EOS P 396 Installation guide

1Training manual
1EOS P396
1Installation ConditionBasic training

1EOS P 396
1Laser-sintering system for plastics

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Training manual • Basic training • Status 03.14
0EOS P 396
1 About this manual ...
Legal notes......................................................................................................................................1.1
Layout and contents ....................................................................................................................1.1
Conventions....................................................................................................................................1.1
Representations ......................................................................................................................1.1
Terms..........................................................................................................................................1.2
Definitions ................................................................................................................................1.2
Pictograms................................................................................................................................1.3
Safety warning in this manual ...........................................................................................1.3
Hotline .............................................................................................................................................1.4
2 Laser sintering process
Basic information on the laser sintering process ................................................................2.1
Physical process ......................................................................................................................2.1
Building process......................................................................................................................2.2
Factors that affect the laser sintering process ....................................................................2.3
Building temperature ............................................................................................................2.3
Exposure....................................................................................................................................2.5
Exposure types ..................................................................................................................2.7
Process-related effects .........................................................................................................2.8
Shrinkage............................................................................................................................2.8
Distortion......................................................................................................................... 2.10
Ambient conditions............................................................................................................. 2.11
3 Layout, function of machine and accessories
Machine...........................................................................................................................................3.1
Layout ........................................................................................................................................3.1
Overview .............................................................................................................................3.1
Front of machine, open ..................................................................................................3.2
Rear of machine, open....................................................................................................3.3
Left of machine, open.....................................................................................................3.4
Front of switching cabinet ............................................................................................3.5
Contents

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0.2 Training manual • Basic training • Status 03.14
EOS P 396
Front of switching cabinet, open.................................................................................3.6
Rear of switching cabinet, open ..................................................................................3.7
Optics chamber.................................................................................................................3.8
Function ....................................................................................................................................3.9
Accessories and Options .......................................................................................................... 3.10
Cooling system ..................................................................................................................... 3.10
Layout............................................................................................................................... 3.10
Function........................................................................................................................... 3.10
Lifting truck........................................................................................................................... 3.11
Layout............................................................................................................................... 3.11
Function........................................................................................................................... 3.11
Unpacking stand .................................................................................................................. 3.12
Layout............................................................................................................................... 3.12
Function........................................................................................................................... 3.12
Shot-peening cabinet......................................................................................................... 3.13
Layout............................................................................................................................... 3.13
Function........................................................................................................................... 3.13
IPCM EOSINT P 3........................................................................................................................ 3.14
Overview................................................................................................................................. 3.14
Layout............................................................................................................................... 3.14
Function........................................................................................................................... 3.14
Powder conveying system P 3.......................................................................................... 3.15
Layout............................................................................................................................... 3.15
Function........................................................................................................................... 3.15
Unpacking and sieving station P 3 ................................................................................. 3.16
Layout............................................................................................................................... 3.16
Function........................................................................................................................... 3.16
Powder conveying vibro-kit.............................................................................................. 3.17
Layout............................................................................................................................... 3.17
Function........................................................................................................................... 3.17
Extension powder conveying............................................................................................ 3.18
Layout............................................................................................................................... 3.18
Function........................................................................................................................... 3.18
Recycled powder conveying ............................................................................................. 3.19
Layout............................................................................................................................... 3.19
Function........................................................................................................................... 3.19
Sieving machine P 3 ........................................................................................................... 3.20

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Layout............................................................................................................................... 3.20
Function........................................................................................................................... 3.20
IPCM P plus ................................................................................................................................. 3.21
Layout ..................................................................................................................................... 3.21
Function ................................................................................................................................. 3.21
4 Basic information on materials
Material types................................................................................................................................4.1
Powder states.................................................................................................................................4.1
Damage to the powder during the building process ..........................................................4.1
Separating the powder when unpacking the parts.............................................................4.3
Sieving the powder.......................................................................................................................4.3
Refreshing the powder................................................................................................................4.4
Mixing the powder .......................................................................................................................4.4
Storage of the powder ................................................................................................................4.5
Problems when handling powder.............................................................................................4.6
Electrostatic charging of the powder...............................................................................4.6
Separation of filled plastic powder ...................................................................................4.7
Material - machine compatibility............................................................................................4.7
5 Part Property Management
Introduction....................................................................................................................................5.1
Parameter sets...............................................................................................................................5.2
Original EOS parameter sets................................................................................................5.3
Exposure types for the original EOS parameter sets (without PPP) ..................5.3
PPP parameter sets ................................................................................................................5.5
TopSpeed.............................................................................................................................5.5
Speed ...................................................................................................................................5.6
Balance................................................................................................................................5.7
Performance ......................................................................................................................5.7
TopQuality ..........................................................................................................................5.8
Overview of PPP properties ...........................................................................................5.8
Exposure types for the PPP parameter sets..............................................................5.9

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Exposure editor .................................................................................................................... 5.11
Initial values for parameters ............................................................................................ 5.12
6 Data preparation
Procedure for data preparation ................................................................................................6.1
Preparing parts with Magics RP ...............................................................................................6.2
Overview....................................................................................................................................6.2
Setting up machine in Magics RP......................................................................................6.2
Adding a scene..................................................................................................................6.3
Build Processor option: selecting and setting up printer .....................................6.5
Loading a machine...........................................................................................................6.7
Importing parts .......................................................................................................................6.8
Selecting parts.........................................................................................................................6.8
Automatically repairing parts .............................................................................................6.9
Repairing parts with the Fix Wizard...........................................................................6.9
Orientating parts ................................................................................................................. 6.10
Orientating parts using the Rotate button............................................................ 6.11
Orientating parts using the Bottom/Top Plane button ...................................... 6.11
Positioning parts.................................................................................................................. 6.13
Positioning parts using the Translate button........................................................ 6.16
Generating a sinter box ..................................................................................................... 6.17
Reducing triangles............................................................................................................... 6.19
Saving processed parts using a new name .................................................................. 6.20
Preparing parts using the Build Processor.......................................................................... 6.21
Making job settings ............................................................................................................ 6.21
Setting part-specific exposure type............................................................................... 6.21
Exporting parts..................................................................................................................... 6.21
Preparing parts using EOS RP-Tools..................................................................................... 6.23
Overview................................................................................................................................. 6.23
Preparing parts using EOS RP-Tools............................................................................... 6.23
Correcting part data using SLIFIX................................................................................... 6.24

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7 Operation of machine & accessories
Overview..........................................................................................................................................7.1
Administering EOS software......................................................................................................7.1
Installing EOS software products.......................................................................................7.1
Licensing EOS software products.......................................................................................7.3
Set-up the machine .....................................................................................................................7.6
Preparing job using the PSW.....................................................................................................7.6
Making material-specific settings.....................................................................................7.7
Loading EOS default job.................................................................................................7.7
Preparing user-defined default job.............................................................................7.7
Loading user-defined default job ................................................................................7.7
Correcting material-dependent shrinkage................................................................7.8
Correcting material-dependent beam offset ...........................................................7.9
Loading a job ...........................................................................................................................7.9
Creating a job....................................................................................................................... 7.10
Making part-specific settings.......................................................................................... 7.10
Correcting part-specific shrinkage........................................................................... 7.11
Setting part-specific beam offset ............................................................................ 7.11
Setting exposure type.................................................................................................. 7.12
Saving a job........................................................................................................................... 7.12
Calculating the building time.......................................................................................... 7.12
Preparing building process......................................................................................................7.13
Build .............................................................................................................................................. 7.13
Monitoring building process using EOSTATE ..................................................................... 7.14
Setting up connection........................................................................................................ 7.14
Monitoring building process using Basic module ...................................................... 7.15
Monitoring building process using Quality Assurance module.............................. 7.16
Monitoring building process using Controlling module........................................... 7.17
Monitoring building process using Machine Park Management module ........... 7.18
Take machine out of operation.............................................................................................. 7.19
Unpacking parts ......................................................................................................................... 7.19
Preparing plastic powder......................................................................................................... 7.20
Preparing plastic powder using the components of the IPCM P ........................... 7.20
Preparing plastic powder using the components of the IPCM P plus.................. 7.21
Prepare refreshed powder using the mixing & qualification station............. 7.21

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Providing refreshed powder to the machine ......................................................... 7.22
Cleaning parts............................................................................................................................. 7.23
8 Process monitoring
Overview..........................................................................................................................................8.1
Checking, determining, setting building temperature .......................................................8.1
Determining shrinkage and beam offset................................................................................8.2
Determining, adjusting material-dependent shrinkage...............................................8.2
Determining, adjusting material-dependent beam offset ..........................................8.4
Documenting machine data and building process..............................................................8.5
Backing up machine configuration ...................................................................................8.5
Documenting building process using the PSW ..............................................................8.6
Documenting building process using EOSTATE..............................................................8.7
Exporting job data ...........................................................................................................8.7
Recording building temperature..................................................................................8.7
Displaying, preparing results, reports, statistics......................................................8.8
Backing up, archiving database ................................................................................ 8.10
9 Troubleshooting and maintenance
Troubleshooting.............................................................................................................................9.1
Machine.....................................................................................................................................9.1
Scoring in the surface of the powder.........................................................................9.2
Curling of exposed surfaces ..........................................................................................9.5
Cracks in the surface of the powder...........................................................................9.6
Parts torn out ....................................................................................................................9.9
Recoater level not optimal ......................................................................................... 9.12
Building with soiled plastic powder......................................................................... 9.14
Accessories and Options .................................................................................................... 9.14
IPCM EOSINT P 3 .................................................................................................................9.14
IPCM P plus ........................................................................................................................... 9.14
Maintenance ............................................................................................................................... 9.15
Machine.................................................................................................................................. 9.15
Cleaning the laser window......................................................................................... 9.15

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Accessories and Options.................................................................................................... 9.17
IPCM EOSINT P 3 .................................................................................................................9.17
IPCM P plus ........................................................................................................................... 9.17

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0.8 Training manual • Basic training • Status 03.14
EOS P 396

11About this manual ...

About this manual ...
1.1
Training manual • Basic training • Status 03.14
EOS P 396
1
About this manual ...
Legal notes
This document must not be electronically or mechanically reproduced, distributed,
amended, transmitted, translated into other languages or used in any other way -
either in full or in part - without the express written approval of EOS.
EOS® and EOSINT® are registered trademarks of EOS.
All terms from the software Windows are registered trademarks of Microsoft.
Layout and contents
The training manual contains basic information on the laser sintering process, about
the machine and the accessories, as well as about the materials necessary for the
operation of the machine.
The operation of software components, data on materials, safety instructions on the
use of the machine as well as instructions for the operation of the machine are in
the Operating instructions for the machine, the material data sheets and safety data
sheets, the parameter sheets as well as in the manuals on the operation of peripheral
software.
Conventions
Representations
➢Terms from menus, buttons, options, check boxes, functions, terms from data
entry and read-only fields, keyboard commands are printed in bold.
➢Buttons with symbols are also printed as pictograms in the margin in addition to
the term.
➢Terms from screen windows, screen areas, tabs, system messages, operating level,
software terms, settings for controls, parameters, file names, paths, references,
operating modes, signals present are printed in italics.
➢Terms for controls, function keys are printed in UPPERCASE and in italics.
➢Placeholders for file names are printed in <angled brackets> and in italics.

1About this manual ...
1.2 Training manual • Basic training • Status 03.14
EOS P 396
Terms
➢EOS
is used to refer to EOS GmbH - Electro Optical Systems, as well as its subsidiaries.
➢Machine
is used to refer to the laser sintering system EOS P 396.
➢PSW
is used to refer to the process software necessary for the operation of the
machine.
➢Accessories
is used to refer to the standard accessories, optional accessories or peripherals.
➢IPCM
is used to refer to the Integrated Process Chain Management for the automated
provision and reconditioning of materials for the operation of the machine.
➢IPCM P plus
is used to refer to the mixing, qualifying and conveying system IPCM P plus for
the automated provision and reconditioning of materials for the operation of the
machine with the components mixing & qualification station (MQS), docking
station and multibox.
➢PPM
is used to refer to the Part Property Management, an EOS concept that
standardises and makes reproducible the building processes and results of
building for e-manufacturing.
➢OEP
is used to refer to the Original EOS Parameter sets, parameter sets approved and
licensed by EOS that are matched to the EOS materials and machines.
➢PPP
is used to refer to Part Property Profiles, defined part properties for laser sintered
parts that can be obtained with a standardised combination of machine, material
and PPP parameter sets.
Definitions
➢Job:
The job contains the positioned parts and their parameters in the process
software (PSW).
➢Default job:
A default job is a template file that does not contain any parts, only material-
specific data (exposure parameters, building temperatures).

About this manual ...
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Training manual • Basic training • Status 03.14
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➢Parameter set:
A parameter set contains optimised settings, e.g. material-dependent values for
the scaling, beam offset, building temperature, exposure types, etc. for the
processing of a material with a machine.
Pictograms
Safety warning in this manual
Notice
Draws your attention to information that you should note.
Warning
Indicates the possibility of minor injury, the possibility of damage to the
machine or its accessories and of possible problems related to the parts
quality.
Warning of hot surface.
Wear protective gloves.

1About this manual ...
1.4 Training manual • Basic training • Status 03.14
EOS P 396
Hotline
When calling the EOS-hotline, ensure you have all the relevant information to
hand, including
➢Machine type
➢Machine serial number
➢Software version number
-Process software (PSW)
-EOSTATE.
Telephone +49 (0)89 / 893 36-151
Fax +49 (0)89 / 893 36-196
Address EOS GmbH - Electro Optical Systems
Robert-Stirling-Ring 1
D-82152 Krailling / München
E-mail [email protected]
Homepage www.eos.info

22Laser sintering process