is a computer reset
button on the right side of the machine, that the
user may need to access in order to reboot the
software if it should become inoperable.
ProX® SLS 6100 Rear View
Computer
Computer
Reset Button
Power Supply
Drop

3D Systems, Inc. 6p/n 76-D020 Rev. A
ProX® SLS 6100 Stack Lights
The stack lights let the user know from a distance what state the system is in. There is a stack light for
both the main system and the ProX® MQC System.
ProX® SLS 6100 System Stack Light Conditions
Light Color Solid Flashing Off
Red E-Stop condition System fault active Normal
Yellow System is in service
mode
System warning active and/or
message present on touchscreen
E-Stop condition
or normal
Green Print job active System Active, not printing,
manual operations possible
E-Stop condition
or normal
Part Transfer Cart Assembly
The print cake Extraction Cylinder, Part Transfer Tray and Part
Transfer Cart, are used to remove the print cake from the ProX® SLS
6100 print chamber and transport it to the MQC System. The system
ships with the cylinder and tray. The transfer cart is optional.
Part Transfer Cart
Part Transfer Tray Extraction Cylinder