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Overview





Workflow



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• Resin ordering: supportus@objet.com Phone: 877-489-9449 or 978-495-5509. Use the purchase order form.

• Printing cost estimation/billing: AlarisCharges.xls or on google spreadsheet

• Purchase order form: USResinOrderFormDesktopAlaris.xls

• PSM local directory: /imager/project/psm/alaris30
• PSM mailing list: alaris-3d@cs.ubc.ca (only for communicating with the vendors. Admins: Wolfgang, Nasa)
• Login:
  • Driver machine: admin/admin
  • Alaris software, to enable advance features: Ctrl+Alt+m (also hide mouse pointer to lower right)

• Trained personnel: Nasa (x709), Wolfgang.

• Resin ordering: supportus@objet.com Phone: 877-489-9449 or 978-495-5509. Use the form purchase order form linked at the top of this page.

• *Username: admin Password: Admin

• Administrative Password: Try Ctrl+Alt+m.
• Cartridge replacement: Ask Nasa or Wolfgang first. The replacement procedure is described here.
• WARNING!! Liquid printing material is toxic: msds_001.pdf. Use gloves and/or goggles if needed.

Quickstart

• Model and export a binary STL file (see the "Google Sketchup" section below for a ASCII to binary converter).

• Ensure control application started on other computer (Alaris30 on the desktop), and press the red button on the application to bring the printer online

• • Choose from glossy or matte finish (top faces only)
  • Support can be light, medium or strong (strong for overhanging structures).

• Clean the tray: Scrape off the excess support material from the print tray with the scraper. Spray some water on the tray and wipe off with a lint-free microfiber cloth. (Supplies are in the box under the table).

• • OpenSCAD http://openscad.org yet another open source CAD program. Uses a different "programmatic" approach for defining the parts instead of a visual one. Can output ASCII STL files, use above converter.
  • Ashlar Vellum Argon http://www.ashlar.com/sections/products/argon/argon.html a professional 3D CAD software, offers a monthly rental model ($40/month, minimum two months).
  • Free-CAD http://sourceforge.net/apps/mediawiki/free-cad/index.php?title=Main_Page, cross platform, open-source CAD software. Can be scripted using Python. Seems to be missing a way to indicate resolution of round objects in STL export.

• MSDS (Material safety data sheet): msds_001.pdf

• Intro videos: http://www.objet.com/eLearning/eLearning2/menu5.html

• Max resolution: 28microns in the Z direction, 1200dpi in X,Y.
• Set "angle" low in CAD software for smooth curves

• CAD application: (third party sortware)
  • solidworks is used to create/edit models. Save in binary format, high triangulation of models would result in smooth curves.
  • Google SketchUp (last tested with version 8) is freely available and works well for our purposes. It does not output STL files, but the plugin skp_to_dxf.rb will allow for export to ASCII STL file (via the Tools menu in SketchUp). Make sure to clean up the geometry before export, and don't export guide lines. The exported STL file must be converted to binary format for use in Objet Studio. Use the attached stl_ascii2bin.py script to convert it.

• Make sure the unit is right (inch, mm)
• Press auto-align toolbar button (it will probably fail). Manually drag object around to non-overlapping positions. For each object, click it and adjust rotation to make it lie down flat. Use the transformation dialog in the bottom left, experiment with rotating by ± 90 in each axis. After getting rotation correct, try auto-aligning again.

• You can pause a print from the host machine if you need for example to take out a part that is done.

• Use the spatula to pick up the parts. Be careful of not hitting the head by chance.
• Clean the tray: Scrape off the excess support material from the print tray with the scraper. Spray some water on the tray and wipe off with a lint-free microfiber cloth (supplied).

• Parts postprocessing guide: Postprocessorapplications7-07.pdf
• Painting printed parts: Penetrating_Dye_Letter_Low.pdf
• Cleaning with NaOH: Model_Cleaning_NaOH.pdf (we don't do it)

Resolution tips

• Keep ± 8 thou (thousands of an inch) space between parts that fit together.
• wall thickness: .5 mm, place walls along X (left-right) direction

• Printing cost estimation/billing: AlarisCharges.xls

• Maintenance Calendar: on google calendar

• PSM mailing list: alaris-3d@cs.ubc.ca (only for communicating with the vendors. Admins: Wolfgang, Nasa)

• Trained personnel: Nasa (x709), Wolfgang.

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• User guide: DOC-04000_A_UserGuide.pdf
• Operator training guide (basic training): 3_ObjetTrainingForOpertorDOC-04023.pdf

Intro videos

http://www.objet.com/eLearning/eLearning2/menu5.html

File types accepted for printing:

• STL files: from the CAD app.
• SLC files: rasterized
• BMP files: Can be sent only from the printer control app, not from the host.

Hardware

• Alaris30: The 3D printer equipment. Runs Windows XP. Installation disks supplied.
• Host machine:
  • OS: Win XP. Vista printer driver in beta.
  • RAM: 4G

Software

• Control Application: Use to set printer online.
• Objet Studio: Runs on host or clients. Used to place models on the tray, to get estimates in terms of amount of material. From the host machine, sending to print would run the job manager and start printing.
• Job manager: Does the rasterization and sends 8 layers at a time to the printer. It must be running while the printing is being carried out. Closing this application would forfeit the print.
• CAD application: (third party sortware) such as solidworks, used to create/edit models. Save in binary format, high triangulation of models would result in smooth curves. Google SketchUp (last tested with version 8) is freely available and works well for our purposes. It does not output STL files, but the plugin skp_to_dxf.rb will allow for export to ASCII STL file (via the Tools menu in SketchUp). Make sure to clean up the geometry before export, and don't export guide lines. The exported STL file must be converted to binary format for use in Objet Studio. Use the attached stl_ascii2bin.py script to convert it.

• Printing cost estimation for "the others" readily usable Google docs or local file: printestimatesheetrev2.xls

• Maintenance Calendar: http://www.google.com/calendar/embed?src=vdbmr5fftdlejcdtfg0gbrlap8%40group.calendar.google.com&ctz=America/Vancouver

Intro videos

http://www.objet.com/eLearning/eLearning2/menu5.html

Vendor Stuff

Vendor contact

• Mark Mason mmason@maverick-solutions.com (On-site installation person)
• Paul Gascho paulg@maverick-solutions.com
• Resin ordering: supportus@objet.com Phone: 877-489-9449 or 978-495-5509

Mailing list for UBC end

• alaris-3d@cs.ubc.ca.
• Only for communicating with vendors.
• Admins: Wolfgang, Nasa.

Dates

• Purchased:
• On-site installation: Oct 21--22, 2010
• Warranty till:

<-- ---++ Online Resources -->

<-- ---+++++ Free 3D models online
http://www.3dcontentcentral.com/default.aspx -->

Hardware

• Alaris30: The 3D printer equipment. Runs Windows XP. Installation disks supplied.
• Host machine:
  • OS: Win XP. Vista printer driver in beta.
  • RAM: 4G

Software

• Control Application: Use to set printer online.
• Objet Studio: Runs on host or clients. Used to place models on the tray, to get estimates in terms of amount of material. From the host machine, sending to print would run the job manager and start printing.
• Job manager: Does the rasterization and sends 8 layers at a time to the printer. It must be running while the printing is being carried out. Closing this application would forfeit the print.
• CAD application: (third party sortware) such as solidworks, used to create/edit models. Save in binary format, high triangulation of models would result in smooth curves. Google SketchUp (last tested with version 8) is freely available and works well for our purposes. It does not output STL files, but the plugin skp_to_dxf.rb will allow for export to ASCII STL file (via the Tools menu in SketchUp). Make sure to clean up the geometry before export, and don't export guide lines. The exported STL file must be converted to binary format for use in Objet Studio. Use the attached stl_ascii2bin.py script to convert it.

Installation

Calibration (Do only at installation, check the installation PDF for details)

• Transparency test: XY alignment, overall. Parameters page.
• Head alignment test:
• Weight test: for voltage calibration. Excel file: Alaris30_Adjustment_Ver11_Master.xls
• Pattern test: to see if nozzles are working

• Printing cost estimation for "the others" readily usable Google docs or local file: printestimatesheetrev2.xls

• Serial number: 7408

• Cleaning with NaOH: Model_Cleaning_NaOH.pdf (we don't do it)

• CAD application: (third party sortware) such as solidworks, used to create/edit models. Save in binary format, high triangulation of models would result in smooth curves. Google SketchUp (last tested with version 8) is freely available and works well for our purposes. It does not output STL files, but the plugin skp_to_dxf.rb will allow for export to ASCII STL file (via the Tools menu in SketchUp). Make sure to clean up the geometry before export, and don't export guide lines. The exported STL file must be converted to binary format for use in Objet Studio. Use the attached stl_ascii2bin.py script to convert it.

Quickstart

• Model and export a binary STL file
• Copy to the computer with Objet Studio installed
• The two computers are connected via KVM switch. Double-press scroll-lock (it will beep) then press enter (on the black keyboard) to toggle between them
• Ensure control application started on other computer, and press the red button on the application to bring the printer online
• Open new tray in Objet Studio and use drag-and-drop to import your STL files (multiple files ok)
• Press auto-align toolbar button (it will probably fail). Manually drag object around to non-overlapping positions. For each object, click it and adjust rotation to make it lie down flat. Use the transformation dialog in the bottom left, experiment with rotating by +/- 90 in each axis. After getting rotation correct, try auto-aligning again.
• Press the model-check button to see if anything is overlapping. If not, there will be no output.
• Press the material check button. It will display amounts in the status bar at the bottom. Compare these to the levels listed in the main printer application on the other computer.
• Start the print job.

• Printing cost estimation readily usable Google docs or local file: printestimatesheetrev2.xls

• Specs: ObjetAlarisspecs.pdf
• MSDS (Material safety data sheet): msds_001.pdf
• PSM local directory: /imager/project/psm/alaris30

Installation

Calibration (Do only at installation, check the installation PDF for details)

• Transparency test: XY alignment, overall. Parameters page.
• Head alignment test:
• Weight test: for voltage calibration. Excel file: Alaris30_Adjustment_Ver11_Master.xls
• Pattern test: to see if nozzles are working

• User guide: DOC-04000_A_UserGuide.pdf
• Operator training guide (basic training): 3_ObjetTrainingForOpertorDOC-04023.pdf

1. Use a water jet (we don't have one installed -- use a knife for now ) for cleaning off the support material. “Lite” support is easy to clean. For some cases, NaOH might be needed (see pdf).

• Parts postprocessing guide: Postprocessorapplications7-07.pdf
• Painting printed parts: Penetrating_Dye_Letter_Low.pdf
• Cleaning with NaOH: Model_Cleaning_NaOH.pdf

• Preventive maintenance Procedures: DOC-04005_Alaris30-PM-Kit.pdf
• Maintenance guide (primarily for vendor engineers): DOC-04204_Maintenance.pdf

• MSDS (Material safety data sheet): msds_001.pdf

• PSM local directory: /imager/project/psm/alaris30

Training videos

Free 3D models online

• Control Application: Use to set printer online.
• Objet Studio: Runs on host or clients. Used to place models on the tray, to get estimates in terms of amount of material. From the host machine, sending to print would run the job manager and start printing.

Calibration (Do only at installation, check the installation PDF for details)

• Transparency test: XY alignment, overall. Parameters page.
• Head alignment test:
• Weight test: for voltage calibration
• Pattern test: to see if nozzles are working

How to print

Resolution

• 28microns in the Z direction, 1200dpi in X,Y.
• Set “angle” low on CAD software for smooth curves
• Keep +/- 8 thou (thousands of an inch) space between parts that fit together.
• wall thickness: .5 mm, place walls along X direction

File types for printing:

• STL files: from the CAD app.
• SLC files: rasterized
• BMP files: Can be sent only from the printer control app, not from the host.

Preparing the model

1. Create .stl files in CAD app in “binary” format. Ascii format files are sometimes rejected.
2. Load STL file on the object software (on the client or host)
3. Use scale if the model is bigger than what it should be.
4. Start with auto placement. Then use “orientate for minimal support”. Manual placement is possible.
5. “Export your tray as packed job” to objzf format. Take it to the host machine, “import packed job” from file menu.

Printer preparation

1. Reinitiate if shut down for more than 72 hours.
2. Fill the head if not filled.
3. Turn the printer online using the controller application.

Printing

1. From object studio on host, load the tray file, send to print. Job manager will run and start sending the layers as soon as the printer is online.
2. Head nozzles can be clogged, but it is not a problem as long as 7 nozzles are not clogged in a row.
3. If you need to pause printing, it is better to pause it from the host.
4. Use the spatula to pick up the parts.
5. Clean the tray: Scrape off the excess support material from the print tray with the scraper. Spray some water on the tray and wipe off with a lint-free microfiber cloth (supplied).

Finalizing the print

1. Use a water jet for cleaning off the support material. “Lite” support is easy to clean. For some cases, NaOH might be needed (see pdf).
2. Color the model, coloring works well.
3. Try not to use a big drill; gradually increase drill size, otherwise, the model might break.

Bringing up the maintenance menu

Replacements/Cleaning

1. Waste bin:

2. Odor filter:

3. Model/support cartridge:

4. Wiper blade head cleaner:

5. Knife:

6. Head:

7. Computer parts:

8. UV lamp:

Head Maintenance

Shutting down the machine

• Model: Objet Alaris 30

File types for printing:

1. Ctrl+Alt+m, a confirmation window pops up
2. Hit ok.

1. Run the head cleaning wizard. It will place the head assembly on top of the tray and lower the tray (“z axis”).
2. Put the mirror on top of the tray to be able to see underneath the assembly where the heads are.
3. Use 99% IPA to clean up the head. Remember to use a pair of gloves, IPA can irritate your skin.
4. Spray IPA into the microfiber cloth
5. Reach under the head and wipe from the middle to one end, don’t come back inward. Again start from the middle and wipe towards the other end. Do the same with the other head.
6. Also reach the roller and clean it. Wipe and roll.

1. Create .stl files in CAD app in “binary” format. Ascii format files are sometimes rejected.
2. Load STL file on the object software (on the client or host)
3. Use scale if the model is bigger than what it should be.
4. Start with auto placement. Then use “orientate for minimal support”. Manual placement is possible.
5. “Export your tray as packed job” to objzf format. Take it to the host machine, “import packed job” from file menu.

1. Reinitiate if shut down for more than 72 hours.
2. Fill the head if not filled.
3. Turn the printer online using the controller application.

1. From object studio on host, load the tray file, send to print. Job manager will run and start sending the layers as soon as the printer is online.
2. Head nozzles can be clogged, but it is not a problem as long as 7 nozzles are not clogged in a row.
3. If you need to pause printing, it is better to pause it from the host.
4. Use the spatula to pick up the parts.
5. Clean the tray: Scrape off the excess support material from the print tray with the scraper. Spray some water on the tray and wipe off with a lint-free microfiber cloth (supplied).

1. Use a water jet for cleaning off the support material. “Lite” support is easy to clean. For some cases, NaOH might be needed (see pdf).
2. Color the model, coloring works well.
3. Try not to use a big drill; gradually increase drill size, otherwise, the model might break.

• Model_Cleaning_NaOH.pdf: Cleaning with NaOH

• Mark Mason mmason@maverick-solutionsDELETEthisTEXT.com (On-site installation person)

• alaris-3d@csDELETEthisTEXT.ubc.ca.
• Only for communicating with vendors.
• Admins: Wolfgang, Nasa.

Bringing up the maintenance menu

Replacements/Cleaning

1. Waste bin:

2. Odor filter:

3. Model/support cartridge:

4. Wiper blade head cleaner:

5. Knife:

6. Head:

7. Computer parts:

8. UV lamp:

Head Maintenance

Head cleaning

• 1. Run the head cleaning wizard. It will place the head assembly on top of the tray and lower the tray (“z axis”).
• 2. Put the mirror on top of the tray to be able to see underneath the assembly where the heads are.
• 3. Use 99% IPA to clean up the head. Remember to use a pair of gloves, IPA can irritate your skin.
• 4. Spray IPA into the microfiber cloth
• 5. Reach under the head and wipe from the middle to one end, don’t come back inward. Again start from the middle and wipe towards the other end. Do the same with the other head.
• 6. Also reach the roller and clean it. Wipe and roll.

Aligning print heads

Flushing the head

Shutting down the machine

• Keep the machine running at all times. Close the control app to turn off the print head fans.
• Once a week, print the business card. If needed, shut down with the shut down wizard. Shutting down may require “voltage” recalibration.

• 1. Create .stl files in CAD app in “binary” format. Ascii format files are sometimes rejected.
• 2. Load STL file on the object software (on the client or host)
• 3. Use scale if the model is bigger than what it should be.
• 4. Start with auto placement. Then use “orientate for minimal support”. Manual placement is possible.
• 5. “Export your tray as packed job” to objzf format. Take it to the host machine, “import packed job” from file menu.

• 1. Reinitiate if shut down for more than 72 hours.
• 2. Fill the head if not filled.
• 3. Turn the printer online using the controller application.

• 1. From object studio on host, load the tray file, send to print. Job manager will run and start sending the layers as soon as the printer is online.
• 2. Head nozzles can be clogged, but it is not a problem as long as 7 nozzles are not clogged in a row.
• 3. If you need to pause printing, it is better to pause it from the host.
• 4. Use the spatula to pick up the parts.
• 5. Clean the tray: Scrape off the excess support material from the print tray with the scraper. Spray some water on the tray and wipe off with a lint-free microfiber cloth (supplied).

Finalizing the print

• 1. Use a water jet for cleaning off the support material. “Lite” support is easy to clean. For some cases, Sodium Hydroxide might be needed (see pdf).
• 2. Color the model, coloring works well.
• 3. Try not to use a big drill; gradually increase drill size, otherwise, the model might break.

Calibration (Do only at installation, check the installation PDF for details)

• Transparency test: XY alignment, overall. Parameters page.
• Head alignment test:
• Weight test: for voltage calibration
• Pattern test: to see if nozzles are working

• Alaris30_Adjustment_Ver11_Master.xls: For voltage calibration

• DOC-04000_A_UserGuide.pdf: User guide

• DOC-04005_Alaris30-PM-Kit.pdf: Preventive maintenance Procedures

• DOC-04006_Alaris30Installation_3.pdf: Installation guide

• DOC-04204_Maintenance.pdf: Maintenance guide (for vendor engineers primarily)

• 3_ObjetTrainingForOpertorDOC-04023.pdf: Operator training guide -- basic training

• ObjetAlarisspecs.pdf: Specifications

• Model_Cleaning_NaOH.pdf: Cleaning with NaOH

• Penetrating_Dye_Letter_Low.pdf: Painting printed parts

• Postprocessorapplications7-07.pdf: Parts postprocessing guide

ALARIS30

Vendor contact

• Mark Mason mmason@maverick-solutionsDELETEthisTEXT.com

• Paul Gascho paulg@maverick-solutionsDELETEthisTEXT.com

Mailing list for UBC end

Only for communicating with vendors.

Admins: Wolfgang, Nasa.

Resolution

• 28microns in the Z direction, 1200dpi in X,Y.
• Set “angle” low on CAD software for smooth curves
• Keep +/- 8 thou (thousands of an inch) space between parts that fit together.
• wall thickness: .5 mm, place walls along X direction

File types fpr printing:

• STL files: from the CAD app.
• SLC files: rasterized
• BMP files: Can be sent only from the printer control app, not from the host.

Dates

• Purchased:
• On-site installation: Oct 21--22, 2010
• Warranty till:

Online Resources

Training videos

http://www.objet.com/eLearning/eLearning2/menu5.html

Free 3D models online

http://www.3dcontentcentral.com/default.aspx

Hardware

• Alaris30: The 3D printer equipment. Runs Windows XP. Installation disks supplied.
• Host machine:

Software

• control application: Use to set printer online.
• Objet studio: Runs on host or clients. Used to place models on the tray, to get estimates in terms of amount of material. From the host machine, sending to print would run the job manager and start printing.
• Job manager: Does the rasterization and sends 8 layers at a time to the printer. It must be running while the printing is being carried out. Closing this application would forfeit the print.
• CAD application: (third party sortware) such as solidworks, used to create/edit models. Save in binary format, high triangulation of models would result in smooth curves.

Maintenance

Bringing up the maintenance menu

On the printer’s computer focus controller app

1. hide the mouse cursor at the bottom right corner of the screen

2. Ctrl+Alt+m, a confirmation window pops up

3. Hit ok.

Replacements

Check the maintenance counters on the control app menu.

1. Waste bin:

Lives in the drawer, inside the cardboard box. Waste accumulates as you operate the machine. It needs to be replaces once >1.8 kg of waste has accumulated. Check the controller app, if the waste bar is red, replace it. Be careful not to twist the plastic bag inside. Open the cardboard box, hold at the neck of the plastic bag, and twist the pipe connector at the top. Put one of the supplied lids on the plastic bag. The waste is in liquid form, either cure it with UV or put it in the sunlight. Once the waste hardens, throw it in the garbage. Waste bags are free for the first year.

2. Odor filter:

Needs to replaced every 1 to 2 years, if needed. It is in a drawer in the back.

3. Model/support cartridge:

Each cartridge holds 1kg of liquid material. There are two model (square) and two support cartridges (rectangular) in the drawer. Once empty, replace. Replacements must be purchased in pairs. The control app shows amounts left in the cartridges.

Toxicity: Liquid form is toxic. Inhaling is not a problem, touching might irritate the skin. Never touch your eyes with it or taste it. Wear gloves when handling the liquid form. Once cured it is not toxic.

Removing the current cartridge: Pull up vertically, the rubber membrane seals off the cartridge. Don’t touch the rubber membrane Top insertion. Don’t put force, just let it slide in position, and then vertically put it down for the needles to penetrate through the rubber membrane.

Expiration: Recommended shelf life: 4 months. There is an expiry date, best if used by then.

4. Wiper blade head cleaner:

Lives in the top-left bay. Change it if it has dips on the rubber surface.

Wiper cleaning: once a week. Run the wiper cleaning wizard.

5. Knife:

if necessary

6. Head:

see head maintenance

7. Computer parts:

The front cover comes off once the front screws are taken out from the top. Motherboard and other computer parts

8. UV lamp:

Replace after 1600 hours.

Head Maintenance

$1300 each!! Not covered by warranty. Replaced only by the engineers from the vendor if needed.

Head cleaning: once a week.

1. Run the head cleaning wizard. It will place the head assembly on top of the tray and lower the tray (“z axis”).

2. Put the mirror on top of the tray to be able to see underneath the assembly where the heads are.

3. Use 99% IPA to clean up the head. Remember to use a pair of gloves, IPA can irritate your skin.

4. Spray IPA into the microfiber cloth

5. Reach under the head and wipe from the middle to one end, don’t come back inward. Again start from the middle and wipe towards the other end. Do the same with the other head.

6. Also reach the roller and clean it. Wipe and roll.

Aligning print heads: once every 6 months, or sooner if quality suffers.

Use the head alignment test wizard. It will print a number of lines with different head alignment on a transparent sheet. Use the magnifier glass to pick the best alignment.

Shutting down: Keep the machine running at all times. Once a week, print the business card. If needed, shut down with the shut down wizard. Shutting down may require “voltage” recalibration.

Flushing the head: Only if the machine is not going to be used for the months, flush the heads with the fill/flush wizard.

How to print

Preparing the model

1. Create .stl files in CAD app in “binary” format. Ascii format files are sometimes rejected.

2. Load STL file on the object software (on the client or host)

3. Use scale if the model is bigger than what it should be .

4. Start with auto placement. Then use “orientate for minimal support”. Manual placement is possible.

5. “Export your tray as packed job” to objzf format. Take it to the host machine, “import packed job” from file menu.

Printer preparation

1. Reinitiate if shut down for more than 72 hours.

2. Fill the head if not filled.

3. Turn the printer online using the controller application.

Printing

1. From object studio on host, load the tray file, send to print. Job manager will run and start sending the layers as soon as the printer is online.

2. Head nozzles can be clogged, but it is not a problem as long as 7 nozzles are not clogged in a row.

3. If you need to pause printing, it is better to pause it from the host.

4. Use the spatula to pick up the parts.

5. Clean the tray: Scrape off the excess support material from the print tray with the scraper. Spray some water on the tray and wipe off with a lint-free microfiber cloth (supplied).

Finalizing the print

1. Use a water jet for cleaning off the support material. “Lite” support is easy to clean. For some cases, NaOH might be needed (see pdf).

2. Color the model, coloring works well.

3. Try not to use a big drill; gradually increase drill size, otherwise, the model might break.

Calibration (Do only at installation, check the installation PDF for details)

• Transparency test: XY alignment, overall. Parameters page.
• Head alignment test:
• Weight test: for voltage calibration
• Pattern test: to see if nozzles are working

-- MushfiqurRouf - 23 Oct 2010