W2P Engineering PowerVat 250 User manual

© Copyright 2023 W2P Engineering GmbH / Rev06
.0
for use with SolFlex 3D Printers
www.way2production.at
Original Instructions

1
This publication, including all photographs, illustrations and software, is protected
under international copyright laws, with all rights reserved. Neither this manual,
nor any of the material contained herein, may be reproduced without written
consent of the author.
© Copyright 2023 W2P Engineering GmbH
The information in this document is subject to change without notice to improve
reliability, function or design. The manufacturer makes no representations or
warranties with respect to the contents hereof and specifically disclaims any
implied warranties of merchantability or fitness for any particular purpose. The
manufacturer reserves the right to revise this publication and to make changes
from time to time in the content hereof without obligation of the manufacturer to
notify any person of such revision or changes. Any description, photograph or
statement contained herein, colors and specifications may vary from the actual
product.
The following table shows an overview of the model which is described in this
manual.
Model
Art. No.
Compatible Printer Models
PowerVat 250
PV25001
SolFlex 250 UHD (B series)
SolFlex 650 (B and C series)
PowerVat 363
PV36301
SolFlex 350 (B and C series)
SolFlex 363 (C series)
PowerVat 650
PV65001
SolFlex 650 (B and C series)

2
Version
Datum
Description
Rev06
01.08.2023
−PowerVat 250 added.
−Instructions for using the film tension regulator
Rev05
18.04.2023
−Added Vaseline (petroleum jelly) as an additional
option for a bonding agent for the O-ring
Rev04
11.06.2019
−PowerVat PV36301 replaces PV35001: graphics and
labels updated
−Film pattern updated in the illustrations
−Compatible printer models added
−Changelog added
−For the cleaning of the film from now on microfibre
cloths instead of paper towels are recommended
−Instructions for changing the O-ring sealing cord
added
−Additions chapter 'Cleaning and Maintenance'
Rev03
21.02.2019
−PowerVat 350 added
−Illustrations added
−Descriptions unified
Rev02
19.12.2018
−Added paragraph regarding printer firmware
−Added user / password to unlock the settings
−Starting values for Stretcher0updated
−Added illustration and instructions for mounting the
building platform
−Absolute starting value for the z0setting
−Chapter z0setting revised
−Job and Excel file names changed

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−Conversion factors adapted for scaling
−Note that the beamer positions must be entered
before the scaling job has been added
Rev01
29.11.2018
−Installation descriptions simplified
−Chapter 'Printer Settings' revised
−Contact addresses added
Rev00
19.11.2018
Initial Release

4
Weight (without resin): 1.300g
Material capacity: 100ml to 600ml

5
Weight (without resin): 1.120g
Material capacity: 100ml to 400ml

6
Weight (without resin): 1.360g
Material capacity: 100ml to 500ml

7
Getting Started ____________________________________________________________ 8
Introduction ________________________________________________________________ 8
Safety Instructions __________________________________________________________ 8
Cleaning Equipment ________________________________________________________ 9
Accessory Checklist ________________________________________________________ 10
Overview___________________________________________________________________11
Preparation _______________________________________________________________ 14
Removing the Transport Protection ________________________________________ 14
Preparing the SolFlex for Use with the PowerVat ___________________________ 16
Preparing the SolFlex for Use with the FlexVat _____________________________ 17
Pre-Cleaning and Installation of the PowerVat _____________________________ 17
Filling the Vat with Material ________________________________________________ 20
Notes on BuildStyles_______________________________________________________ 22
Cleaning and Maintenance _______________________________________________ 23
General Cleaning and Maintenance Instructions ___________________________ 23
Disassembly _______________________________________________________________ 24
Assembly __________________________________________________________________ 26
Changing Resins___________________________________________________________ 31
Changing the Film _________________________________________________________ 31
Changing the O-Ring Sealing ______________________________________________ 32
Evaluating the Condition of the Vat ________________________________________ 32
Printer Settings ___________________________________________________________ 36
Stretcher Zero Position ____________________________________________________ 37
Z-Stage Reference Position (z0) ____________________________________________ 38

8
The PowerVat features a rigid vat design for use with SolFlex 3D printers. The
newly developed design enables manufacturing of models with large cross-
sections as well as using highly viscous resins. The vat frame’s solid metal
construction combined with the translucent glass/film construction allows a long
service life, perfect printing results and low maintenance.
This document describes the proper use, cleaning, and maintenance of the vat.
The product described herein is for use only with SolFlex series 3D printers.
It is strongly recommended to read the instructions in this manual carefully before
using the material vat. Please follow the safety instructions to maximize the
lifespan of the vat and to get the best printing results.
Warning symbols in this manual are used to protect you from dangerous
situations. The following symbols are used to alert you to important information:
Important: Provides additional information that should not be overlooked.
Caution: Alerts you to situations that may damage the unit.
Ignoring the following instructions may result in reduced print quality or inability
to use the PowerVat.
Use only approved 3D printing resins and cleaning instruments. Avoid
contact of the PowerVat with other media. Improper use can damage the
vat’s film and therefore shorten maintenance intervals.
Never use sharp or pointed objects to clean the PowerVat or to remove any
residual material, as this could damage the film and the glass below the film.
Use only elastic and soft parts for cleaning.

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Avoid excessive pressure when using cleaning instruments. This can lead to
scratches or cracks in the film.
Check the condition of the film regularly. If damage occurs (e.g. cracks,
holes, deformations), the film must be replaced immediately.
If the printer is used to produce medical products it is necessary to use separate
PowerVats for each printing material. Otherwise, cross-contamination cannot be
prevented. Between the PowerVat top part, the rubber seal and the film, a small
amount of 3D printing resin can accumulate. When changing the material, it is
therefore recommended to disassemble the PowerVat upper part so material
residues can be completely removed. Make sure to follow the instructions of the
3D printing material manufacturer, especially with regard to backfilling and, if
necessary, sieving the material.
Utilize the exposure area of the PowerVat evenly so that the entire surface is used
uniformly throughout its lifetime. Localized exposure leads to higher local wear
and thus reduces the overall life of the film.
For a proper cleaning of the PowerVat, a clean working environment must be
ensured.
Please use only the following tools or materials:
soft cleaning tissues or paper towels
microfiber cloth
silicone spatula (solvent resistant - soft)
cleaning pad (solvent resistant)
isopropanol (purity at least 95%)
blunt spatula for cleaning corners and removing material residues
Use only oil and grease-free compressed air. Make sure that there are no persons
in the airflow when using compressed air.

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Material vat
(incl. transport
protection)
PowerVat Cover
incl. for PowerVat 250
Torx wrench TX10
Torx wrench TX20
4 countersunk screws M3x8 (spare parts)
2 countersunk screws M4x16 (spare parts)
2 countersunk screws M4x20 (spare parts)
If any items are missing, appear damaged or if the unit does not work properly,
please contact your reseller immediately. It is recommended to keep the original
packing material for the event of returning the equipment for warranty service.

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Pos.
Name
Qty
Unit
1
PowerVat bottom part
1
piece
2
PowerVat clamping plate
1
piece
3
PowerVat top part
1
piece
4
PowerVat glass
1
piece
5
Locking disc
4
pieces
6
Non-stick film
1
piece
7
Rubber O-ring sealing, Ø 1.6mm
1
piece
8
Countersunk screw ISO 14581 - M3x8
24
pieces
9
Countersunk screw ISO 14581 - M4x20
4
pieces
10
Countersunk screw ISO 14581 - M4x16
4
pieces
11
Countersunk screw ISO 10642 - M5x16
4
pieces
12
Transport protection
4
pieces
3
8
2
6
4
12
1
11
5
7
10
12
9
10
9

12
Pos.
Name
Qty
Unit
1
PowerVat bottom part
1
piece
2
PowerVat clamping plate
1
piece
3
PowerVat top part
1
piece
4
PowerVat glass
1
piece
5
Locking disc
4
pieces
6
Non-stick film
1
piece
7
Rubber O-ring sealing, Ø 1.6mm
1
piece
8
Countersunk screw ISO 14581 - M3x8
28
pieces
9
Countersunk screw ISO 14581 - M4x20
4
pieces
10
Countersunk screw ISO 14581 - M4x16
4
pieces
11
Countersunk screw ISO 10642 - M5x16
4
pieces
12
Transport protection
4
pieces
13
Film tension regulator
1
piece
3
8
2
13
4
12
1
10
11
5
7
9
12
9
10
9
10
10
9
6

13
Pos.
Name
Qty
Unit
1
PowerVat bottom part
1
piece
2
PowerVat clamping plate
1
piece
3
PowerVat top part
1
piece
4
PowerVat glass
1
piece
5
Locking disc
4
pieces
6
Non-stick film
1
piece
7
Rubber O-ring sealing, Ø 1.6mm
1
piece
8
Countersunk screw ISO 14581 - M3x8
28
pieces
9
Countersunk screw ISO 14581 - M4x20
8
pieces
10
Countersunk screw ISO 10642 - M5x16
4
pieces
11
Transport protection
4
pieces
12
Film tension regulator
1
piece
3
8
2
12
4
11
1
10
5
7
11
9
9
6

14
In order to minimize the tension of the film during storage and transport, 4 spacers
are installed between the upper and lower part as transport protection before
delivery. Prior to the first use, the transport protection must be removed:
Loosen the 8 screws on the underside of the vat with the supplied Torx wrench
TX20 by about half a turn.
Then remove the 4 spacers as shown above.
TX20

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Tighten the 8 screws on the bottom of the vat with the Torx wrench TX20. The
figure above shows the recommended sequence for tightening the screws (red
numbers):
a) Slightly tighten the screws crosswise (see picture for order)
b) In analogy to a), tighten with the nominal tightening torque
The film of the PowerVat now has the required tension and is ready for use.
Caution: Do not start print jobs before all transport protections have been
removed and the 8 countersunk screws on the bottom of the PowerVat have
been properly tightened to guarantee the function and tightness of the vat.
If the transport protections are not removed before printing, material could
leak out of the vat and damage the printer.
TX20
1
2
3
4
5
6
7
8

16
This section is only applicable if the FlexVat has been previously installed.
During the print job, an automatic locking mechanism is engaged to securely lock
the PowerVat in place. After the print job, the vat is released and can be removed.
To enable this function, the 4 clamping bolts of your SolFlex 3D printer must be
equipped with the supplied locking discs [5]. Use the 4 supplied M5x16
countersunk screws [11].
1. First, remove the building platform and platform cover of your SolFlex 3D
printer and move the z-stage to the lower end position for better access to
the clamp bolts. To achieve this, use the JOG MODE on the touch screen
and select Move To Bottom.
2. As soon as the printer has reached its final position, mount the 4 locking
discs [5] on the clamping bolts of the printer. Use the 4 countersunk screws
M5x16 [11] and the 3mm hex wrench.
11
5
Hex wrench 3mm

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Important: Make sure that the locking discs are always in perfect condition,
otherwise the PowerVat may not be fully locked in place during printing.
3. In the JOG MODE menu click on the button Vat Type to select the vat type
PowerVat and initialize the machine by clicking the Initialize button.
In order to use your SolFlex 3D printer with the FlexVat system, the locking discs
[5] and countersunk screws [11] must be removed. Before inserting a FlexVat, make
sure that the vat type FlexVat is selected under JOG MODE →Vat Type.
Afterwards the printer has to be initialized.
Before installing a PowerVat in your SolFlex 3D printer, always make sure that the
vat surface is free of material residues and clean the PowerVat if necessary.
Contamination in the beam path can lead to artifacts in the printed object. Before
each print job, always make sure that the PowerVat has no contamination in the
beam path. For evaluation of the vat status, have a look at the vat from different
angles. Light reflections can help to identify soiled spots. Be sure to wear clean
gloves when cleaning the vat to avoid re-contamination of the vat.
Grease and small residues of the printed material can be carefully picked up with
a tissue soaked with isopropanol (purity min. 95%). Depending on the degree of
contamination, this step must be carried out several times. In the meantime, the
remaining isopropanol on the surface can be blown away with oil-free compressed
air to ensure a streak-free surface.
2
1

18
Particles can finally be removed with compressed air. The final cleaning of the
PowerVat with compressed air must not be carried out in the SolFlex 3D printer as
this may lead to unwanted contamination in the printer.
Please note that cleaning may need to be done on both the inside (film) and the
bottom (glass) of the PowerVat. After cleaning the vat is ready for use. It is
recommended to handle the PowerVat by holding it only at the grips located on
the sides of the vat to avoid further contact with the film or the glass surfaces.
After selecting the vat type PowerVat under Vat Type in the JOG MODE menu,
initialize the printer (JOG MODE →Initialize).
Insert the PowerVat like illustrated below.
1
2

19
If inserting the PowerVat is not possible without applying pressure, the stretcher
zero position must be readjusted (see section Stretcher Zero Position).
The vat will only be locked during the printing process which requires no further
action by the user. Before starting the printing process, the PowerVat can be
moved slightly horizontally
Important: Do not start a print job unless the vat has been inserted correctly.
When inserting the PowerVat, make sure that the locking discs fit into the
recesses of the PowerVat. If the PowerVat rests only on the clamping bolts /
locking discs on one side (so the vat has an inclined position) both the vat
and the printer might be damaged when starting a print job. Always ensure
correct stretcher zero position adjustment (see section Stretcher Zero
Position) to ensure proper insertion of the PowerVat.
Important: The film must be replaced immediately in case of damage (for
example when cracks or undulating bulges occur). Before each print, make
sure that the PowerVat film is in good condition (see the section Evaluating
the Condition of the Vat). Using a damaged film leads to poor printing
results. The number of print jobs that can be performed with a single film
depends on the material and BuildStyle used, as well as the size of the
printed objects. New films can be obtained from your reseller.
Caution: Before each print job, ensure that the vat parts are in perfect
condition. Do not use a damaged vat, as otherwise material could leak and
flow into the interior of the PowerVat. If material should enter the SolFlex 3D
printer, remove it immediately to avoid damage. Be sure to contact your
SolFlex service team ([e-mail]).
Caution: Do not insert the PowerVat into the printer until the transport
protection has been removed and the 8 countersunk screws on the
underside of the vat have been properly tightened to guarantee a proper
function and tightness of the vat. If the transport protection is not removed
before printing, material could escape from the vat and damage the printer.