ALARIS30

• Model: Objet Alaris 30
• serial number: 7408

Vendor contact

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

Mailing list for UBC end

• alaris-3d@csDELETEthisTEXT.ubc.ca.
• 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 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.

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/Cleaning

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.

Flushing the head

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

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.

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

• 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