Renishaw AM250 User manual

Laser melting machines for Additive Manufacturing in metals
H-5800-0704-03-B User guide AM250
Renishaw additive manufacturing system
AM250

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Publication information
© 2014 Renishaw plc
This user guide covers the AM250.
The rights derived from this, in particular those of translation, printing, radio transmission,
photo-mechanical or similar reproduction, magnetic tape recording and reproduction via
presentation of either storage or analysis and evaluation, including partial use thereof, are
reserved by Renishaw plc.
Individual duplicates or translations may be produced for commercial use with the written
consent of Renishaw plc.
Disclaimer
Renishaw has made considerable efforts to ensure the content of this document is correct at
the date of publication but makes no warranties or representations regarding the content.
Renishaw excludes liability, howsoever arising, for any inaccuracies in this document.
Trade marks
RENISHAW and the probe symbol used in the RENISHAW logo are registered trade marks
of Renishaw plc in the United Kingdom and other countries. apply innovation and names
and designations of other Renishaw products and technologies are trade marks of
Renishaw plc or its subsidiaries.
All other brand names and product names used in this document are trade names, trade
marks, or registered trade marks of their respective owners.

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Summary
The Renishaw Additive Manufacturing process creates homogeneous solid metal
components, using high-powered laser energy to melt fine powder, to manufacture parts
from 3D CAD data.
This manual covers basic machine operation and the relevant safety procedures for many
commercially available materials. Users should be aware that raw materials used by the
machine require tightly controlled safety and handling protocols to be adhered to.
Additionally, the system must only be operated by staff who have followed a Renishaw
approved training course, and in accordance with the instructions and advice contained in
this manual. If in doubt about the particular requirements of the Renishaw AM machine for a
specific material, please contact us for advice and guidance.

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Contents
1.Scope of supply ............................................................................................... 9
1.1 Equipment ......................................................................................................................... 9
2.Warranty and liability..................................................................................... 10
2.1 Spare parts ..................................................................................................................... 10
3.Introduction .................................................................................................... 11
3.1 Definitions ....................................................................................................................... 11
3.2 Text structure .................................................................................................................. 12
3.3 Safety warnings in this manual ....................................................................................... 13
3.4 Training schedule ............................................................................................................ 14
4.Contact details ............................................................................................... 15
5.Safety .............................................................................................................. 16
5.1 Basic safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 
5.2 Safety signs .................................................................................................................... 18
6.Laser warning labelling ................................................................................. 19
6.1 Laser safety labelling details ........................................................................................... 19
7.General safety instructions ........................................................................... 23
7.1 What to do in an emergency ........................................................................................... 23
7.2 Normal operation ............................................................................................................ 24
7.3 Training ........................................................................................................................... 24
7.4 Safe disposal of waste products ..................................................................................... 24
7.5 Personal Protective Equipment (PPE) ............................................................................ 25
7.6 Correct usage ................................................................................................................. 25
7.7 Improper use ................................................................................................................... 26
7.8 Handling of metal powders ............................................................................................. 26
7.9 Toxicity/personnel exposure ........................................................................................... 27
7.10 Flammability .................................................................................................................... 27
7.11 Fire-fighting ..................................................................................................................... 27
7.12 Handling and processing ................................................................................................ 28
7.13 Storage ............................................................................................................................ 28
7.14 Spills .............................................................................................................................. 29
7.15 Metal powder safety checklist ......................................................................................... 29

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7.16 Residual dangers, maintenance and protective measures ............................................. 30
8.Safety during maintenance ........................................................................... 31
8.1 Guide to general maintenance ........................................................................................ 31
8.2 Work on electrical equipment.......................................................................................... 32
8.3 Thermal hazards ............................................................................................................. 32
8.4 Hazards due to “latent” energy sources .......................................................................... 32
8.5 Hazards due to unexpected malfunctions ....................................................................... 33
8.6 Hazards due to fire or explosion ..................................................................................... 33
8.7 Identifiable ignition sources ............................................................................................. 34
9.Technical specifications, services and installation requirements............. 35
9.1 Installation requirements ................................................................................................. 36
9.2 Inert gas .......................................................................................................................... 40
9.3 Oxygen level monitoring within the room ........................................................................ 41
9.4 Room air conditioning requirements ............................................................................... 41
9.5 Network connection and build preperation PC ............................................................... 41
9.6 Transport and machine relocation .................................................................................. 42
10.Safety precautions for end users and operators......................................... 43
10.1 Laser safety precautions ................................................................................................. 43
10.2 Fire precautions .............................................................................................................. 44
10.3 Metal powder handling advice ........................................................................................ 44
10.4 Inert gas safety ............................................................................................................... 45
10.5 Substrate materials ......................................................................................................... 46
11.Machine controls and features overview ..................................................... 47
11.1 AM250 front .................................................................................................................... 47
11.2 Left-hand user access door AM250 ................................................................................ 48
12.Functional description................................................................................... 49
12.1 Main switch and emergency stop button ........................................................................ 49
12.2 Touch screen (HMI) and Programmable Logic Controller (PLC) .................................... 50
12.3 Main computer ................................................................................................................ 50
12.4 Laser .............................................................................................................................. 50
12.5 Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.6 Beam aperture protective window .................................................................................. 50
12.7 Viewing window .............................................................................................................. 51
12.8 Loading metal powder using powder flasks .................................................................... 51

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12.9 Loading the powder hopper ............................................................................................ 52
12.11 Powder level sensor ........................................................................................................ 52
12.12 Powder delivery .............................................................................................................. 52
12.13 Recoater assembly ......................................................................................................... 52
12.14 Gas circuit ....................................................................................................................... 52
12.15 Substrate plate ................................................................................................................ 53
12.16 Heating/temperature control ........................................................................................... 53
12.17 Safe change filter ............................................................................................................ 53
12.18 Oxygen monitoring .......................................................................................................... 53
12.19 Disposal of waste materials ............................................................................................ 54
13.Ancillaries....................................................................................................... 55
13.1 Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
13.2 ATEX vacuum cleaner .................................................................................................... 56
14.Argon supply connection and changeover.................................................. 58
14.1Removing and re-installing the gas cylinder ................................................................... 58
15.Machine controls............................................................................................ 61
15.1 Powering on the machine ............................................................................................... 61
15.2 Powering on the chiller .................................................................................................... 63
15.3 Pages not requiring log-in ............................................................................................... 65
16.Logging in....................................................................................................... 66
16.1 Logging out ..................................................................................................................... 67
17.Opening and closing the machine doors..................................................... 68
17.1 Opening the process chamber door ............................................................................... 68
17.2 Opening and closing the lower chamber door ................................................................ 71
18.Powder transfer from supplier’s containers ................................................ 72
19.Powder loading .............................................................................................. 74
20.Installing the overflow flasks ........................................................................ 77
20.1 Rear overflow .................................................................................................................. 77
20.2 Front overflow ................................................................................................................. 79
21.Safe change filter ........................................................................................... 81
21.1 Installing a new filter element ......................................................................................... 81
21.2 Installing the safe change filter on the machine.............................................................. 83

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22.Preparing the build chamber......................................................................... 86
22.1 Build substrate requirements .......................................................................................... 86
22.2 Homing the recoater ....................................................................................................... 86
22.3 Installing the build substrate ........................................................................................... 87
23.Installing and setting the recoater blade ..................................................... 90
23.1 Installing the recoater blade ............................................................................................ 90
23.2 Setting up the recoater .................................................................................................... 93
24.Heat soak procedure...................................................................................... 97
25.Transferring a build ....................................................................................... 99
25.1 Setting up a file transfer service ..................................................................................... 99
25.2 Sending a file to the machine........................................................................................ 100
25.3 Setting up FTP .............................................................................................................. 101
25.4 Selecting a file from the list ........................................................................................... 103
26.Starting the build.......................................................................................... 103
26.1 Process checks ............................................................................................................. 104
26.2 Initiating the build .......................................................................................................... 105
26.3 Stabilising the atmosphere ............................................................................................ 107
26.4 Maintaining the build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 7
26.5 Setting the dosing percentage ...................................................................................... 107
27.Completing the build ................................................................................... 109
28.Removing the overflow flask....................................................................... 111
29.Post-build powder handling ........................................................................ 113
29.1 Powder transfer from large overflow to small powder flask .......................................... 113
29.2 Powder removal from build volume .............................................................................. 116
29.3 Machine clean-down – upper chamber ......................................................................... 120
29.4 Cleaning the lens cover (protective window) ................................................................ 125
29.5 Machine clean-down – lower chamber ......................................................................... 131
30.Safe change filter assembly removal ......................................................... 132
31.Changing the filter element......................................................................... 135
31.1 Safe change filter disassembly ..................................................................................... 135
32.Hopper and dosing mechanism removal/exchange.................................. 138

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32.1 Emptying the hopper ..................................................................................................... 138
32.2 Removing the hopper .................................................................................................... 138
32.3 Disassembling and cleaning the silo ............................................................................. 140
32.4 Removing the dosing mechanism ................................................................................. 142
32.5 Re-installing the dosing mechanism ............................................................................. 144
33.Inspection and maintenance schedule ...................................................... 145
33.1 Machine and filter maintenance .................................................................................... 146
33.2 WEEE directive ............................................................................................................. 147
33.3 Batteries ........................................................................................................................ 147
34.Appendix A – substrate drawing ................................................................ 148
35.Appendix B – part numbers of spares ....................................................... 149

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1. Scope of supply
The following section gives details of the equipment supplied with the machine, and the
equipment available as options.
1.1 Equipment
Standard equipment
1. Renishaw AM250 Additive Manufacturing machine
2. Chiller
3. User guide
4. Operator training documentation
5. Starter kit
6. Commissioning kit
7. Powder flask kit with three small powder flasks with valves and one large overflow
flask with valve
8. Additional safe change filter assembly
9. File preparation software (Magics or AutoFab)
Required accessories
1. Powder conditioning system for material sieving
2. Ruwac ATEX industrial vacuum cleaner
3. Metal powder flasks
4. Computer for offline file preparation
5. Metal powder
Optional items
1. Furnace
2. Bead blast unit
3. Replacement sieve mesh
4. Additional material hopper
5. Additional material doser
6. Additional filter housing
7. Additional material flasks and valves
8. Additional Magics software modules

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2. Warranty and liability
Our equipment is sold subject to the terms and conditions of sale supplied with your
purchase of the machine; or available on request from Renishaw AMPD, subsidiary, or
distributor.
2.1 Spare parts
All components and sub-assemblies are subject to rigorous quality control. Components
purchased from sub-suppliers, such as ball bearings, electric motors or hydraulic cylinders,
are supplied in accordance with Renishaw specifications. Renishaw will not honour any
warranty claims where faults arise due to non-OEM replacement parts being fitted.
When ordering spare parts please quote the following:
 Description of the spare part and its part number, if known.
 Equipment name and model.
 Serial number.
 Year of manufacture.

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3. Introduction
The Renishaw AM250 is a complex piece of manufacturing equipment and must be used
correctly to ensure optimum performance. It must not be used by untrained staff who have
not completed a Renishaw approved training course.
3.1 Definitions
The following definitions are used throughout this manual:
The client or end user is the company responsible for purchasing or using the equipment.
The supervisor is an individual or individuals who is/are ultimately responsible for ensuring
the safe operation and maintenance of the equipment.
The operator is an individual or individuals working for the client or end user who is/are
competent to operate, maintain and clean the equipment safely. This is because they have
been formally trained and assessed in the individual tasks required.
The technician is an “operator” who is qualified to carry out a particular aspect of
maintenance. This is because they have been formally trained and assessed in the individual
tasks required.
The equipment is the scope of supply from Renishaw that the client has purchased.
Ancillary equipment is any item which is required to complete the installation that is not
included in the scope of supply.
Manufacture or manufacturing is any process where the equipment is commissioned,
trialled, operated, maintained or cleaned.
AM Additive Manufacturing
ATEX ATmosphères EXplosives (explosive atmospheres)
COSHH Control of Substances Hazardous to Health
DSEAR Dangerous Substances and Explosive Atmospheres Regulations
EMC Electro-Magnetic Compatibility
HMI Human Machine Interface (touch screen)
IEE Institute of Electrical Engineers (or local governing body)
LED Light Emitting Diode
PC Personal Computer
PLC Programmable Logic Controller
PPM Parts Per Million
PV Present Value
SDS Safety Data Sheet
SOP Standard Operating Procedure
SP Set Point

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3.2 Text structure
The following structure has been used throughout this manual:
 The names of menus, buttons, options, icons, check boxes, functions, names of input
fields and hot keys are written in bold.
 Program windows, parameters, settings for controls, system messages, signals,
paths, file names, software names, areas of the screen and operating modes are
written in italics.
 Controls and function keys are written between <angled brackets>.
 Wildcards for filenames are written in <angled brackets> and in italics.

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3.3 Safety warnings in this manual
PROCEED WITH EXTREME CARE
Indicates possibility of serious and irreparable personal harm
or death and possibility of substantial property damage.
CAUTION
Indicates possibility of minor personal harm, damage to the
Renishaw AM250 and problems related to component quality.
WARNING
Danger by electrocution.
WARNING
Danger by crushing.
WARNING
Hot surface.
INDICATION
Indicates important information that requires your attention.
WARNING
Danger of asphyxiation.
CAUTION
Risk of injury when handling heavy object.
CAUTION
Use of pressurised water fire extinguishers not
recommended.

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3.4 Training schedule
Renishaw provides a basic level of training to operate the equipment safely. Renishaw also
offers extended training courses for operators and process engineers. Please refer to this
manual and the training documentation supplied as part of the user training course, that all
users must be complete before using the system.
Topic Key areas
INTRODUCTION TO THE MACHINE

Commissioning and installation
requirements
 Starting and shutting down the machine
 Understanding of machine mechanics
SAFETY

Changing the filters
 Cleaning the machine
 Safety equipment
 Powder handling
 Description of machine safety devices
ANCILLARIES

Chiller maintenance operation and care
 ATEX vacuum cleaner operation and care
 Sieving station
 Safety equipment
 Consumables and spare parts
FILE PREPARATION

Part orientation
 Hatching
 Slicing
 Support selection and positioning
 Data transfer
PART MANUFACTURE

Understanding the gas circuit
 Setting recoater blade and substrate levels
 Material preparation
 Material processing
 Part suppression
 Support removal
 Sieving the powder
BASIC MAINTENANCE

Basic maintenance issues on a daily,
weekly, monthly and annual basis.
FAULT DIAGNOSIS AND
TROUBLE-SHOOTING

Common faults – what to look for and how
to solve them

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4. Contact details
Phone number [phone]
Hours of work: Monday – Friday
08:00 hrs – 17:00 hrs BST (British Summer Time)
Email [email protected]
Service address Renishaw AMPD
Whitebridge Way
Whitebridge Park
Stone
Staffordshire
ST15 8LQ
United Kingdom
Please quote the details above. The serial number plate can be found on the rear of the
machine (see Figure 15A) and the software version on the start screen (Figure 15B).
Figure 15A Build information plate Figure 15B Software information
Additional support can be sought by contacting your local Renishaw office. See:
http://www.renishaw.com/en/worldwide-locations--6438
1. Machine type
2. Machine serial number
3. Software version numbers
HMI
PLC
PC

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5. Safety
Relevant national legislation and internal company policies will dictate normal minimum
requirements for health and safety.
Operation of the Renishaw AM250 is only
permitted by operators who have completed a
Renishaw approved training program.
Safety interlocks and circuits must NEVER be
overridden.

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5.1 Basic safety measures
Risk assessments for all foreseeable hazards must be carried out prior to operating the
system.
All end user companies must undertake a full risk assessment to establish the requirement
for additional measures such as a COSHH and DSEAR assessment. This will subsequently
inform the provision of correct personal protective equipment and site operating conditions
and procedures for safe use of the equipment, storage and handling of raw materials and
waste product. Any ancillary equipment must be selected giving due consideration to these
requirements.
Governing bodies will differ depending upon geographic location, and the appropriate
governmental and regulatory bodies must be identified for each territory. Considerations
need to include regulations governing:
 The use of lasers.
 Fine metallic powders below 45 µm in diameter.
 The use, storage and monitoring of inert gas.
 Small quantities of waste product including nano soot particles captured by the filter
system.
Review all data sheets containing Control of Substances Hazardous to Health (COSHH) for
the metal powder.
By following the correct procedures, it is possible for most powder handling to be executed
under an inert atmosphere, however measures must be taken to minimise exposure to any
airborne metallic powder produced during the handling and processing of builds by the use of
the appropriate PPE and other equipment as the components are removed from the
machine.
If in doubt about the health and safety issues and your legal obligations, our recommendation
is to engage the services of a competent person.

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5.2 Safety signs
Various safety indicator signs are fixed to the equipment. These are described below.
Warning – DANGER BY ELECTROCUTION
Sticker on the inside of the switch cabinet door
Warning – DANGER OF HOT SURFACES
Sticker on the process chamber
Sticker on the cabinet door
Class 1 laser equipment, normal operation with the machine door
closed and an inert atmosphere in place.
Class 2 operation for the purposes of setting up laser beam profile
recording equipment by using the targeting laser.
See section on Laser warning labelling.
Classification
The Renishaw AM250 in normal operation is classified as “Class 1”
according to the Standard DIN EN 60825-1, edition: 2001-11,
Safety of Laser Equipment – Part 1.
Label on the process chamber door.
In normal use laser operation, the main chamber door is
interlocked.
Potential for Class 4 laser emissions
WARNING! Never override interlocks.
During any adjustment or maintenance with the laser on and the
chamber door open, laser eyewear MUST BE WORN, as specified
in DIN EN 207 (DIN 58215) which provides protection against laser
beams with wavelengths of 1000 nm to 1100 nm. Failure to do so
may result in permanent irreparable eye damage.
Any maintenance MUST be carried out by a suitably qualified
person.

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6. Laser warning labelling
In order to comply with international standards, the Renishaw AM250 carries various safety
warning labels regarding the emission of laser light. These labels form part of the safety
information and it is recommended that users regularly (we suggest weekly) check the
condition and presence of the labels in the locations shown in the following images.
Replacement warning labels can be ordered from Renishaw.
6.1 Laser safety labelling details
Figure 19A General clasification label
Class 2 “general classification label” inside
the chamber (Figure 19A). To reference the
targeting laser, this is not affected by the
door interlock system.
Figure 19B Laser specific label
Class 2 Custom laser-specific label
detailing the Class 2 targeting laser
positioned directly below the Class 2 label
on the right-hand side recoater cover inside
the chamber (Figure 19B).

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Figure 20A Laser warning triangle
Laser warning triangle to be displayed on
the top door (Figure 20A).
Figure 20B Interlocked housing label
Class 4 “Interlocked housing label” to be
added to the header, placed in line with the
outer edge of the Top Door (Figure 20B).
Figure 20C General classification label
Class 1 “general classification label”,
displayed to the right of the serial plate
(Figure 20C).