3D Systems sPro User manual

SLS process
user’s guide
Thank-you for purchasing 3D Systems® SLS® equipment and
DuraForm® materials. Before you start building parts in your
SLS™ process facility, please read this guide carefully to
enjoy optimum process performance and longer equipment
service life.
CONTENTS
Document 23348-M12-00 Revision BAugust 2017
Copyright © 2006 by 3D Systems Corporation. All rights reserved.
3D Systems, the 3D logo, Sinterstation, sPro, SLS, and DuraForm are registered trademarks of 3D
Systems, Inc. Other trademarks are the property of their respective owners.
LIn accordance with laboratory equipment safety standards (EN61010-1, Sect. 5.4.4). If this equipment is used
in a manner not specified by the manufacturer, protection provided by the equipment may be impaired.
Observe all warning labels, and conform to all safety rules described in this manual.
™
Contents
`About This Guide . . . . . . . . . . . . . . . . . 2
`Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
`SLS Process . . . . . . . . . . . . . . . . . . . . . . 43
`Prepare to Build . . . . . . . . . . . . . . . . . 55
`Build Parts. . . . . . . . . . . . . . . . . . . . . . .73
`Break Out Parts . . . . . . . . . . . . . . . . . . 90
`RCM . . . . . . . . . . . . . . . . . . . . . . . . .101
`IRS & IPC. . . . . . . . . . . . . . . . . . . . . . . 133
`SLS System . . . . . . . . . . . . . . . . . . . . 180
`BOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
`Contacting 3D Systems . . . . . . . . . 242
`Glossary . . . . . . . . . . . . . . . . . . . . . . . 245
`Index. . . . . . . . . . . . . . . . . . . . . . . . . . 268
Original Instructions
S

SLS process
user’s guide
ABOUT THIS GUIDE
This guide describes how to create finished SLS parts made of DuraForm® PAplastic
powder laser sintering (LS) material using 3D Systems’ sPro SLS® system and
SLS equipment.
`What’s Inside?. . . . . . . . . . . . . . . . . . . . . . . . . . . .3
`Hazard Warnings. . . . . . . . . . . . . . . . . . . . . . . . .5
`Instruction Formats . . . . . . . . . . . . . . . . . . . . . 6
`Other Useful Documents . . . . . . . . . . . . . . . . 7

SLS process 3 ABOUT THIS GUIDE
user’s guide what’s inside?
What’s Inside?
This SLS Process User’s Guide includes the
sections summarized below. General safety
guidelines are presented first. The rest of the
Guide is organized in two parts. The first part
covers SLS process procedures and the second
covers SLS equipment.
At the end of this guide, you will also find a
Glossary of SLS process terms and an Index. Click
on any red TLA (three-letter acronym) or
SLS process term in this section to display a
definition.
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 DuraForm material.
LTo verify that your facility was properly
prepared for SLS system installation, see the
sPro SLS Process Facility Guide and SLS Process
Facility Layout. For detailed material safety
information, see the DuraForm Material Safety
Data Sheets (MSDS’s). Printed copies of these
documents were included in your SLS powder
material shipment. You can also download
MSDS’s for SLS materials
from3D Systems’ website. (See Other Useful
Documents on page 7.)
SLS Process Procedures
The instructions in these four sections step you
through the SLS process in a general way. When
necessary, they refer you to detailed machine
operating and maintenance instructions in the
equipment section of this guide.
SLS Process - overview of the SLS process from
powder to parts.
Build Preparation - how to prepare 3-D parts for
building using the SLS system’s Build Setup
software; how to clean, power-up, and start-up
SLS equipment, and perform pre-build checks.
LA “build” is a 3-D printout of a build packet
containing STL files of one or more 3-D parts.
You create build packets in the Build Setup
application. See your Build Setup online Help
for detailed build packet setup instructions.
Build Parts – how to run builds on the SLS
system, and how to monitor, control, and modify
a build in progress.
LYou use the Sinter application to run a build.
See your Sinter application online Help for
detailed build instructions.

SLS process 4 ABOUT THIS GUIDE
user’s guide what’s inside?
Breakout Parts – how to remove and cool down
the part cake after a build, then use the BOS to
remove parts from the part cake. This section also
describes how to recycle or dispose of used part
cake powder.
SLS Equipment
This second half of the User’s Guide provides
detailed instructions for the functions you need
to perform on SLS equipment during SLS process
procedures. The process instructions in the first
part of the guide frequently reference equipment
instructions these sections.
SLS Equipment - overview of SLS equipment
featuresand functions. This section includes
illustrations that help you locate SLS equipment
components and controls and convenient menu
maps for the IRS and BOS operator panel
displays.
The four sections after the equipment overview
contain complete safety, operation,
maintenance, and troubleshooting instructions
for each SLS process machine. They focus on the
following:
IRS and IPC - loading powder from the IPC to the
IRS and transferring powder between the IRS,
SLS system, and BOS.
SLS® system - preparing for, and running builds
using the Sinter application and utilities, and
maintaining the SLS system between builds.
BOS - breaking parts out of the part cake and
managing waste and recycled part cake powder.

SLS process 5 ABOUT THIS GUIDE
user’s guide hazard warnings
Hazard Warnings
You will find nine different types of warnings in
this guide. Always heed these warnings. Ignoring
them can expose you and your SLS equipment to
the hazards listed below.
LSee the Safety section for descriptions of safety
labels on your SLS equipment.
WARNING TYPE HAZARD
Safety Alert Machine damage, part damage, and/or data loss.
Electric shock Injury or death from electric shock.
Hot surface Burn injury or fire on hot non-handling surface. Allow surface to
cool before touching.
Hot surface - touch Burn injury or fire on hot handling surface. Allow surface to cool
before touching.
Laser radiation Eye injury or blindness; burn injury; fire.
Crush Injury or death from crushing weight.
Impeller Injury or death from rotating blade or impeller.
Notched belt
entanglement Injury or death from entanglement in notched pulley drive belt.
Air-pressurized
powder
Eye injury or blindness; dust-cloud ignition from escaping
pressurized powder.

SLS process 6 ABOUT THIS GUIDE
user’s guide instruction formats
Instruction Formats
Instructions in this guide use special text formats
to highlight menu commands, keys on the
keyboard, operator panel buttons, and text on
the operator panel display.
Text on Computer Display
Text in LS software menus and windows you
need to find or act on is in bold; for example:
“Open the Machine menu and select Manual
Operations > Inerting.”
“Click the Build button on the main toolbar.
Text you enter in LS software programs is
underlined in typewriter font; for example
In the Heater Control window, enter 130.0
for the temperature Setpoint (°C).”
Keys
Keyboard key names are capitalized; for example:
“Press the Enter key.”
Labeled Controls and Indicators
Labeled switches, buttons, lights, and gauges are
in bold, uppercase text; for example:
“Turn the BOS POWDER TRANSPORT switch
to RECYCLE.”
Operator Panel Buttons
The icons represent operator panel
buttons on the IRS and BOS. The buttons
perform these functions:
Scroll menu options up/down; increase/
decrease/change parameter values.
Select option/accept change; similar to
Enter key on keyboard or YES or OK
dialog button.
Cancel/reject change/exit up one menu
level; similar to Esc key on keyboard or
NO, Cancel, or Exit dialog button.
Operator Panel Display Text
Text displayed on the IRS or BOS operator
panel appears in green text; for example:
From the Process Params menu, choose
RCM Type, then press .

SLS process 7 ABOUT THIS GUIDE
user’s guide other useful documents
Other Useful Documents
The documents listed below will help you get the
most out of your SLS process and equipment. You
can find them in the ..dtm\docs folder of your LS
software installation hard drive (...except for Build
Setup Help and Sinter Help. You access these
through the Build Setup and Sinter applications).
`SLS Process Facility Guide – details SLS
process requirements for facility electrical
power, room construction and atmosphere,
compressed air, nitrogen, coolant, powder,
and network. It also provides SLS equipment
specifications, shipping and information, and
moving instructions. (This guide was sent to
you before installation. A pdf copy is included
in the ..dtm\docs folder for reference.)
`SLS Process Facility Layout – illustrates SLS
process requirements for facility electrical
power, room atmosphere, compressed air,
nitrogen, and coolant. It also shows
equipment dimensions and a recommended
arrangement for your SLS equipment. (This
layout was sent to you before installation. A
pdf copy is included in the ..dtm\docs folder
for reference.)
`Material Safety Data Sheets (MSDS’s) –
online copies of the printed MSDS’s that ship
with DuraForm materials. Make sure
everyone in your facility who handles
DuraForm materials reads these MSDS’s and
follows the safety guidelines in them. To
order extra printed copies of these MSDS’s,
contact 3D Systems Customer Support.
`Build Setup Help – provides detailed
instructions on how to use the Build Setup
application to create and modify build
packets you can run on the SLS system. To
view Build Setup Help, run the Build Setup
program, then select Help > Help on Build
Setup ... from the main window menu bar.
For help on the currently selected Build Setup
command or window, press function key F1.
LYou can also run Build Setup from the
Sinter Application by clicking the Setup
toolbar button.

SLS process 8 ABOUT THIS GUIDE
user’s guide other useful documents
`Sinter Help – provides detailed instructions
on how to use the Sinter application to run
and manage builds on the SLS system. To
view Sinter Help, run Sinter, then select
Help > Online Help from the main window
menu bar. For help on the currently selected
Sinter command or window, press function
key F1.
`Material Guides – give you the material,
machine, and software configuration
information you need to build good parts
with the SLS process. Each Material Guide
describes SLS processing characteristics for
one family of 3D Systems’ DuraForm powder
materials, such as DuraForm PA. They also
include safety and regulatory guidelines for
DuraForm material handling.

SLS process
user’s guide
SAFETY
This section gives the information you need to use 3D Systems’ SLS equipment and
DuraForm LS materials safely. It includes the following topics:
`General Safety Guidelines . . . . . . . . . . . . . . 10
`SLS Equipment Safety Features . . . . . . . . . 12
`Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
`Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . 17
`Environmental Issues. . . . . . . . . . . . . . . . . . . 18
`Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
`Powder Safety . . . . . . . . . . . . . . . . . . . . . . . . . 28
`Nitrogen/Oxygen Safety . . . . . . . . . . . . . . . . 32
`Mechanical Motion Hazard Locations . . . 34
`Hot Surfaces and Powders . . . . . . . . . . . . . . 35
`DuraForm Material Handling Safety . . . . . 36
`IPC Handling Safety . . . . . . . . . . . . . . . . . . . . 37
`Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
`Emergency Shutdown . . . . . . . . . . . . . . . . . . 40
Before using any SLS equipment, your company should have a safety program in place. The
safety program should do the following:
✓Label and point out hazardous equipment,
materials, and procedures.
✓Explain what to do in an emergency
situation.
✓Provide information about the hazards of
equipment and materials in the form of
Material Safety Data Sheets. These are
provided with all materials supplied by
3D Systems.

SLS process 10 SAFETY
user’s guide general safety guidelines
General Safety Guidelines
All SLS equipment is designed with safety in
mind. However, improper use, malfunctions, and
excessive exposure could cause injury.
Follow these general safety guidelines when
operating any SLS equipment:
Training and Instructions
`Do not operate any SLS equipment before
receiving proper training.
`Read and follow all operating instructions.
`Follow all safety rules in this section and heed
all hazard warnings in this guide.
`Do not try to do any equipment maintenance
procedures you were not trained to do.
•Operators are trained to operate the
system and perform all the necessary tasks
to print a part.
•Certified service personnel are those
who have completed the 3D Systems
service training package and are certified
to perform service tasks. Certification may
occur at various levels, and servicers
should only perform tasks they are
authorized and certified to complete.
Machine Handling
`Do not try to access, service, or adjust any
components inside any SLS equipment
enclosure.
`Do not try to open any panel or door while a
machine is running.
`Do not access any area of the machine near
the process chamber high-temperature-
material builds.
`Use special caution when handling a heated
RCM and when dealing with the heated, inert
environment inside the SLS system’s process
chamber. Take note of all thermal hazard
warning labels on the machines.
`Always disconnect the RCM cable before
moving the RCM out of the SLS system or
BOS.
`To prevent crush injuries to the body, use
extra caution when rolling the RCM into and
out of the SLS system and BOS, and when
closing the BOS overhead door. Take note of
all crush hazard warning labels on the
machines.

SLS process 11 SAFETY
user’s guide general safety guidelines
`Dress electrical cables, powder transport
tubing, and coolant hoses to prevent
tripping; especially the umbilical tubing that
connects the IPC to the IRS.
Material Handling
`Do not use any material without first
reviewing its Material Safety Data Sheet
(MSDS).
`To prevent injury and equipment damage, be
sure to follow all handling guidelines in
Powder Safety on page 25 and Nitrogen/
Oxygen Safety on page 30.
Laser
`Do not try to access, service, or adjust the
laser system in any way.
`Do not enter any area displaying posted
warning signs during open beam operations.
Open beam operations refer to the laser, and
they only occur during service procedures.
Alarms and Warnings
`If you hear an alarm, or if you see an error,
alarm, or warning message on any SLS
equipment display, note the state of that
machine’s Stacklight and refer to its
troubleshooting section in this guide. Clear
the alarm, error, or warning message before
resuming operation. (The SLS System
Troubleshooting section might refer you to
the Messages and the Message List Window
topic and/in your Sinter application online
Help.)
`Displayed error, alarm, or warning messages
can result from unsafe practices, such as
opening an enclosure door or panel when
equipment is powered up and running.

SLS process 12 SAFETY
user’s guide SLS equipment safety features
SLS Equipment Safety Features
The main design goal for all SLS equipment is to
provide a safe operating environment. The frame
and enclosure designs passively limit hazardous
access while the electronics and software actively
and automatically sense and react to unsafe
conditions when they arise. For example, if the
SLS system detects unsafe operating conditions,
it will immediately stop operating and, in some
cases, shut down completely.
Safety Interlocks
Safety interlock devices on the SLS equipment
help prevent accidental laser exposure, electrical
shocks, crush injuries, burns, and fires.
SLS equipment will not operate unless all safety
interlocks are satisfied.
If any SLS equipment safety features
fail, your actions may be all that will
prevent potentially hazardous
operating conditions.
Never try to disable or override any
safety interlock device on any
SLS equipment. Operating
equipment without all safety
interlocks enabled can cause
equipment damage, injury, or death.
If you suspect a safety interlock
device is not working properly, do
not operate your SLS equipment.
Rather, disconnect power from the
equipment and contact 3D Systems
Customer Support for assistance.

SLS process 13 SAFETY
user’s guide SLS equipment safety features
SLS SYSTEM RESPONSE IF AN INTERLOCK FAILS
Safety interlock devices mounted on the SLS
system sense the hazardous operating conditions
below. The SLS system takes the actions listed
when an interlock fails.
Limited Access And Barrier Shielding
SLS equipment frame and enclosure designs limit
access to the following:
Service areas, such as cabinets and enclosures
for electrical power and automation controls. This
prevents accidental exposure to electrical shock
hazards.
Powder areas, such as powder feed hoppers,
storage bins, and transport tubes. This prevents:
✓burn hazards by minimizing exposure to
heated powder
✓slip hazards by keeping powder from
dropping on the floor
✓fire hazards by minimizing airborne dust
cloud formation and potential ignition. See
MSDS for complete hazard details.
SAFETY INTERLOCKED CONDITION IF THIS INTERLOCK FAILS...
RCM door open when SLS system is attempting to
start a build • Build will not start
• Warning message appears on SLS system display
• Yellow Stacklight illuminates
RCM not fully raised or engaged with the process
chamber floor after RCM loading
One or more internal process chamber panels are
opena
E-stop button pressed on user interface console • SLS system shuts down
• Nitrogen generator (if in use) shuts down
• Warning message appears on SLS system display
• Yellow Stacklight illuminates
External oxygen monitor connected to SLS system
detects too little oxygen in room
a. Internal panels are for service access only.

SLS process 14 SAFETY
user’s guide SLS equipment safety features
Laser beam optics and scanning areas,
including the fully-enclosed Image Processing
Module (IPM)—where the laser beam
originates—and the interior of the process
chamber, into which the beam projects. The IPM
and process chamber are designed to minimize
hazards such as burns, eye injury, and fire in the
following ways:
✓The IPM optics and laser beam duct (at the
top of the process chamber, below the
removable laser window) prevents the laser
beam from being aimed outside the process
chamber.
✓The fully enclosed process chamber blocks
laser radiation from escaping to the outside.
✓The process chamber window material also
blocks laser radiation so you can safely
observe the part bed during a build.
Other Active Safety Features
✓The Breakout
Station (BOS),
coupled with the
Dust Collector, removes airborne powder
during part breakout in accordance with
standard industrial ventilation practices.
✓An overpressure sensor line monitors the
pressure in the Intelligent Powder Cartridge
(IPC) when it is connected to the Integrated
Recycling Station (IRS). This prevents IPC
container ruptures and accidental material
leakage.
✓Aroom oxygen monitor automatically
initiates SLS system shutdown when it
detects toolittle oxygen in the room.
✓Software in the SLS system, IRS and BOS
automatically initiates immediate equipment
shutdown if certain unsafe conditions are
detected during operation.
See BOS on page 208.

SLS process 15 SAFETY
user’s guide safety labels
Safety Labels
Safety labels are posted on all SLS process
machines. The following table describes each of
these labels.
SAFETY LABEL WHAT IT MEANS
ELECTRIC SHOCK HAZARD
High voltage electricity is accessible in the vicinity of this sign or behind the access panel.
High voltage can cause severe burns or death. Access panels are for service only and
should be opened only by certified service personnel or trained maintenance personnel.
HOT SURFACES HAZARD
There are surfaces and powders in the vicinity that may be hot and could cause severe
burns or fire.
SLS equipment has two types of hot surface hazard labels; one with a hand and one
without. The label with the hand appears on hot surfaces that are normally handled, such
as process chamber access panels. The label without the hand appears on hot surfaces
that are not normally handled, such as the heat shield around the RCM part cylinder.
LASER RADIATION HAZARD
Invisible laser radiation is accessible in the vicinity of this sign or behind the access panel.
Direct and scattered radiation can cause severe burns and blindness. Access panels are
for service only and should be opened only by certified service personnel. See Laser
Safety on page 20.

SLS process 16 SAFETY
user’s guide safety labels
CRUSH HAZARD
Mechanical motion of machine components presents a crush hazard in the vicinity of this
sign. Crush hazards can result in severe bodily injury or death. See Mechanical Motion
Hazard Locations on page 33.
ROTATING BLADE CUTTING HAZARD
Rotating motion of machine blade or impeller presents a cutting hazard in the vicinity of
this sign. Cutting hazards can result in severe bodily injury or death. See Mechanical
Motion Hazard Locations on page 33.
NOTCHED BELT/PULLEY ENTANGLEMENT HAZARD
Motion of notched drive belt on pulley presents an entanglement hazard in the vicinity
of this sign. Entanglement hazards can result in severe bodily injury or death. See
Mechanical Motion Hazard Locations on page 33.
AIR-PRESSURIZED POWDER HAZARD
Sudden, explosive escape of air-pressurized powder presents a hazard in the vicinity of
this sign. Failing to shut off the main powder valve before servicing can result in sudden
explosive escape of air-pressurized powder. This can result in bodily injury or fire if the
powder cloud ignites. See DuraForm Package Handling Safety on page 35.
SAFETY LABEL WHAT IT MEANS

SLS process 17 SAFETY
user’s guide electrical safety
Electrical Safety
To prevent electrical shock, SLS equipment will
not operate unless all external panels are
installed and all electrical safety interlock circuits
are closed.
All SLS equipment was designed to minimize
operator exposure to electrical hazards during
normal operations. All exposed electrical circuits
are inside limited-access cabinets. This is to
separate the operator from service and
maintenance areas.
When operating any SLS equipment, keep the
following electrical safety points in mind:
✓Only 3D Systems certified service personnel
should operate SLS equipment with access
panels or service doors open.
✓Heed high voltage warning signs and labels.
✓Take common-sense safety precautions when
operating any electrical equipment.
✓After any change to the electrical wiring,
make sure the equipment is properly
grounded.
Hazardous voltage exists inside the
enclosures of all SLS equipment.
Injury or death from electrical shock
can result if you remove external
panels or try to defeat safety
interlocks. Panels should only be
removed, and interlocks should only
be defeated, by trained and certified
3D Systems Customer Support
personnel.
Verify your facility’s electrical service
ratings before connecting power to
any SLS equipment.z Power must
only be connected by certified
electrician.

SLS process 18 SAFETY
user’s guide environmental issues
Environmental Issues
The SLS system emits no toxic substances when
using materials approved by 3D Systems.
Emissions
Powder heating – Analytical testing on
3D Systems powders indicates no detectable
emissions outside acceptable limits from the
SLS system. (See the MSDS’s.)
Nitrogen – The SLS system uses nitrogen, which
must be passively vented to the outside.
LDo not install a fan in the nitrogen vent. The
nitrogen-inert atmosphere in the SLS system
process chamber is at higher pressure than the
outside atmosphere. The chamber will vent
without a fan. Installing a fan in the nitrogen
vent will draw nitrogen-rich air out of the
process chamber too fast, raising the oxygen
concentration in the chamber. This can keep
the SLS system from reaching inert, or cause an
in-process build to abort.
Waste Heat
Almost all the electrical power used by the SLS
system and RCM is converted to heat that must
be removed from the room. Air conditioning for
the installation room should be sized based on
room dimensions; the size, number, and location
of wall openings (such as windows and doors),
the number of people typically working in the
room, and the electrical power supplied to the
SLS system(s) and RCM(s).
Use the sPro SLS system, RCM-140, and
RCM-230 electrical power requirements below
to sizeyour facility A/C:
Powder Disposal
Refer to the DuraForm material MSDS for disposal
information. Follow any applicable local
regulations.
MACHINE POWER (HEAT)
sPro 17 kW (~58000 Btu/h)
RCM-140 4.8 kW (~16400 Btu/h)
RCM-230 5.3 kW (~18000 Btu/h)
BOS/IRS negligible (compared to SLS
system and RCM) for the
purpose of A/C sizing

SLS process 19 SAFETY
user’s guide environmental issues
Noise Levels
The following table quantifies the noise levels for
various components of the SLS system.
EQUIPMENT NOISE LEVEL
SLS System <85 dBA @ operator
standpoint
BOS and Dust Collector
BOS only
Dust Collector only
Dust Collector self-
cleaning cycle
<85 dBA @ operator
standpoint
IRS idle
IRS transporting
powder
IRS blending powder
<85 dBA @ operator
standpoint

SLS process 20 SAFETY
user’s guide laser safety
Laser Safety
The SLS system
contains a 70-watt
continuous-wave CO2
laser. The laser itself is
designated Class IV. Very brief exposure to a
direct—or specularly or diffusely reflected—laser
beam can cause significant burns or eye damage.
It can also be a fire hazard.
During normal operations of the SLS system, the
laser beam path is wholly contained within the
machine. This makes the entire machine a Class I
Laser System. That means the SLS system does
not produce damaging emissions under normal
operations.
Laser Safety Classifications
Class I and Class IV are designations established
by the U. S. Department of Health and Human
Services, Public Health Service, Food and Drug
Administration, Center for Devices and
Radiological Health (CDRH), and by IEC 60825
(the International Electrotechnical Commission's
Radiation Safety of Laser Products, Equipment
Classification Requirements, and User's Guide). The
Class I and Class IV laser designations also comply
with DIN VDE 0837/02.86+A1/07.90.
You can read more about laser safety and
classifications in ANSI Z136.1-1993 (the American
National Standards Institute standard for the safe
use of lasers).
Reporting Laser Radiation Exposure
If anyone at your site is exposed to laser radiation
from the SLS system, report the following
information to 3D Systems, Inc.:
`Nature of the accident and circumstances
surrounding it
`Where the accident occurred
`Model and serial number of the machine
`Number of people involved
`Any other pertinent information
Please send this information to 3D Systems
within a day of the accident. The information can
be sent by regular mail to 3D Systems marked
“Attention: Laser Safety Officer” or by e-mail to
[email protected].
See Laser Safety
Classifications below.