Zcorporation Z 406 User manual

Z406 System User Manual
November 2002
Copyright © 2002 Z Corporation Part Number 09504
Z®406 3D Color Printer User Manual
Z Corporation
Revision D

Z Corporation Z406 System User Manual
2Z Corporation Service [phone]/(887)88-ZCORP
Table of Contents:
1YOUR Z406 SYSTEM .................................................................................................. 6
1.1 INTRODUCTION ................................................................................................... 6
1.1.1 OVERVIEW...................................................................................................................6
1.1.2 HOW IT WORKS ..........................................................................................................7
1.2 THE PARTS OF THE Z406 3D PRINTER........................................................... 10
1.3 THE PARTS ON THE PRINTER ASSEMBLY AND GANTRY ............................ 11
1.4 Z406 SYSTEM COMPONENTS .......................................................................... 12
1.4.1 STEP 1: IMPORTING THE FILE.................................................................................13
1.4.2 STEP 2: PREPARING THE 3D PRINTER ..................................................................13
1.4.3 STEP 3: PRINTING THE PART..................................................................................13
2PREPARING THE Z406 SYSTEM TO PRINT........................................................... 14
2.1 HARDWARE CONTROLS ................................................................................... 14
2.2 PREPARING THE 3D PRINTER ......................................................................... 15
2.2.1 FILLING THE FEED BOX WITH POWDER ................................................................16
2.2.2 CLEANING THE SERVICE STATION ........................................................................18
2.2.3 CHECKING FLUID LEVELS .......................................................................................20
2.2.4 CHECKING POWDER OVERFLOW BIN....................................................................21
2.2.5 PUTTING THE MACHINE ONLINE ............................................................................22
3SETTING UP THE BUILD.......................................................................................... 23
3.1 OPEN OR IMPORT THE FILE............................................................................. 23
3.2 ORIENTING THE PART ...................................................................................... 24
3.2.1 PART CONTAINING AN OPENING OR HOLLOW AREA ..........................................24
3.2.2 PART CONTAINING OVERHANGS ...........................................................................24
3.3 CHECKING BUILD SETTINGS ........................................................................... 25
3.3.1 POWDER SETTINGS.................................................................................................26
3.4 PRINTING THE BUILD ........................................................................................ 27
4POST PROCESSING THE PART.............................................................................. 28
4.1 REMOVING THE FINISHED PART..................................................................... 28
4.2 DEPOWDERING THE PART............................................................................... 29
4.3 DRYING THE PART ............................................................................................ 30
4.3.1 STARCH AND PLASTER PARTS ..............................................................................30
4.3.2 ZCAST PARTS ...........................................................................................................30
4.4 INFILTRATING THE PART.................................................................................. 31

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4.4.1 USING Z CORP. RECOMMENDED RESIN ...............................................................31
5ADVANCED USER FEATURES ................................................................................32
5.1 ORIENTATION FOR SPEED ...............................................................................32
5.2 ORIENTATION FOR STRENGTH .......................................................................32
5.3 ORIENTATION TO PREVENT WARPING ..........................................................32
6MAINTENANCE .........................................................................................................33
6.1 CHANGING THE PRINT HEADS.........................................................................33
6.2 ALIGNING THE PRINT HEADS...........................................................................36
6.3 COLOR ALIGNMENT...........................................................................................42
6.4 FLUSHING THE BINDER ....................................................................................44
6.5 OILING THE FAST AXIS......................................................................................44
6.6 OILING THE SNOWPLOWS (FOR NON-ZCAST POWDER USERS)................45
6.7 CLEAN UNDER THE GANTRY ...........................................................................45
6.8 OIL SLOW AXIS FRONT RAIL (FOR ZCAST POWDER USERS)......................46
6.9 REPLACING THE SCRAPER BLADE (FOR ZCAST POWDER USERS) ..........47
6.10 CHANGING THE BINDER SUPPLY ....................................................................48
6.11 CHANGING MATERIAL SYSTEM .......................................................................49
7TROUBLESHOOTING ...............................................................................................54
7.1 THE BINDER SOLUTION IS BEING APPLIED IN ERRATIC STRIPES .............54
7.2 THE SOFTWARE FREEZES DURING USE ......................................................54
7.3 THIN PLANAR PARTS ARE WARPING ..........................................................54
7.4 NOTHING HAPPENS WHEN I TRY TO PRINT ..............................................54
7.5 MY STARCH-BASED PARTS ARE UNUSUALLY “CAKEY”...............................55
7.6 PARTS ARE UNUSUALLY WEAK OR CRUMBLY..............................................55
7.7 PRINTER LOOKS LIKE IT IS PRINTING, BUT IS NOT LAYING DOWN BINDER55
8Z406 SYSTEM DETAILS............................................................................................56
8.1 DESCRIPTION OF REAR I/O PANEL .................................................................56
8.2 SYMBOLS USED .................................................................................................57
8.3 SYSTEM SPECIFICATIONS................................................................................58
8.4 MATERIAL STORAGE PRECAUTIONS..............................................................59
8.5 ERROR CODES...................................................................................................59
9INDEX .........................................................................................................................66

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Table of Figures
Figure 1. The Printing Process ................................................................................................. 7
Figure 2: The Z406 System Shelling and Infrastructure Features............................................ 8
Figure 3: Illustration of Z406 System Print Orientations .......................................................... 9
Figure 4: The Z406 3D Printer ................................................................................................ 10
Figure 5: Gantry and Printer Assembly................................................................................... 11
Figure 6: Z406 System Components ...................................................................................... 12

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Use of Equipment
The Equipment was manufactured under patents licensed to Z Corp. to be used for the fabrication of
appearance models and prototypes. Other uses may be restricted; contact Z Corporation for further
information.
The Equipment is designed to be used by design engineers and other professionals in the production
of early-stage 3D appearance models and prototypes. The Equipment is not to be used to produce,
either directly or indirectly, medical or other products that may require precise dimensions or
tolerances to ensure the safe and effective operation of such products. You agree to indemnify,
defend and hold Z Corporation and its officers, directors and employees harmless from and against
any and all claims, losses, damages, costs and expenses resulting from any use of the Equipment
other than for the production of early-stage appearance models and prototypes.
If you have purchased all relevant casting-specific products as recommended by Z Corp. (casting-
specific service contract, hardware, software, and consumables), as well as a casting license, then
you are authorized to utilize the Equipment to fabricate molds for casting.

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1 YOUR Z406 SYSTEM
1.1 INTRODUCTION
1.1.1 OVERVIEW
This Z406 3D Color Printer Manual will speed you along the path towards quickly and
inexpensively building parts. The manual contains the following sections:
1. Introduction. This section will give you an overview of the principles behind the Z406
System, familiarize you with the terminology we will use to describe the Z406 System
and introduce you to some of the features of this manual. This section concludes with an
outline of the three quick and easy steps to printing parts.
2. Preparing the Z406 System to Print. This section will guide you through putting
powder, binder solution and washer fluid in the Z406 3D Printer, and preparing the
system to print a part.
3. Setting Up The Build. This section gives you a brief overview of how to set up a build on
the ZPrint Software. For more information about the softwre and its features, please refer
to the ZPrint User Manual.
4. Printing the Part. This section describes the steps of actually printing the part.
5. Post Processing a Part. This section guides you through removing your printed part,
removing any excess powder and infiltrating the part with resin to improve strength and
finish.
6. Advanced User Features. This section will help you get the maximum performance out
of your Z406 System.
7. Maintenance. This section contains instructions for keeping your Z406 3D Printer in
proper condition through regular preventative maintenance.
8. Troubleshooting. This section offers some troubleshooting tips.
9. Z406 System Details.This section contains system specifications about the Z406 3D
Printer.
10. Index.

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1.1.2 HOW IT WORKS
The Z406 System is based on the Massachusetts Institute of Technology’s patented 3DP(3D
Printing) technology.
The software first converts a three-dimensional design built using 3D CAD (and saved in VRML or
STL format) into cross-sections or slices that can be between 0.003” – 0.009” thick.
The Z406 3D Printer then prints these cross-sections one after another from the bottom of part to the
top.
Inside the Z406 3D Printer there are two pistons (see Figure 1.)The feed piston is represented in the
diagrams below on the left and is shown in the ‘down’ position filled with powder. The build piston is
the piston on the right, shown below in the ‘up’ position. Also represented in the diagrams is the roller
(drawn as a circle) and the print assembly (drawn as a square.) On the Z406 Printer, the roller and
the print assembly are mounted together on the gantry which moves horizontally across the build
area.
To begin the 3D printing process, the Z406 System first spreads a layer of zp series powder in the
same thickness as the cross section to be printed. The Z406 print heads then apply a binder
solution to the powder causing the powder particles to bind to one another and to the printed cross-
section one level below. The feed piston comes up one layer and the build piston drops one layer.
The Z406 System then spreads a new layer of powder and repeats the process, and in a short time
the entire part is printed.
Step 1: As the gantry traverses left
to right, the roller collects powder.
Step 2: The roller spreads a thin
layer of powder over the build
piston.
Step 3: The roller discharges
excess powder down the powder
overflow chute.
Step 4: As the gantry traverses
right to left, the print head prints
the part cross-section.
Step 5: The feed piston moves up
one layer, the build piston moves
down one layer, and the process is
repeated.
Figure 1. The Printing Process

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The Z406 System employs several techniques to quickly build parts. First, binder solution is applied
in a higher concentration around the edges of the part, creating a strong “shell” around the exterior of
the part. Within parts, the Z406 3D Printer builds an infrastructure by printing strong scaffolding
within part walls with a higher concentration of binder solution. The remaining interior areas are
printed with a lower saturation, which gives them stability, but prevents over-saturation, which can
lead to part distortion of the part.
Figure 2: The Z406 System Shelling and Infrastructure Features
After printing, the part is removed from the powder bed, depowdered and dried. The part can then be
infiltrated with wax, epoxy, or other materials to increase strength and durability. You will have the
part in your hands and can start improving your design within the same day—usually within hours.
Because the powder layers support the structures being printed above, the Z406 System prints parts
without support structures and can print parts with complex geometries that are impossible for other
systems.
There are several important characteristics of the Z406 System that will help you print the best parts
for your intended purpose.
Part Placement. The software will automatically place the parts within the build box to maximize
build speed, the most important criteria for the majority of our users. The software positions the parts
with the smallest dimension in the z (vertical) axis. In addition to part placement, the following other
characteristics should be considered.
Strength. The ultimate strength of the part will be somewhat affected by its orientation within the
print box. The part will be strongest along the y-axis and the x-axis and less strong along the z-axis.
This is because the cross sections are printed in continuous strips along the y or the “fast” axis (the
print heads direction of travel), bands across the x or the “slow” axis (the gantry direction of travel)
and laminated layers along the z-axis. (See figure 3 below.) This discussion only applies to
untreated parts; once parts are infiltrated, they uniformly take on the strength characteristics of the
infiltrating material.
Exterior walls
p
rinted at hi
g
her
Interior infrastructure
printed at a higher
saturation
Other interior areas
printed at lower
saturation

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Figure 3: Illustration of Z406 System Print Orientations
Accuracy. The accuracy of the system depends on the materials you choose. You can employ the
anisotropic scaling feature in the software to adjust for expected shrinkage and bring your parts into
true scale. More information on anisotropic scaling factors are found in Section 3.31, Powder
Settings..
Strong
z-axis
x-axis
y-axis
Strong
Less Strong

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1.2 THE PARTS OF THE Z406 3D PRINTER
Figure 4: The Z406 3D Printer
Overflow Bin
Washer Fluid
WasteBottle
Clear Binder Bottle
Primary Color Binder
Feed Box
Print Heads
Build Box
Control Panel
Overflow Chute
Service Station
Power Switch (Hold
down for 6-8 seconds
to shut off Printer.)
Light

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1.3 THE PARTS ON THE PRINTER ASSEMBLY AND GANTRY
Figure 5: Gantry and Printer Assembly
Carriage Cover
Head Clamp Cover
Head Clamp Latch
Print Heads
Head Release Lever
Spreader Roller
Gantry

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1.4 Z406 SYSTEM COMPONENTS
ZD4i Depowdering Station
Z406 3D Printer
ZW4 Automated Waxer
Figure 6: Z406 System Components

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Printing a Part Overview
Printing a part using the Z406 3D Printer is fast, easy, clean and fully compatible with an office
environment. This manual will show tips on how to print the most challenging parts, but for most
purposes, printing a part is as simple as 1-2-3.
1.4.1 STEP 1: IMPORTING THE FILE
OPENING A FILE – Upon launching the ZPrint Software, you will be presented with the ‘Open’ dialog
box. Select the file you wish to print. The software allows you to open a variety of monochrome and
color file formats including STL, PLY, SFX, VRML (WRL), BLD, ZEC, ZBD and ZCP files. The
software also allows you to move and scale your part, or pick a color for monochrome (STL) files
before printing.
1.4.2 STEP 2: PREPARING THE 3D PRINTER
Carefully following the steps outlined in Chapter 2, you can prepare the 3D printer in less than ten
minutes. You will put powder in the feed piston, and ensure fluid levels are correct and that the
powder overflow bin is empty.
1.4.3 STEP 3: PRINTING THE PART
The Z406 3D Printer prints most parts in minutes and prints even the largest parts in a few hours.
You may then remove the part, depowder any excess powder and, if desired, dry and infiltrate the
part with wax or other materials to give the part the desired strength and finish. The post-processing
phase takes less than ten minutes for small parts and only an hour or so for the most massive parts.
Once you have completed these steps you are ready to start using parts to improve design,
communicate with other departments and reduce the time it takes you to get new products to market.

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2 PREPARING THE Z406 SYSTEM TO PRINT
2.1 HARDWARE CONTROLS
The front control panel on the Z406 3D Printer has the following features:
Online Button.
Enables and
disables printer
communication.
Spread Button. This button allows
you to move the gantry from left to
right. Moving the gantry from left to
right allows you to spread powder
over the build box. Holding down this
button will result in continuous
spreading of powder.
Feed Up/Down Buttons.
Allows user to raise or
lower the piston in the
Feed Box. A light tap
raises or lowers one layer
thickness; holding down
causes continuous motion.
Build Up/Down Buttons.
A
llows users to raise or
lower the Build Box. A
light tap raises or lowers
one layer of thickness;
holding down causes
continuous motion.
PLEASE NOTE: When the s
y
stem is online
,
all buttons exce
p
t the Online button are disabled.
LCD Panel. Displays
the current status of
the Z406 3D Printer.

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2.2 PREPARING THE 3D PRINTER
If the machine is off, switch it on by pressing and releasing the Power ON/OFF Switch. The red power
light and yellow error light will turn on. Then the Gantry will move slowly as it orients itself. We
recommend that you leave the machine on at all times—in sleep mode the machine will exercise the print
heads during periods of inactivity to prevent clogging.
1. Wait for the green Online light indicating that the power-up procedure has completed. The
warm up process should take between 60 and 90 seconds.
2. Take machine offline by pressing and releasing the Online Button.
3. Open the Top Cover to gain access to the build area.
Technical Tip -
LEAVE THE MACHINE ON! This allows the printer to perform a periodic self maintenance.

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2.2.1 FILLING THE FEED BOX WITH POWDER
3. Grip the Powder Scoop and using a
stabbing motion, insert it repeatedly a few
inches into the loose powder to compact it.
Continue for about 10-15 seconds until the
powder feels firm.
4. For each powder bag added to the Feed
Box, repeat steps 2, 3 and 4.
5. When Feed Box is filled to top, take the
Tamper and slowly press it onto the powder
surface. Be careful not to “slap” the Tamper
into the Feed Box, which will produce
airborne particles. About 10-15 pounds of
force will give a smooth, flat, and compact
surface. Failure to firmly pack Feed Box will
affect part quality.
1. Press and hold the Feed Down button until
the piston reaches the bottom of the Feed
Box. The piston will stop when it reaches
the bottom. The Front Display will read
“F: 100% B: 100%”
2. Carefully scoop powder from the bucket and
place in the feed piston.

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6. Vacuum up any powder spilled on the Top
Deck.
7. Spread the gantry so that it is above the feed
piston. Press and hold the Feed Up Button until
the surface of the powder is even with the Top
Deck.
8. Raise the build piston until it is approximately
one inch from the top. Pour powder into the
build piston and tamp down until the powder is
even.
9. Raise the build piston until the level of powder is
approximately an eighth of an inch above the
Top Deck.
10. Press and hold the Spread Button until a uniform
bed of powder is formed in the Build Box. Make
sure powder is even throughout the Build Box.
Technical Tip -
Keep powder containers closed when not in use to keep powder dry.
Scoop powder carefully to minimize airborne powder.
Make sure that you carefully vacuum up excess powder. It only takes a minute, and the tidier the machine is, the
less often it will need maintenance!
Carefully read the Material Safety Data Sheet for powder before use.
WARNING: Use only powder supplied by Z Corporation. Use of any other material may
impact the performance and/or safety of your Z406 System and will void warranty of
equipment.

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2.2.2 CLEANING THE SERVICE STATION
Figure 9: Service Station Detail
The Service Station cleans the array of the print heads during printing. The Service Station should be
cleaned after every build. This should remove any deposits of powder. Make sure Parking Caps are dry
before beginning the build.
Print Head
Parking Caps
Squeegee
Nozzl
e

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To clean the Service Station:
1. Move the gantry to the left of the top deck
by pressing the ‘Spread’ button.
2. Lift the Top Cover.
3. Manually lift up the metal plate covering
the service station.
4. Squirt distilled water onto the squeegee
and wipe clean with the small brush
provided with your Z406 3D Printer until
all debris is removed.
5. Squirt the distilled water onto the parking
cups and wipe clean with the small brush
until all debris is removed.
6. Use a paper towel to soak up any
standing water in the parking caps.

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7. Squirt distilled water on the nozzles. Use
the brush to clean off any debris.
8. When finished, replace the service station
cover.
9. Close the Top Cover.
10. Return the gantry by pressing the
‘Spread’ button.
2.2.3 CHECKING FLUID LEVELS
1. Open the front cabinet doors.
2. Check the binder bottles and
waste bottle. If the clear binder
bottle and zc3 wash fluid are half
full or empty, refill them. If the
waste bottle is half full or more,
empty it out. Waste should be
treated in accordance with local
regulations.
3. Refill the primary color binder
before every build. Pull out the
color binder rack.
Color Binder
Solution
Binder Solution Cleaning Solution
Waste