Noztek fusionX User manual

USER MANUAL
© Noztek.com 2021. All rights reserved

Warranty / Safety 3
Diagram 4
Power Switch & Start-up Guide 5
User Interface 6
Connecting Your Extruder to Your Computer 7
Changing the Nozzle 8
Colour Mixing 8
Maintenance/Lubrication 8
Barrel Jam 8
IN THE BOX
fusionX - fully assembled
Accessories:
Hopper weight
- This can be used to press the material in the hopper into the feed section
of the screw and is especially useful when using light powdered materials
Torque wrench
- Used to tighten and loosen the bolts on the front and top of the block. Make sure the wrench
is set to 24Nm when tightening the top bolts and 18Nm for the front nozzle holder bolts.
4 x M8 35mm grub screws
(These are inserted into all four corners of the block, tightened
in turn to split the block apart for cleaning)
4 x M4 40mm bolts
- Used to remove the mixing blades)
Copper grease
- When reassembling the block it is advisable to coat the thread with this anti
seize copper solution. Also when swapping or replacing the nozzle, coat the thread with the copper
slip.
FusionX protective cover
- To be used when dismantling the block to protect the chassis from being scratched.

3
DIAGRAMS
67.5cm
33cm
24cm
hopper
touch screen
quick power-off
power socket (IN)
power switch
USB connection
thermocouple 1
barrel
nozzle

SAFETY
1. Carefully read the instruction manual.
2. Learn the proper, safe use and limitations of
the equipment.
3. DO NOT operate or use this equipment for any
purpose other than its intended use.
4. DO NOT modify this equipment.
5. DO NOT perform adjustments or maintenance
while system is operating or energize
6. DO NOT clean the equipment with flammable
solvents.
7. DO NOT wash down the equipment with water.
This could cause an electrical hazard.
8. DO NOT probe into extruder vent with the
machine running. Never Use a metal probe in
the vent area. The screw may shear the probe,
causing extensive damage to the barrel
and screw. A wooden probe is recommended.
9. DO wear a face shield, insulated gloves when
operating and when in close proximity to
the extruder during operation. These protective
items must also be worn when adjusting
the die, cleaning the screw, etc. The extruder tem-
peratures are extremely hot and failing to
protect yourself may cause serious injury.
10. The feed hopper MUST be installed on the
extruder feed section at all times when in oper�
ation
11. NEVER put hands in the feed section or vent to
remove material.
13. DO NOT switch on the motor until the recom-
mended temperature has been reached.
4
POWER SWITCH AND START UP
To begin, first cuse the power switch on the side
of the machine to power up.
Powering up will take just a few moments, after
which you’ll use the touch screen to set all
extruding parameters and set the machine to
begin.
TEMPERATURE SETTINGS
You are able to set two temperatures, the extrud-
ing temperature and the mixing temperataure.
To toggle between °C & °F, tap on °C/°F directly.
TECH SPECS
- 1000w rectangular ceramic heater (max tem-
perature 500c)
- DAK Nozzle Band Heater 35D 25L 230-250V
max.210W (max temperature 450c)
- Auto switching 110v/220v Traco power supply
24V 10 amp
- Precision machined solid stainless steel barrel
- DC motor 17 RPM – 17 Nm torque
- Precision turned bespoke stainless steel mixing
screw
- 7 inch TFT touch screen
- Stainless steel micro hopper (with hopper
weight)
- 1.75mm and 3mm stainless steel nozzles
- 3 sets ( 6 in total) of hardened steel cutting
blades 10mm, 3mm and 1mm
WARRANTY
• Equipment manufactured by Noztek carries the
standard machine tool guarantee of freedom
from defects in workmanship and material for
one year from date of shipment.
• TO INSURE THAT YOUR WARRANTY IS HELD IN
EFFECT, PROPER OPERATION PROCE� DURES
MUST BE OBSERVED.
• NOTE: READ THE SAFETY PRECAUTIONS
BEFORE OPERATING THIS MACHINE.

5
2 - MENU
This is where you control the settings. Use the
three ‘set’ buttons to control the respective
settings for the run.
3 - SET TEMPERATURES
Here you can set the mixing temperature and the
extruding temperature. Use the slider and/or the
+ and - buttons to control the settings.
(please find more guidance on temperature
settings on p. 7)
Pressing SET will take you to the WARM UP
screen
USER INTERFACE
4 - WARM-UP
This screen has a timer to allow the machine to
warm to the correct temperature. You will not
be able to escape this screen until the warm-up
is complete, at which time, you will return to the
HOME screen.
1 - HOME
This screen shows all your settings, and appears
red to begin with as nothing has been set. As you
define settings, the corresponding boxes will
turn green to show that they are ready to go.
Press MENU to begin.

6
6 - SET TIMER
This represents the time you want to extrude the
material
5 - SET SPEED
This sets your extrusion speed. Maximum speed
is ______
7 - COOL DOWN
This screen will show whilst the cool down is
happening. The preset is 62 minutes
7 - HOME (READY)
When you see that all boxes are green, you are
ready to extrude. Press the Motor box to begin.

7
CONNECTING THE fusionX TO
YOUR COMPUTER
1 - Download the Noztek Controller software from our
website - https://www.noztek.com/software-down-
load/
2 - Connect the fusionX machine to the laptop with a
USB cable.
3 - Once the cable is connected and the controller
software has been opened on the laptop, you can
control the settings from the laptop interface
- To change temperature or the motor settings. enter
the value you want in the relevant field using the
keyboard and then press “Set”.
- To activate or deactivate the fanpress the “ON/OFF”
button next to “Fan state”.
- To visualize the data on a graph, go to Display >
Display data on graph.
- To export you data just click on “Export data to .csv”
on the bottom right of the window.
For more in depth guidance on the controller soft-
ware, please find the dedicated controller software
manual in the manuals section of our website
CLEANING
Make sure that most of the material has been
extruded from the barrel before cleaaning
Please use the fusionX protective cover provided to
protect the main body of the machine from any
chemicals used in the cleaning process.
The cover has been custom made for the machine,
please place each tab between the cables and
fixtures underneath the barrel and the motor (back
lays down first). Use the velcro to keep the cover
pieces in place.
OPENING THE BARREL
1. Unscrew the 4 bolts connecting the motor
casing, pull motor casing back or remove.
2. Unscrew the two front and two rear grub
screws connecting the couplings to the screw and
pull this back until the coupling has disengaged from
the screw spindle.
3. Remove both thermocouple couplings (one
connected to the nozzle and the other on top of the
block).
4. Remove the front nozzle and unbolt the front
nozzle bracket (5 x M8 bolts),
5. Remove the 10 M10 bolts on the top of the
block
6. Located on the top block are four M5 allen
bolts (‘block splitters’). Screw down each corner 5 or
6 turns and continue until the top block splits apart
from the bottom section.
7. To remove the screw gently lift the front tip
and the screw should come loose from the bottom
barrel block (Depending on the type of material
debris in the barrel a solvent may be required to
assist the removal process).
NOTE - We do not recommend that you remove the
bottom half of the barrel from the base. We advise
that you clean the barrel in situ.

8
CHANGING THE NOZZLE
Before attempting this operation please use insulated
gloves. To switch between nozzle sizes to heat up the
unit to175c. Unscrew the nozzle, clean off any excess
plastic from the internal threads, then screw on new
nozzle
COOL DOWN
There are two fans connected to the main case: One
is to cool the motor, the other is to cool the heat sink
section underneath the hopper.
This has been installed to reduce any hopper neck
clumping when extruding at higher temperatures.
BLENDING/MIXING
All our fusionX extruder's are shipped with three sets
of hardened cutting blades. Usually these are placed
in sequence within the block. For example the 10mm
blade would be first in line, then the 3mm and lastly
the 1mm blade. This ensures a gradual hot melt
mixing set up, so by the time the material reaches the
nozzle it is thoroughly blended.
For materials that require more extensive blending,
the Noztek Pelletiser can be utilsed to cut the
filament in order to be reinserted back into the unit.
LUBRICATION
The thrust bearing assembly will require occasional
lubrication; this is a relatively simple operation,
when the barrel is split remove the screw and squirt
a 2 second burst of a lubricant like WD40 Lithium
Grease around the outer diameter of the bearing.
For optimal performance we recommend that this
procedure is carried out every 20 hours of
operation. BARREL JAM
Depending on what type of material you are using,
you may experience a barrel jam. If at any time
during extrusion the motor starts to labour and slow
right down then you should switch off the motor
immediately. In the first instance you can raise the
temperature by 30c and turn on the motor. Failing
that, split the barrel and remove any debris
8. The cutting blades can be removed by levering
each blade individually out of it's slot. If this proves
difficult, there are two threaded holes on each end.
Use a 25mm M3 bolt to screw down and lift each side.
*Make sure both flat surfaces of the barrel are com-
pletely clean before reassembly.*
Copper grease (provided) : When reassembling the
block it is advisable to coat the thread with this anti
seize copper solution.
Please also make sure both block surfaces are
perfectly clean. Place the top on the lower bleck and
bolt on the nozzle holder in the front (finger tight),
this will align both sections.Then tighten all eight M8
bolts on the top of the block using the torque wrench
provided (set to 24Nm). and tighten the nozzle
holder again at 24 Nm.