technical user guide prox-300 - product...

TECHNICAL USER GUIDE ProX-300

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TECHNICAL USER GUIDE

ProX-300


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1 INTRODUCTION..........................................................................................................................4

2 SAFETY REQUIREMENTS .............................................................................................................5

2.1 Personal Protective Equipment .........................................................................................6

2.2 Safety measures ................................................................................................................7

2.3 Review of the risks involved in operating machinery that uses a powerful laser ..............7

2.3.1 Biological risks............................................................................................................................ 7

2.3.2 Chemical risks ............................................................................................................................ 8

2.3.3 Mechanical risks ......................................................................................................................... 9

2.3.4 Risks relating to gas bottles ........................................................................................................ 9

2.4 Normal operation ............................................................................................................ 10

2.4.1 Health ...................................................................................................................................... 10

2.4.2 Fire - Explosion ......................................................................................................................... 10

2.4.3 Interactions.............................................................................................................................. 10

2.4.4 Conditions relating to the manufacture of 3D objects by laser sintering .................................... 11

2.4.5 Conditions relating to the Layering ........................................................................................... 12

2.5 Safety devices .................................................................................................................. 13

2.5.1 Operator safety ........................................................................................................................ 13

2.5.2 Machine safety ........................................................................................................................ 13

2.5.3 Identification of labels .............................................................................................................. 14

3 SYSTEM PRESENTATION ........................................................................................................... 23

3.1 Generalities ..................................................................................................................... 23

3.2 General machine operation ............................................................................................. 24

3.3 Description of the machine ............................................................................................. 25

3.3.1 Part 1: Manufacturing area ...................................................................................................... 26

3.3.2 Part 2: airlock for loading and unloading................................................................................... 30

3.3.3 Part 3: Electrical and pneumatic data management – control cabinet ....................................... 31

3.3.4 Part 4: power supplies and laser management – supply cabinet................................................ 33

3.3.5 Part 5: Powder recycling ........................................................................................................... 35

3.3.6 Part 6: optical devices .............................................................................................................. 37

3.3.7 Part 7: Control display or HMI .................................................................................................. 38

4 SETTING UP .............................................................................................................................. 41

4.1 SELECTING A LOCATION ................................................................................................... 41

4.1.1 General environmental characteristics ..................................................................................... 41

4.1.2 Connection .............................................................................................................................. 41

4.1.3 Installation ............................................................................................................................... 42

4.2 Start up ............................................................................................................................ 43

4.2.1 Connection .............................................................................................................................. 43

4.2.2 Start......................................................................................................................................... 43

5 SYSTEM USE ............................................................................................................................. 45

5.1 Machine software............................................................................................................ 45

5.1.1 Supervision .............................................................................................................................. 46

5.1.2 PX Manager ............................................................................................................................. 47

5.1.3 Machine management window ................................................................................................ 48


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5.1.4 Maintenance mode window ..................................................................................................... 49

5.1.5 PROX-300 HMI menu ............................................................................................................... 50

5.1.6 Client module .......................................................................................................................... 57

5.2 Machine preparation ....................................................................................................... 63

5.2.1 Axes reset ................................................................................................................................ 63

5.2.2 Loading a sintering plate .......................................................................................................... 63

5.2.3 Loading the feed piston with powder ....................................................................................... 65

5.2.4 Roller cleaning ......................................................................................................................... 66

5.2.5 Search of sintering zero ............................................................................................................ 66

5.2.6 Creating the powder bed – Filling the gaps ............................................................................... 67

5.2.7 Cleaning the laser optic system ................................................................................................ 68

5.2.8 Inerting the chamber (only for oxidizable materials) ................................................................. 71

5.3 Launching a manufacturing ............................................................................................. 72

5.4 Unloading the machine ................................................................................................... 73

5.4.1 Sintered plate cleaning ............................................................................................................. 73

5.4.2 Unloading of the plate.............................................................................................................. 74

5.4.3 Cleaning the chamber .............................................................................................................. 75

5.5 Shutting down the system ............................................................................................... 76

6 USER MAINTENANCE ............................................................................................................... 77

6.1 Changing or cleaning of the filters ................................................................................... 77

6.1.1 Lens cleaner filter ..................................................................................................................... 78

6.1.2 Vacuum and recycling filters..................................................................................................... 80

6.2 Procedure for changing powder ...................................................................................... 81

6.3 Procedure for cleaning the roller (optional) .................................................................... 83

7 CONDITIONS OF APPLICATION OF THE STANDARD WARRANTY .............................................. 84

8 PREVENTIVE MAINTENANCE .................................................................................................... 85

9 GLOSSARY ................................................................................................................................ 86


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1 INTRODUCTION

This technical user guide is provided with the PROX-300. It deals with the following topics:

Safety rules

System presentation

System setting up

System use

Maintenance Operator

Warranty

Glossary

This document is a reference for the PROX-300 system user. Nevertheless, it is necessary that the

user attends training held and validate by Phenix Systems.


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2 SAFETY REQUIREMENTS

PROX-300 system is a class 1 laser product CE-certified. This means that the machine is safe to work

with and does not require additional eye protection, provided that the machine is used under

normal operating conditions and that all shielding doors are in proper working order and

positioned correctly.

Any work on the control racks must be carried out by qualified personnel with the relevant

authorization.

Never modify any part of the machine nor separate it from its safety system; this could lead to a risk

of disrupting its operation and also of jeopardizing the safety of persons and equipment.

Only an operator qualified and trained by PHENIX SYSTEMS can work on this system.


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2.1 Personal Protective Equipment

Personal protective equipment (PPE) is not supplied by PHENIX SYSTEMS. For information and as an

example, the items of personal protective equipment likely to be used with our machines are:

Gloves,

Masks (FFP3),

Overalls,

Etc.

Users of these PPE should check that they fully complied with applicable regulations (European

directive 89/686/CE in Europe). The employer is required to:

Provide the appropriate PPE,

Check the correct choice of PPE has been made in relation to the risks involved,

Ensure that PPE is used effectively,

Check their conformity,

Notify the people responsible for their implementation (workshop manager, etc.),

Make sure that any PPE are in proper working order and are correctly maintained,

Notify users against which risks the PPE protects them,

Train and coach users.

In any case, conform PPE (self-certified or certified by an accredited body) shall be marked both

visibly and indelibly with (CE marking for Europe):

The manufacturer's name and logo,

PPE trade name or reference,

Expiry date, where appropriate.

PPE must be delivered with a notice as well as a declaration of conformity to applicable regulations

(to the main requirements of European directive 89/686/CE in Europe).


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2.2 Safety measures

During installation or maintenance of the machine, please follow the security measures:

The PROX-300 system includes safety mechanisms that ensure completely safe use. The

machine operates automatically at high speeds and can present a danger if these safety

mechanisms are removed or disabled; therefore, they must never be removed or disabled.

All electrical work must be carried out by a qualified and authorized electrician in order to

prevent any damage to persons or property.

Do not modify control circuits or machine components.

Make a daily inspection of the machine before starting work.

Never wear a tie, scarf or loose-fitting clothing when adjusting or operating the machine.

Make it a rule that only one trained and qualified operator uses the machine at any given

moment.

Make sure that the sintering module is cleared of any obstacles before powering up the

machine.

Following the locking-unlocking procedure (ref 5006717Z 00) isolate the main electric switch

prior to inspection or maintenance of the machine, unless there is a voltage requirement. In

these specific cases, only trained personnel with the appropriate certification will be

authorized to work on the machine.

2.3 Review of the risks involved in operating machinery that uses a

powerful laser

2.3.1 Biological risks

The main risk is to the eyes. The laser beam presents a danger in two ways:

Direct radiation, where the eyes are in the beam axis,

Reflected radiation, where the beam hits a surface that does not fully absorb it, resulting in

partial reflection of the emitted beam.

Note: specular reflections (due to reflective objects) present exactly the same risk as direct radiation,

as not only are they insidious, but they also contain up to 90% or more of the initial energy content.

Effects due to laser radiation depend on the wavelength; in the near infrared range (700 to 1400

nm), the cornea and lens are highly transparent to laser radiation, which thus reaches the retina. If

Safety equipment is mandatory during any contact with the powder. This includes

wearing:

A FFP3-type protective respiratory mask

Safety gloves

Disposable coveralls


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the eye receives a significant energy density, the laser beam may cause small, irreversible lesions

with extremely variable consequences depending on the location of the affected area. This can result

in the formation of a hole in the retina with no adverse effect on vision, or in a blind area (or black

spot) due to damage to the macula or even in almost total loss of vision when the fovea is affected.

A laser safety window conforms to standard CE EN207 allows to observe interaction of laser /

material while avoiding the risk of burns and loss of visual acuity.

2.3.2 Chemical risks

These risks can have several sources:

Laser – material interaction: in this case, the emission, to a greater or lesser extent, is caused

by the vaporization and decomposition of materials during a laser procedure (emission of

fumes, aerosols and dust, some of which may be carcinogenic),

Use of gas to control the sintering atmosphere (Argon Ar – inert gas: anoxia, Nitrogen N2 –

inert gas: anoxia, Hydrogen H2 – Explosive)

The PROX-300 system rejects filtered inert gases (HEPA filters: 99,97 % of particles dimensions higher

than 0,3 µm are filtered). A connection or exit towards the outside is only necessary if the flow of the

premises is lower than 50 m3 / hour.


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2.3.3 Mechanical risks

These include risks relating to any machine-tool where digitally-controlled movements are likely to

be susceptible to rapid changes in position.

This results from inadvertent movements of the motorized axes:

Sintering axis,

Feed axis,

Layering system.

And from inadvertent movements of pneumatic actuators:

Opening/closing of the airlock,

Scraper

Opening/closing the grip,

Window shutter,

Powder tamping system.

2.3.4 Risks relating to gas bottles

Whenever necessary, compressed air bottles are to be stored outside the buildings in an enclosed

and ventilated shelter. The bottles must be placed vertically in the racks attached to the walls.

Any gas bottles that cannot be attached and that have to be used close to the equipment, must be

placed on a suitable support that makes it impossible for them to tip over.

Remember that there is a risk of asphyxia in small, poorly ventilated, rooms.

Furthermore, an excess-flow shut-off valve must be fitted to the regulator output, upstream of the

gas pipe. This valve starts to operate when the flow exceeds approx. 10% of the flow value used

under normal operating conditions.


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2.4 Normal operation

Laser sintering operations are performed on metal powders only.

The use of each metal powder should only be considered after the check of the information provided

by the supplier, the material safety data sheet (MSDS) and the applicable regulations.

2.4.1 Health

Check the potential risks (paragraphs 3, 4, 8, 11, 15 and 16 of SDS) and implement appropriate

protection solutions for staff when handling powders outside of the machine.

Never present any reflective materials (such as glasses, lenses, mirror...) bellow the scanner head.

During laser sintering operations, never neutralize security systems.

2.4.2 Fire - Explosion

All combustible dust, capable of undergoing an exothermic reaction with air when inflamed, can

cause fire or explosion when the particle size is less than 500 microns. This feature is mentioned in

paragraph 15 by the symbols and risk phrases (R10 Flammable, R11 Highly flammable R12 Extremely

flammable ...) of the MSDS.

Therefore, the use of such powders requires precautions (if there is uncertainty about the

characteristics of a powder, follow the recommendations mentioned in this document):

• Maintain the inerting of the chamber prevents dust inflammation (about 5% of O2 for

powders of titanium, for example).

• Follow the recommendations mentioned in this document during the phases of change in

materials or maintenance:

These indications are intended to prevent the manipulation of large quantities of powders when the

machine is not inert, to avoid formation of dust clouds and remove inflammation sources.

2.4.3 Interactions

During the implementation of a new material supplied by our Company, the following points have to

be verified by one of our technicians:

- Interaction system-material: Verify that the new powder is compatible with all machine equipments

(i.e: recycling system, layering…),

- Laser-material interaction: the technician has to make sure the laser interaction is correct by

adapting focal length, laser power…;

Flammable Dust: Do not use extractor hood


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2.4.4 Conditions relating to the manufacture of 3D objects by laser sintering

Conditions relating to the manufacture of 3D objects by laser sintering may require the

implementation of a qualification phase to validate all the conditions of manufacturing:

- A 3D object manufacturing with at least one of the layers including more than the half of

total surface sintered on the manufacturing plate,

- or a 3D object manufacturing with an undercut angle< 45 ° compared to the horizontal

surface of the manufacturing plate,

- or a 3D object manufacturing with its minimum thickness is 5 times smaller than the part

height above the considered cross-section,

The material hereunder requires stronger limitations:

- Titanium Ti-6Al-4V: the maximum volume of a part fully solid sintered should not exceed

50x50x10mm (L x W x H).

Without being exhaustive these criteria represent the majority of identified cases requiring technical

implementation phases of validation to confirm all the conditions for making a 3D object by laser

sintering.

The specific requirements for 3D parts manufacturing are described in the annex. They depend on

application requirements.


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2.4.5 Conditions relating to the Layering

During the process, the roller must not modify the conditions of previously sintered layers.

This is why the correct conditions required for the manufacturing of layers are given in the following

diagram.

e 0

cn-1

cn

cn-2

e

c: Thickness of layers (c = cn-1 = cn-2...)


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2.5 Safety devices

The following functions ensure safe and risk-free operation of the machine.

2.5.1 Operator safety

Components approved in accordance with standards EN 60204-1 (safety of machinery):

Emergency stop (as per IEC 947-5-1): the emergency stop is located on the control display; it activates immediate shutdown of the following components: oven, laser, motors, turbine, as well as the pneumatic drives,

Emergency shutdown (as per IEC 947-3): this involves a circuit-breaker located on the network upstream of the machine. It can be used to cut off the power supply to the machine in a single operation,

Disconnection from electricity grid: this involves the main isolating switch located on the machine's connection panel. When the machine is off this device isolates the machine from the network and enables electrical isolation (subject to shut off the UPS),

Safety switches (as per EN 1088): these devices isolate the laser when opening one of the main doors or the galvanometric head. They make it possible to lock and unlock the main doors,

Laser safety window (as per EN 207): this device is located on the front face of the machine and enables the operator to look inside the chamber while being protected from laser reflections. There is, therefore, no need to wear laser eye protectors when the system is in normal operating mode.

Additional components:

Differential circuit-breaker and over-current circuit-breaker,

Locking key on the control display: The machine cannot be switched on unless the key is in the ON position.

2.5.2 Machine safety

Detection of a drop in air pressure: Control indicates a fault if the air feed pressure drops below the required pressure,

Detection of the laser rack water level: The chiller in the laser rack signals that the water level has dropped below the required threshold,

Detection of chamber temperature: inability to open the doors if the temperature is above 50 ° C,

Protection of motors: The axis stop if an abnormal temperature is observed,

Opening of the airlock : 10 s delay before opening (for depressuring),

Anti-collision system: The HMI (Human Machine Interface) and the various sensors fitted on the PROX-300 make it possible to avoid collisions between moving system components,

Protection of the Laser: control of the diodes Temperature and control the integrity of the fiber,

Protection of the scanner head: control of the head temperature.


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2.5.3 Identification of labels

2.5.3.1 Nameplate

PHENIX SYSTEMS

4 rue Richard Wagner

63200 RIOM

SIRET: 432 209 617 00039

Type / Type : 5003472C00

Produit / Product : PXL

N° de Série / Serial nbr : SER0711050

Date / Year : 2008

Tension / Voltage : 400 V

Puissance / Power : 15 kW

Figure 1: PROX-300 nameplate

COMPLIES WITH 21 CFR 1040.10

AND 1040.11

Location:

Figure 2: location of the PROX-300 nameplate

d

e

location


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2.5.3.2 Safety switches

Figure 3: safety switches

1

4

6

3

2

5

7


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1. On the gloves trap:

Figure 4: interlock on the door trap

2. On the sliding door:

Figure 5: interlock on the sliding door


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3. On the galvanometric head access door :

Figure 6: safety switch on the access door to the galvanometric head

4. On the door of the airlock:

Figure 7 : interlock on the airlock door

5. On left-side door:

Figure 8: safety switch on the left-side door


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6. On right-side door:

Figure 9: safety switch on the right-side door

7. On the main chamber door :

Figure 10 : safety switch on the chamber door


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2.5.3.3 Laser safety labels

1. Front face of the machine :

Figure 11: laser safety labels on the front face of the machine

CAUTION – CLASS 4 INVISIBLE LASER RADIATION WHEN OPEN

AND INTERLOCKS DEFEATED

AVOID EYE OR SKIN EXPOSURE TO

DIRECT OR SCATTERED RADIATION


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2. Access door to the galvanometric head:

Figure 12: laser safety labels on the access door to the galvanometric head

λ = 1070 nm P = 500W CLASS 1 LASER SYSTEM

CEI 60825-1 (2007)

ISO 11553-1 (2009)


AVOID EYE OR SKIN EXPOSURE TODIRECT OR SCATTERED

RADIATION

CAUTION – CLASS 4 INVISIBLE LASER RADIATION WHEN OPEN AND

INTERLOCKS DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT

OR SCATTERED RADIATION


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3. Airlock (Right side):

Figure 13: laser safety label on the airlock


INTERLOCKS DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT

OR SCATTERED RADIATION


AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED

RADIATION


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4. Front face of the galvanometric head:

Figure 14: laser safety label on the galvanometric head

5. Back of the galvanometric head:

Figure 15: laser safety label on the galvanometric head


INTERLOCKS DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT OR

SCATTERED RADIATION

LASER APERTURE


INTERLOCKS DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT OR

SCATTERED RADIATION


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3 SYSTEM PRESENTATION

3.1 Generalities

Founded in 2000, Phenix Systems designs, manufactures and markets powder bed additive

manufacturing equipments. The parts are directly created from their three-dimensional perception in

CAD software. Each representative section of the part is laser sintered in solid phase with or without

instantaneous consolidation at the melting point, depending on the material being used.

Phenix Systems is well known for the reliability and repeatability of its laser sintering process. The

industrial maturity of the "PX" range of equipments is the result of 10 years of research and

development.

With the PROX-300 system, additive manufacturing becomes an industrial method for the

production of metal parts with an innovative design. It is also a high-performance alternative to more

traditional and less productive manufacturing processes.

The various production strategies developed by Phenix Systems enable their user to meet highly

diverse technical and economic specifications.

The principal technical PROX-300 systems characteristics are mentioned on the table below:

Fiber Laser P=500 W – λ=1070 nm

Layering system Adjustable

Building volume 250 x 250 x 300 mm

Metal materials Stainless steel, tool steels, non-ferrous alloys, super alloys…

Ceramic materials Alumina, cermet, …

Repeatability X=20 µm ; y=20 µm ; z=20 µm

Detail size X=100 µm ; y=100 µm ; z=20 µm

Loading system Automatic

Recycling system Automatic

CAD/CAM software Phenix Processing – Phenix Molding – Phenix Manufacturing

Control software PX Control

CAD read formats IGES, STEP, STL

Dimensions, weight L=2,4 m ; l=2,2 m ; h=2,4 m, about 5000 kg

Energy (power supply requirements) Max. 15 KVA – 400 V tri

Certification CE

Class 1 laser machine in standard production.

CEI 60825-1 (2007) NF EN ISO 11553-1 (2009)


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3.2 General machine operation

The manufacturing process takes place as follows:

Processing of the CAD file with a PHENIX software in order to obtain a version of the part in the form of a succession of digitized superimposed cross-sections. Creation of a manufacturing file, used by PHENIX machines (.FAB or .FAB2 files).

Figure 16: example of a CAD industrial file sliced

Preparation of the machine, loading of the manufacturing plate holder and adjustment of chamber settings (atmosphere)

Loading of the file *.fab/*.fab2 on PHENIX CLIENT,

Making of a powder layer on the manufacturing plate (Layering cycle)

Sintering of a selected part of the powder corresponding to the digitized cross-section using extra energy input from a laser (Sintering cycle),

Figure 17: sintering process and part after post-processing

Execution of the Layering and sintering cycles of each new layer constituting the part produced.

Unloading of the machine and possible post-processing and finishing in order to obtain the desired characteristics.


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3.3 Description of the machine

The following picture shows system decomposition into seven distinct parts:

Figure 18: the various machine parts

Part 1: manufacturing chamber

Part 7: Human Machine Interface

Part 5: powder recycling

Part 2: airlock

Parts 3 and 4: electrical and

pneumatic data management,

Control panel

Part 6: laser assembly


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3.3.1 Part 1: Manufacturing area

This first section presents all the modules directly relating to part manufacturing.

This section includes:

The chamber door (1),

The layering module consisting of a roller (a), a roller cleaner (b), a roller scraper (c), feed piston (d), sintering piston (e), and a collecting tank to catch unsintered powder (f),

Lens cleaner and protection shutter (3),

Powder tamping module (4),

Heating element (5),

Vacuum cleaner (6),

Oxygen analyzer sensor (7),

Smokes cleaner device (8),

Vibrating channel (9).

Figure 19: manufacturing area

(1)

(5)

(9) (b) (d) (e)

(f)

(6) (4)

(7)

(a)

(3)

(c)

(8)

(8)


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3.3.1.1 The chamber door

The operator accesses the inside of the chamber through the two glove ports located on the front

face of the machine. Two interlocks, on the sliding door and on the gloves door, block all movements

(tamping module, carriage, etc…).

When open, the door provides access to the entire chamber for cleaning and maintenance.

3.3.1.2 The layering module

This module consists of:

The roller

The roller can move in a straight line using the carriage:

- Maximum position: 975 mm

- Maximum speed: 800 mm/s

- Accuracy: <1 mm

And rotate:

- Maximum speed: 2500°/s (7 turn per second)

- Accuracy: <5°

The combination of different movements of roller and carriage are adjustable for carrying out actions

of layering such as spreading, smoothing and compacting. The layer thickness of powder differs

depending on the material properties (particle size, flowability...) and on the field of manufactured

part application.

The roller cleaner

When the appropriate sequence is executed, the roller cleans

itself by rotating on a blade made of treated steel.

The chamber is equipped with a laser safety window

>920.1064 D L5 IR L6 SPERIAN CE EN207.

Only a maintenance technician or other qualified person may perform movements

with the chamber door open (cf. maintenance mode).

Figure 20: roller

Figure 21: roller cleaner


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Scraper

Its geometry enables to carry the powder from the feed

piston to the sintering piston. The scraper is in treated

steel.

The scraper brackets are equipped with a cleaner device

for removing dusts from the top of the roller.

Feed piston

This piston contains the volume of powder that will be used for sintering. Its characteristics are given

below:

- Dimensions: 500 x 250 mm

- Powder volume: 50 liters

- Stroke: 400 mm


- Positioning accuracy: ± 5 µm

- Maximum charge: 500 kg

Sintering piston

The parts are manufactured on a plate set on a plate holder (cf. glossary). This set is positioned and

maintained on the sintering piston. Its characteristics are given below:

- Dimensions of the sintering plate : 250 x 250 mm with 23.5 mm radius

- Useful stroke: 300 mm (With a manufacturing plate of 25 mm thick)

- Minimum speed 5 mm/s


- Positioning accuracy: ±3 µm

Collecting tank

It recovers all non-sintered powders and residues of sintering that will be treated in the internal

recycling system.

Figure 22: scrapper


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3.3.1.3 Lens cleaner and protection shutter

A filtering unit is fitted on this system to avoid fumes and dust from the sintering process being

deposited on the lens.

A gas flow sweeps permanently the underside of the lens protective window; this airflow is filtered

using a filter cartridge. The particles are stopped by the cartridge membrane and stored in a

collector.

During manufacturing, the filter cartridge is cleaned periodically using an automatic unclogging

system.

A protection shutter completes this device. It is open only during sintering.

3.3.1.4 Tamping piston

The tamping piston is used for leveling and tamping the powder in the feed piston during machine

preparation and for closing the feed piston during recycling process.

3.3.1.5 Heating element

The internal chamber temperature can be controlled via a resistor with the following characteristics:

Max. internal chamber temperature: 100 °C (depending on machine configuration)

Control accuracy: ±10 °C

Heating element power rating: 4100 Watts

3.3.1.6 Vacuum cleaner

Inside the manufacturing chamber the user ca use a vacuum cleaner hose for cleaning the

manufacturing area. The powder collected is processed in the recycling system.

3.3.1.7 Oxygen analyzer

The PROX-300 machine is equipped with an oxygen analyzer that monitors the level of oxygen

continuously (value is expressed in percent till 1% and in ppm bellow).

3.3.1.8 The smoke extraction system

This device which consists of a blower located bellow the airlock door above collecting tank and a

suction tube on the left of the sintering piston generates a gas flow for evacuating sintering dusts

(smokes…) which can negatively affect the process.

3.3.1.9 Vibrating channel

The vibrating channel transfers the powder stored in the tank to the feed piston during the recycling

process.

Filter cartridges must be cleaned weekly and changed every two weeks according

to the instructions provided for this purpose (preventive maintenance program,

ref.: 9000261U00)


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3.3.2 Part 2: airlock for loading and unloading

Figure 23: airlock for loading and unloading

The airlock lets operators load and unload a plate, thus maintaining its inerting (see §5.2.8). The

loading or unloading capacity is 100 kg.

Transfer continues automatically.

Note: If the locking is not done properly, closing the outside door will not be possible.


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3.3.3 Part 3: Electrical and pneumatic data management – control cabinet

3.3.3.1 Input/output panel, safety, pneumatic and gas.

Initial configuration of the system:

- Gas pressure regulation (1) : 0.2 MPa (2 bars),

- Pneumatic pressure regulation (2) : 0.55 MPa (5,5 bars),

- Valves pressure regulation (3) : 0.45 MPa (4.5 bars),

- Gas flow regulation (4) : 10 L/min (this value allows to reach 1000 ppm during

manufacturing using gas quality as required in §4.1.2),

- Gas flow regulator in the « purge » mode (5) : 50 L/min

Input/Output Circuit breakers

Safety and

start parts

Power contactors

Purge and gas

solenoid valves

Gas pressure

regulators (1)

Purge flow meters

(5)

Pneumatic

solenoid

valve

Pneumatic pressure

regulators (2)

Valves pressure

regulators (3)

Gas flow

meters (4)

Figure 24: electrical and pneumatic data management


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3.3.3.2 Electrical control devices

Figure 25 : electrical control devices

EC 1000 card:

manage the

galvanometric unit

24/-24V power

supply

Computer: IPC

Motor speed

controller : sieving

control

Regulator: heating

element control

Servo drives 1 &

2 : axis control

Circuit breakers

and contactors

Motor speed

controller: hose

winding control


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3.3.4 Part 4: power supplies and laser management – supply cabinet

Figure 26: Power supplies and laser management

Laser chiller

500W Laser

Transformer

UPS2

Water cooling filter

UPS1


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The laser rack generates the infrared laser beam. It is fitted with an emergency stop and a locking

key. It switches on automatically when the machine is powered up.

The laser chiller stabilizes laser temperature via a hydraulic circuit.

The cooling circuit is fitted with a particle filter. This filter requires preventive maintenance. Please

refer to the PROX-300 preventive maintenance schedule.

UPS (Uninterruptible Power Supply) 1 and 2 prevent machine stoppage during micro cut-offs or brief

mains power outages (approx. 5 minutes).

Activation button – Press this button to switch the UPS on for a protected, conditioned power

supply.

Bypass button UPS1–Press this button once to transfer the load to the bypass power supply (in

this case the UPS is transparent); press the button twice within 4 seconds to cut the power to the

output jack and connected loads.

Figure 27 : UPS1 in Bypass mode Figure 28 : UPS1 Activated

Bypass button UPS2–Press this button more than 3s to transfer the load to the bypass power

supply (in this case the UPS is transparent); in this state, the UPS automatically switches off when the

rack isolation switch is switched “OFF”.

Figure 29 : UPS2 in Bypass mode Figure 30 : UPS2 Activated


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3.3.5 Part 5: Powder recycling

3.3.5.1 Principe

The processing chain of the powder is composed of the following:

The recycling cycle is adjustable. Please refer to the User Logistical Document.

3.3.5.2 Sieving device

The sieving device is located bellow the airlock.

Figure 31 : sieving device

By default, it is equipped with a 75 µm sieve. A sieve cleaning is required every 4 weeks. Mesh size

and interval between periodic cleaning can be modified regarding materials used (chemical

composition, granulometry…).


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3.3.5.3 Feeding hopper

The feeding hopper is composed of:

Figure 32: recycling powder device

Fan

Gas container for unclogging

Filter access door

Sieved powder container

Valve

Sieved powder input

Vibratory channel


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3.3.6 Part 6: optical devices

The main optical devices are :

A laser source: continuous, single-mode, output power of 500W collimator, wavelength in the infrared short (around 1070nm)

A collimator: outlet beam diameter at 1 / e ² 15 mm,,

A galvanometric head,

A flat field F-Theta lens (420mm focus length).

Figure 33: galvanometric head module

Adjustable stand

Flat field lens

Head with

galvanometric mirrors

Locking in open

position


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3.3.7 Part 7: Control display or HMI

The control display contains the three elements below:

Control panel

External controls

Stack light

3.3.7.1 Control panel

This touch screen provides a means for human-machine dialogue, and for

visualization of the various windows and steps in the manufacturing

process.

The touch screen displays all controls, status indicators and positioning

information from different parts of the machine.

3.3.7.2 External controls

Closed to the control panel, an external control is used to manage the main parts & events during a

manufacturing cycle:

Figure 35: External control panel

1. Start key

2. “Laser ON” light

3. Powder recycling

4. Unlocking of the sliding door and the airlock door

5. Winding unit of vacuum cleaner hose

6. Vacuum cleaner

7. Button “Yes”

8. Button “No”

9. Stop

10. Cycle break

11. Mains supply present

12. ON

13. Emergency stop

14. Emergency stop

1

3

9

1

1

2

5

7

4

6

8

10

12

13

Figure 34 : control panel


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1. Start key

This key activates/deactivates the machine start option using the "ON" button.

2. Laser ON light

This light is extinguished when the laser cannot emit.

3. Powder recycling

This starts the powder recycling system.

Note: Powder recycling can only start with the tamping piston down.

4. Unlocking of the sliding door and the airlock door

This button unlocks:

the airlock door (10 s delay),

the locking system of the gloves door,

the sliding door.

5. Winding unit of vacuum cleaner hose

This button is used to wind the vacuum cleaner hose. When the tip of the vacuum cleaner is correctly

engaged, the hose is maintained in its housing.

6. Vacuum cleaner

This button starts the vacuum cleaner to clean the plate or the manufacturing chamber.

7. Button “Yes”

To interact with the different manufacturing sequences. The “Yes” button allows any action

suggested.

8. Button “No”

To interact with the different manufacturing sequences. The “No” button rejects any action

suggested.

9. Stop

This button instantly stops all currently operating processes (power, heating element, motor, laser,

etc.). If the machine is stopped during a sintering operation, manufacturing will be stopped

immediately and may not be continued. All processes will have to be reset.

10. Cycle interruption

This button interrupts a cycle at its completion and lets the operator choose either to continue the

cycle by pressing the button again or to end the process by making a stop (layering or sintering cycles

for example).

11. Main supply present

This light indicates when the machine is powered on and started.


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12. ON

This pushbutton switch turns the machine on when it is powered up with the "start-up key" switched

to "1".

13. Emergency stop

This button activates immediate shutdown of the heating element and cuts the power supply to the

laser and the motors. It also triggers an emergency software stop.

A second panel on the right-hand side of the machine includes the following actuator and plugs:

Figure 36 : second external control panel

14. Emergency stop

Same as point 13

15. USB

Allows to connect any USB device.

16. Ethernet

Allows a network connection via an RJ45 cable.

3.3.7.3 Stack light

The stack light provides information about the status of the machine:

Green continuous: Machine available,

Flashing green: Manufacturing,

Flashing orange and green: Manufacturing error

Flashing orange: Unlocking / cycle break / initializing,

Orange continuous: STOP

Red continuous: Emergency / stop

14

15 16


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4 SETTING UP

4.1 SELECTING A LOCATION

4.1.1 General environmental characteristics

Working temperature: between 15 °C and 30 °C,

Storage temperature: between 5 °C and 50 °C,

Moisture percentage: between 20 % and 90 %,

Electromagnetic compatibility: as per CEI 61000-6-2: 2001.

4.1.2 Connection

Electric:

Use voltage: 380 VAC – 50/60Hz – 32A; 3 phases + ground

Maximum power input: 15 KVA

Gas connection:

Maximum pressure: 8 bars

Minimum pressure: 6 bars

Minimum flow rate: 5 L/min

Recommendations on nitrogen quality:

Nitrogen (N2) > 99.99 % (v),

Pneumatic connection:

Maximum pressure: 8 bars

Minimum pressure: 6 bars

Minimum flow rate: 100 L/min

Recommendations on compressed air quality (as per standard ISO 8573-1):

Solid particles (class V): size <40 µm and concentration <10 mg/m3,

Oils (class IV): concentration <5 mg/m3 (lubricator integrated with the machine),

Dew point (class IV): +3 °C

Network socket:

Ethernet 10/100 MBps

Socket RJ-45

Socket supplied:

Automatic coupler with splined adaptor for flexible hose with internal diameter 6 mm.

Cables and hoses not supplied.


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4.1.3 Installation

PROX-300 installation requires a location with the following minimum dimensions to make

maintenance work.

Figure 37: PROX-300 installation

System Length (mm) Width (mm) Depth (mm) Weight (Kg)

Machine 2270 2380 1550 3750

Rack 1/3 1970 800 1010 450

Rack 2/3 1970 950 1010 800


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4.2 Start up

4.2.1 Connection

The connection panel is located at the back of the supply cabinet. It contains the following

connections:

Figure 38: connection panel

Note: only gases from airlock purge are evacuated by the plug on this panel. These gases are not

filtered. After each unloading, it is required to clean the airlock.

4.2.2 Start

1) Make sure that the 32A circuit-breaker is engaged upstream of the machine,

2) Turn on the main switch disconnector on the connection panel,

3) Switch on the UPS, (Cf. §3.3.4),

4) Make sure that emergency stops are not pushed, and that the compressed air valve is

opened and switch the locking key to position 1,

5) Start the machine by pressing the start pushbutton.

Figure 39: starting up the machine

Gas supply:

Valve and automatic coupler

with 6 mm splined adaptor

Pneumatic supply:

Valve and automatic coupler

with 6 mm splined adaptor

Evacuation:

for 6 mm tube

Ethernet socket:

Network cable RJ-45

Mains cut-off switch:

ON/OFF switch

Electric power supply:

Electric terminal strip

receiving the three-phase

network


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6) Wait for the automaton turns on: the stack light turns green and the lighting of the chamber

turns on. Then open the session by clicking the icon “Client”.

Figure 40: session opening

7) Once the Client session is started, the “PX Manager” module starts automatically. The

following window appears.

Figure 41: manager on machine start-up

Note: The state of the driver should display "DRIVER_ON". If the state indicates "Fault" (red light), it is

possible to reset the driver by clicking the ON button of the driver to turn off (switching off), then click

OFF button to activate it (switch on ON).


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5 SYSTEM USE

5.1 Machine software

When starting up of the machine, modules Supervision and Manager start up automatically. They

control the PROX-300 system.

At the end of the start-up process, the following screen is displayed on the HMI:

Figure 42: PROX-300 home window


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5.1.1 Supervision

The Supervision window on the right-hand side of the display at start-up contains 10 different

functionalities:

This button manages chamber lighting. It is always available for use,

This button opens the window “HMI PROX-300” in order to prepare the machine by

controlling the actuators, and executing the automatic cycles.

Machine off button,

This button has the same function as the stop button on the external controls panel. It

instantly shuts down the currently operating process,

This button provides access to the machine manager window,

This module start the PX client

The laser settings menu provides access to the different parameters of the laser and

scanner configuration,

Remark: this menu is locked by a code

This button provides access to the maintenance mode management, and to the machine

software versions window.

The cycle break button has the same functionality as the one on the external controls

panel. It breaks the cycle at cycle-end and lets the operator choose whether they want to

continue the cycle or stop it definitively.

Inactivated button.

The collision area provides data on the various parts that may be

moving. There are 3 possible colors:

Green: The axis is free to move in both directions,

Yellow: The axis can only move in one direction,

Red: The axis cannot be moved.


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5.1.2 PX Manager

The console button displays the driver console, showing the evolution of the system

communication,

The Configuration button provides access to different control parameters of the laser

and the scanner head (Compensations parameters, unfocusing parameter, etc.).

Note: this menu is locked by a code

The driver button provides control of the PROX-300 Laser card in order to reinitialize the

system (a confirmation is needed),

There are 4 possible colors :

- Green : Started,

- Grey : OFF,

- Red : Fault,

- Blue : Maintenance.

Figure 43: configuration panel window


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5.1.3 Machine management window

By clicking the button, the Machine manager window appears:

Figure 44: machine manager window

Hour timers: contains information of the using time of the machine. The counter "Total machine

running duration" tells the number of hours that the machine has been running.

Loaded plate number: plate loaded in the machine (Number indicated by the user at the end of

loading).

Trace file: each machine preparation action and each manufacturing will be archived in the trace file.

The file is created automatically after loading the plate. The name of the trace file contains the

machine serial number and plate number.

Trace files are stored in the folder:"C: \ Monitoring Manufacturing PROX-300 \"

The Management tools button allows to :

- Open a Trace file of previous production,

- Saving the current trace file to the desired location,

- To print the trace current file on the default printer (if installed).


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5.1.4 Maintenance mode window

By clicking the button, the Maintenance mode window appears:

Maintenance mode, locked by a code, allows to work safely on the machine during maintenance

operations (speeds and torques reduced on the moving axes).

All unsafe operations are prohibited. The automatic preparation cycles are prohibited and the launch

of the Client module is blocked.

This is the only way to control the machine if the Chamber door is open.

Access to the software controlling the inputs/outputs of the machine is possible.

Figure 45 : maintenance mode

This mode is not available if the Client module is already open or if the initialization has not yet been

performed (starting machine).

This window also displays the version of the software installed on the machine and the date of last

update done.


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5.1.5 PROX-300 HMI menu

By clicking , the HMI window appears.

5.1.5.1 Preparation cycles dialog box

Figure 46: preparation cycles

The buttons on this window launch the following cycles:

Load the plate: loading and clamping of a new sintering plate on the sintering piston. At the end

of the loading cycle and based on the settings configured during installation:

a. Either the user enters a plate number (10 digits).

b. Either a plate number is incremented automatically.

Zero sintering Search: the cycle of zero sintering researching.

Programmed Sequence: sequence selected in the "Sequence” tab. It is better to apply the

changes before each execution.

Unload the plate: Plate unloading cycle.

Machine reset: gives access to machine initialization features (see next paragraph).


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5.1.5.2 Machine initialization

Figure 47 : Initialization area

Origin Machine Position: Lift the Tamping piston and the Scraper, then move the carriage to its zero position

Zero sintering reset: Remind the current position of the sintering axis as the Zero position, and launch a checking cycle to ensure that there is no collision risk between the plate and the roller.

Back to main actions : returns to the main actions area (see § 5.1.5.1)

5.1.5.3 Motion tab

Figure 48 : manual tab

a: selection of the axis; status of each axis (fault = red, green = OK)

b: moves manually the selected axis or enter a set-point

c: raise / lower the scraper,

d: open / close the lens protection window, if open: launch automatically the lens cleaner,

e: raise / lower the Tamping piston,

f: open / close the airlock, locking / unlocking the clamping jacks to transport the plate, clamping / unclamping of the plate on the sintering piston

a

b

c

d

e

f


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5.1.5.4 Oven/gas tab

The oven/gas tab is used to control the chamber's internal environment.

Figure 49: Oven/Gas tab

Oven area: activation of the oven by clicking "oven", and entering a set point. A graph shows the evolution of temperature. The LED indicates the status of the oven. Green: activated; Black: off; Red: default (except at system startup).

Gas area: the sintering is performed under inert gas for oxidizable powders.

The button "Gas" activates a continuous gas flow (10L/min), adjusted by the flow controller present on the gas panel (see § 3.3.3.1),

The button "Regulation" activates the "regulated" mode of gas supply: when the O2quantity is above the setpoint (filled in ppm) gas supply is turned on (continuous flow) and when the O2 quantity is below this setpoint, gas supply is stopped.

The "Purge" button activates a high gas flow (50l/min default) to purge the chamber (see § 3.3.3.1),

The "SAS Purge" button activates a high gas flow to purge the airlock,

"Gas State" LED is green when the gas is activated; Red indicates an absence of gas upstream the machine or, in the case of regulation, that the O2 sensor is not started (or alarm: set point temperature not reached).


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5.1.5.5 Sequence tab

The Sequence tab provides to load programmed sequences

Figure 50: sequence tab

Settings: parameters related to the sequence and editable by clicking on the fields,

Sequence importation area: click on the icon to load a sequence corresponding to the

material in the machine or to the desired sequence,

Name of the sequence currently used,

"Defaults settings" button: Setting of the default parameters values,

"Apply Changes" button: load the new settings in the machine sequence.

5.1.5.6 Flow tab

Figure 51 : flow tab


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Lens cleaner : protects the lens against pollution caused by the manufacturing process by creating a gas flow. When the protection shutter is opened, the lens cleaner starts automatically.

The « Turbine » button activates the lens cleaner device.

The« Unclogg »button injects pressurized gas to clean the filter.

The« Clean cycle » green LED indicates that the cycle is on. (Cycle with closing of the lens trapdoor and automatic unclogging)

Powder recycling: these buttons allow activate one by one the actuators related to the recycling powder cycle as the turbine or the vibrators.

Le bouton « Paramètres », accessible uniquement en mode maintenance, ouvre la fenêtre suivante et permet de régler les paramètres du cycle de recyclage de poudre,

Figure 52 : recycling powder settings window

Vacuum : The vacuum cleaner is used to clean inside the Chamber.

The "Turbine" button activates the vacuum following the setpoint given in%.

The "Unclogging" button injects pressurized gas to clean the filter.

Important: the vacuum cleaner can be used for a single type of metal powder. Before using the

vacuum cleaner, make sure that inerting is sufficient for explosive or flammable powders.

Pressure: Indicates the pressure inside the chamber in mbar. The green light indicates that the valve is closed.


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5.1.5.7 Manufacturing tab

The manufacturing tab provides data on manufacturing status. It has three sections.

Figure 53: manufacturing tab

Manufacturing progress, this dialog box provides data on:

- Manufacturing progress as a %,

- The current layering process,

- The latest sintered layer,

- The maximum number of layers available.

Main statuses, this dialog box provides data on:

- Chamber temperature in °C,

- Chamber oxygen level as a % or in PPM (particles per million),

- Activation of the gas = green lamp. If gas control is activated, this lamp is green

although gas is switched off,

- Activation of the lens cleaner = green lamp.

- Activation of the plate holder clamp = green lamp,

- The button "red pointer" lets move the laser over the sintering piston, with no laser power.

- The laser instruction as a %.

Data, this dialog box provides in real-time data on:

- The zero position of the sintering piston in mm,

- The defocusing value in mm,

- The height of the powder available in the feed piston in mm,

- The height of the sintered part in mm,

- The duration of the layering process,


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- The sintering time for the layer in process,

- Total manufacturing time.

5.1.5.8 Diagnostic tab

Figure 54 : diagnostic tab

Axes: indicates the status of speed changer for four engines,

Laser: indicates the status of the laser card (EC1000) and the laser,

Security: includes all the security of the machine that can block movements or starting of the manufacturing

General: indicates the status of the compressed air and electrical power at the back of the machine, and the key switch on the control panel,

Doors: States of interlocks: open, locked,

Button "Fault History" opens a window of error history

Figure 55 : errors historic


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5.1.6 Client module

The Client module is launched by clicking on the logo in the display window. This module lets

load a manufacturing file and also access the various related settings. This module contains six

functions.

Figure 56: client Module

Open the manufacturing file,

Configuration of the layering settings parameters,

Objects and number of layers to load configuration

List Client module events,

Loading of the layers, opening of the work bench,

Close the Client module.


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Opening the manufacturing file

This function is used to select the manufacturing file to be run on the machine.

Figure 57: opening a manufacturing file

Switch from the left window to right window,

Go back to the list of directories,

Move around in the lists,

Confirm a selected file,

Close a file without selecting it (cancel),


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Configuring settings

This function contains the useful settings for the layering. Click on "Apply" to confirm the

settings.

Settings can only be changed after entering the relevant code.(See §5.1.2, page 47)

Figure 58: settings configuration

Changing layering sequences triggers the opening of a new window displaying the various sequences available.

Click on the relevant value to change it. A numerical keypad is displayed. Just key in the

desired value and confirm using the button

To cancel, and therefore close the numerical keypad, press on

Figure 59: numerical keypad

Note: for a *.FAB2 file created from Phenix Molding software, if there are several sets of layering

parameters, it will be impossible to change these parameters. And if there is one set of layering

parameters, it will be possible to change the parameters after the file will be loaded.


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Sequencer, configuration of objects and layers

This functionality lets select the various "Phenix Objects" contained in a manufacturing file.

The button "All" selects all the "Phenix Objects" in the manufacturing file, in addition to all the

available layers.

Customize the number of layers to be produced (useful for tests) by clicking on the field; this displays

a numerical keypad.

Confirm the selection by clicking on "Apply".

Figure 60: selection of objects to be produced and the number of layers

If some objects are cloned (duplicated), they will be reminded as "number of duplicate objects" and not as "total number of objects."

Warning: If a clone is selected, its original object should be equally, if not, the loading is impossible.

Figure 61: sequencer with a duplicated object (cloned)


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List of Client Module events

This window displays Client Module events. The last line is the most recent event.

Figure 62: window displaying Client Module events

Launching manufacturing once the manufacturing file has been loaded

This function is used to load the manufacturing file. A status bar shows the progress of file

copying to the machine. Once copied, the main window opens and provides access to these

functionalities:

Cycle start: Stops the purge automatically (see §5.1.5.4 page 52) if this is in process, and starts the

gas flow following confirmation.

Cycle end: executes actions programmed in the “End cycle” part of the layering sequence.

Laser sintering: Activates sintering for the selected cycle.

Layering: Activates layering for the selected cycle.

Figure 63: main launch window


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Confirm using the button "Run".

The bottom section of the window changes and asks for the numbers of the start and end layers.

Click on the fields to complete them, a numerical keypad is displayed.

The button "+1" increases start layer by one and duplicate this value for end layer (useful when

producing the first layers step-by-step).

For example: {start layer: 2 / end layer : 987} => « +1 » => {start layer: 3 / end layer : 3}

The button " …]" will launch all the remaining layers, starting with the last layer that was launched.

Figure 64: final launch window

Closing the Client module workbench

This button closes the Client module. Each time this module is closed, the manufacturing file has to

be reloaded, the layer files have to be reselected and the sequences reconfirmed.


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5.2 Machine preparation

5.2.1 Axes reset

When the machine has just been turned on, axes need to be reset. Click on “Machine reset” in the

“Machine preparation” window and then click on “General reset” (see §5.1.5.2).

Once the axes are reset, it is possible to work in both Client and Machine preparation windows, so as

to prepare the machine while loading the manufacturing file.

5.2.2 Loading a sintering plate

1) Use a brush and the vacuum cleaner to clean the bottom part of the plate holder (inside the

chamber),

Remark: Clean the gear teeth thoroughly. They position the plate + plate holder assembly in the

machine.

2) Degrease the upper face of the plate holder,

3) Finish cleaning with a clean dry paper towel,

4) Attach the plate to the plate holder using the 8 screws supplied,

Important note: The regrinding lines on metal plates must be parallel to the roller, and the front of

the plate holder is marked. It is important to respect this positioning when attaching the plate to the

plate holder.

Figure 65: fixing screws of the plate on the plate holder

Plate fixing

Hirth gear teeth


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5) Press the unlock door button to unlock the airlock door,

Remark: It is necessary to wait ten seconds.

Figure 66: opening of the airlock

6) Press the lock device on the left of the carriage, and pull it to its end position,

7) Place the plate holder + plate on the carriage against the mechanical stop,

Figure 67: setting of a plate into the airlock

8) Then pull the lock device and push the carriage to the end position, ensuring that the lock

device is latched,

Figure 68: positioning of the plate

9) Close the airlock door,

10) Purge the airlock for 5 minutes,

11) Via the HMI, select « Loading plate» in the “Machine preparation” window

10s


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5.2.3 Loading the feed piston with powder

Flammable powders :

Purge the chamber before using the powder inside the chamber

Before using a new metal powder, ensure the absence of humidity in the powder, which would affect

its flow.

To do so, sifting and oven drying are recommended.

Such operations to be implemented before the use of a new metal powder:

Sieve the fresh powder once,

Place the fresh powder into a large tray in order to obtain a thin layer (maximum 4cm).

Place the tray in the oven at 70°C for 24H in order to dry the powder out completely,

Note: the best method is to shake the powder delicately from time to time in order to speed up the

process of moisture loss.

Sieve the powder again,

Flammable powders :

Do not heat the powder in case the oven is not inerted.

Flammable powders are provided in packaging under inert atmosphere and free of

humidity.

The powder loading system is accessible on the right side of the machine.

The procedure for loading the feed piston with powder is:

1) lower the tamping piston,

2) activate recycling,

3) connect the powder bottle to its clamp,

4) pull the powder feed system,

5) connect the clamp and its bottle to the valve,

6) open the feed valve to empty the powder into the circuit,

Figure 69: loading the feed piston

7) after the loading, level off the powder with a scraper,

8) on the HMI, raise up the feed piston until the powder reaches the top of the jacket,

9) still on the HMI, lower the tamping piston,


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10) raise up the feed piston until the tamping piston starts raising up,

11) raise up the tamping piston, and check if the powder is tamped enough, (it should be flat and

without holes),

12) repeat these steps as long as the powder is not tamped.

5.2.4 Roller cleaning

The roller has to be clean before the searching of the sintering zero.

1) Click on and select the roller cleaning sequence,

2) confirm the changes by clicking on "Apply changes",

3) Lastly, click on "Programmed sequence" in order to run the sequence.

5.2.5 Search of sintering zero

The zero searching is performed with the roller.

• The manufacturing plate must be clean; no dirt must be located on its surface,

• The roller should not get in touch with any powder during this cycle.

For a good implementation of this cycle, ensure to keep clean the areas described below:

Areas to clean

Figure 70 : clean chamber


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5.2.6 Creating the powder bed – Filling the gaps

5.2.6.1 Using of the programmed sequences

1) Via the HMI, click on the icon in the "Parameters" tab in order to select the desired

sequence (select the sequence according to the type of powder used),

2) Confirm the loaded sequence by clicking on "Apply changes",

3) The interface allows the operator to change the sequence default parameters.

Figure 71: settings for programmed sequences

4) Check the parameters (it’s possible to set the defaults parameters by clicking “defaults

settings”),

5) Confirm the changes by clicking on "Apply changes",

6) Lastly, click on "Programmed sequence" in order to run the sequence,

5.2.6.2 Gaps filling

Use the «gaps filling "sequence. Adjust the number of scraping iterations. The default value is 1, but

for proper filling, it is advisable to perform 20 iterations. Repeat this sequence if necessary.

5.2.6.3 Creation of the powder bed

Use the sequence of "powder bed" to deposit the first layer on the manufacturing plate.

If the layer is thin and uniform, preparation can continue. Repeat the process if necessary.

Remark: Check carefully that the thickness of the layer is set at 40µm.


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5.2.7 Cleaning the laser optic system

1) Open the access hatch to the galvanometric head,

2) Using the Allen key, unblock the clamp that holds the head in position,

3) Rotate the clamp a quarter turn in the anti-clockwise direction,

Figure 72: clamp in unblocked position

4) Tilt the head to the left. The head is held in position when the locking pin is locked,

Be equipped with PPE during handling of the powder outside the

enclosure (mask, gloves ...).


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5) Clean the area between the window and the laser hatch (bellow and lens diffuser),

6) Use the clean air aerosol (reference : 1001116K00) to clean any large dust particles off the

lens,

Important: - Hold the aerosol as upright as possible without shaking it. - Spray the aerosol once into free air in order to clear the gas tube of any dust that could damage the

lens.

- avoid touching the lens with the spray nozzle.

Figure 73: cleaning the lens with clean air

7) Soak slightly an optical paper towel in optical cleaning fluid,

8) Holding the optical paper towel by both ends, wipe the towel over the lens from the top to

the bottom.

9) Use the clean air aerosol to blow away any dusts,

10) Use a lamp to observe the lens in order to check for any traces of dirt,

Figure 74: using a lamp to check for dirt

11) Repeat these steps until the lens is clean,

When the cleaning is done, tilt the head to its initial position.


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12) Make sure the raised button is clean.

Figure 75: mechanical stop

13) Make sure the head-lens support contact is clean.

Figure 76: head-lens support contact

14) Ensure the cleanliness of the bellows and the lens cleaner diffuser.

Figure 77: bellows and the lens cleaner diffuser

15) Close the head-lens assembly, making sure that the raised button is in localized contact with

the head-lens support.

16) Tighten the assembly until reaching the end stop.

Note: excessive tightening risks marking the head-lens support, which would damage the localized

contact.

Comply with the following steps in order to ensure the correct positioning of the

head after opening.

bellows Diffuser

Mechanical stop


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Figure 78: clamped galvanometric head

5.2.8 Inerting the chamber (only for oxidizable materials)

The purge of the machine is only required for oxidizable materials or flammable

1) This step must be perform only if the O2 sensor indicates a value higher than the desired set

point,

2) On the HMI, in the "Oven & Gas" tab, click the "Purge" button to activate the chamber purge.

Figure 79: Oven and Gas tab

3) Click on the "Purge" button again to stop the chamber purge.

Note: The purge can be stopped when the oxygen level is below the setpoint value.

During purging, the operator can use the machine

Tightening clamp

Scanner head

Mechanical stop


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5.3 Launching a manufacturing

Flammable powders:

It is important to purge the chamber before sintering or layering

(see previous paragraph)

The launch of a manufacturing is performed as follows:

1) To run a production:

a. Load a manufacturing plate,

b. Run the zero searching sequence

c. Fill the gaps all around the plate,

d. Create the powder bed,

2) Run the sintering of the layer 0,

3) Run the layering of the layer 1. Repeat this operation if the layer obtained is not correct,

4) Run the sintering of the layer 1,

5) Run the layering of the layer 2. If it is correct on the first try, then run the full manufacturing in

automatic mode. If not, continue manufacturing step by step until a proper layering on the first try.

Only a perfect layering done in the first try allows launching the manufacturing in automatic mode.

Important: make sure that during the first 10 layers, a lack of powder does not appear

.


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5.4 Unloading the machine

Flammable powders :

The chamber must be inerted before handling powder in the machine

5.4.1 Sintered plate cleaning

1) Using the brush, clean the sintering plate by sweeping any unsintered powder from left to

right towards the ashtray,

Figure 80: collecting tank

2) With the vacuum cleaner, finish the cleaning of the sintered plate,

3) Take the gloves off, raise the sintering piston to the upper position using the arrows on the

HMI, in order to access the groove,

4) Clean the groove between the plate and the plate holder to help tighten the jaws during

unloading. grips,

Figure 81: groove cleaning


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5.4.2 Unloading of the plate

1) Lower the sintering piston to 0,

2) Click on “Unloading plate” in the “Machine preparation” section,

3) Press the unlock door button to unlock the airlock door,

Remark: It is necessary to wait 10 seconds.

Figure 82: airlock opening

4) Then push up the lock device and pull the carriage to the end position,

Figure 83: plate positioning

5) Remove the manufacturing plate from the carriage

6) Lift the lock device and push the carriage making sure that the lock device is latched,

7) Close the airlock door.

Be equipped with PPE during handling of the powder outside the

enclosure (mask, gloves...).


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5.4.3 Cleaning the chamber

Flammable powders :


The chamber may be realized in the following order:

Figure 84 : Chamber

1) Using the brush and the vacuum cleaner, clean the top of the aspiration manifold (1); be

careful of the residual powder which can fall in the feeding piston.

2) Move the carriage to the top of the sintering piston, and clean the powder situated in the

roller scabbard and in the scrapper assembly (2) by the collecting tank.

3) Using the brush and the vacuum cleaner, clean the area between the two pistons (3), so that

the roller does not get dirty when searching the zero for the sintering plate at the next

manufacturing run.

4) Clean the all chamber, in front and behind the pistons (4); be careful of the powder which

can go behind strip.

5) Open the airlock. Clean the gaz blowing device (5) with the vacuum cleaner.

Figure 85 : gaz blowing device (green area to clean)

1

2

3

4

5

Green area to clean


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6) Using the brush and the vacuum cleaner, clean the Hirth device of the sintering piston.

Figure 86: sintering piston cleaning

5.5 Shutting down the system

1) Close the Client module,

2) Turn off the core on the Manager by switching to OFF,

3) On the machine, select the Off button ,

Note: The machine cannot be switched off during manufacturing.

If the operator needs to stop the machine during manufacturing, he has to perform a cycle break

followed by a stop.

At this time, they will then be able to access the main menu in order to switch the machine off.

4) Switching off the UPS: see §3.3.4,

5) Switch the machine's isolating switch to OFF,

6) Switch the compressed air and nitrogen valves to OFF.


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6 USER MAINTENANCE

6.1 Changing or cleaning of the filters

There are 3 different filters in the system:

Then lens cleaner filter

Then recycling filter

Then vacuum filter

These filters must be cleaned once a week, and changed every two weeks. These frequencies are

given for indication and should be modified with the manufactured parts and the materials used.

Take care of the lens cleaner filter which guaranties the cleanliness of lens window protection.

These are the two indicators which allow to know if the filter has to be changed:

The filter is still dirty after unclogging :

Figure 87 : example of a dirty filter

The Teflon coating is damaged :

Figure 88 : example of a damaged filter

The filter’s angles are

damaged; there are

holes in the coating.


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6.1.1 Lens cleaner filter

Flammable powders: Observe the following procedure

The metallic fume box should always contain some alumina powder (ref:

1003104C00 - fused alumina, DURALOX DF800E). 1 liter of Alumina powder

inside the metallic fume box is the minimum volume required.

The use of vacuum cleaner is prohibited

Refer to document 9000550C 00 for further details

1) On the HMI, stop the purge,

2) Ensure that the Red Pointer is « off » and that the lens cleaner trapdoor is closed (in order to

make sure that the lens cleaner turbine is off),

3) Open the side door in order to access to the lens cleaner system,

Figure 89 : Lens cleaner filter rack

4) Disconnect the quick coupling of the filter rack,

5) Lower the locking handle of the filter rack,

6) Remove lens cleaner filter rack,

The machine should not be in process.

Wear PPE during handling operations (refer to MSDS of material).

Use of a vacuum cleaning system is prohibited.


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7) Remove the 4 screws from the upper part of the filter rack,

8) Use the 2 handles to lift the top cover with the filter,

Figure 90 : filter change

9) Remove the filter by unscrewing the filter using the knurled nut,

10) Clean the filter using a brush and fall down the heaviest particles in a special container used

for this action.

11) Replace the cleaned filter or change the filter, and screw the knurled nut. Ensure that the

filter is well positioned and screwed. The top collar must be in contact with the gasket

without any space all around it to avoid to have powders or smokes in the lens.

Figure 91 : filter’s positions

12) Replace the cleaned filter in the filter cartridge, and tighten the four screws from the upper

part of the filter rack,

13) Replace the filter rack lens cleaner on the machine,

14) Connect the quick connector to the cartridge filter,

15) Close the side door.

Bad position

Good position


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6.1.2 Vacuum and recycling filters

1) From the HMI, make sure that the recycling and the vacuum are not running,

2) Open the left side access door to the system,

3) Open the access hatch to the filter,

4) Loosen the filter and remove it from the module,

To change the filter, insert the new filter without rotating it, making sure it is

correctly positioned, centered in the slot and tightened,

To clean the filter, using a brush, stand above a tray and delicately remove all the

fume particles found on the filter, insert the cleaned filter without rotating it, making

sure it is correctly positioned and tightened in the box,

5) Close the module hatch,

6) Close the left-side door.

The machine should not be in process.

Wear PPE during handling operations (mask, gloves, etc.).

(view the FDS of the powder used)

Use of a vacuum cleaning system is prohibited.


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6.2 Procedure for changing powder

Flammable powders :


1) Proceed to a recycling cycle to make sure the recycling system is empty,

2) Put all the powder in cans and extract it from the machine,

3) Open the manufacturing chamber to clean it,

Flammable powders: sprinkle alumina powder (ref: 1003104C00 - fused alumina,

DURALOX DF800E) to achieve a ratio residual traces of powder / alumina less than 10%.

Figure 92: vacuum residues with a vacuum cleaner (ATEX certified for flammable powders)

The chamber may be realized in the following order:

Figure 93 : Chamber

1

2

3

4

5


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a) Using the brush and the vacuum cleaner, clean the top of the aspiration manifold (1); be

careful of the residual powder which can fall in the feeding piston.

b) Move the carriage to the top of the sintering piston, and clean the powder situated in the

roller scabbard and in the scrapper assembly (2) by the collecting tank.

c) Using the brush and the vacuum cleaner, clean the area between the two pistons (3), so that

the roller does not get dirty when searching the zero for the sintering plate at the next

manufacturing run.

d) Clean the all chamber, in front and behind the pistons (4); be careful of the powder which

can go behind strip.

e) Open the airlock. Clean the gaz blowing device (5) with the vacuum cleaner.

Figure 94 : gaz blowing device (green area to clean)

f) Using the brush and the vacuum cleaner, clean the Hirth device of the sintering piston.

4) Clean all the components of the recycling system + change the hoses by new,

Flammable powders: sprinkle alumina powder (ref: 1003104C00 - fused alumina,

DURALOX DF800E) to achieve a ratio residual traces of powder / alumina less than 10%.

Vacuum residues with an ATEX certified vacuum cleaner (for flammable powders)

Green area to clean


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6.3 Procedure for cleaning the roller (optional)

1) In the “Movements” tab of the “Machine preparation” window, lower the sintering piston to

0, and position the carriage at 400mm,

2) Clean the chamber, and open the door of the chamber, (special tools are required),

3) With a paper soaked of acetone, degrease the roller, while turning it via the HMI, in the

“Movements” tab of the “Machine preparation” window.

Figure 95: Cleaning of the roller

Only a maintenance technician or other qualified person may perform movements

with the chamber door open.

Wear PPE during operations (please refer to MSDS of the material).


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7 CONDITIONS OF APPLICATION OF THE STANDARD WARRANTY

The equipment is guaranteed free from defects caused by a fault in material, manufacture or design

under the conditions set out below.

The warranty covers operating faults that appear within a period of 12 months as from the date of

delivery.

This warranty does not cover cases where:

The operating fault was caused by unauthorized work being carried out on the goods,

The manufacturing plates are not supplied by PHENIX SYSTEMS,

The faulty operation is the result of normal wear and tear of the goods, or of abnormal use,

or of incorrect handling or due to the buyer's defective maintenance,

The defective operation is due to a case of force majeure.


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8 PREVENTIVE MAINTENANCE

Item

Weeks

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

Change filters

Sieve cleaning

Carriage lubrication

Laser cooler cleaning

Vibrating channel cleaning

Exhaust clamping filter cleaning

Turbines swing valve checking

Airlock translation rail cleaning

Remplacement du filtre hydraulique refroidisseur

cabinets cleaning

technical user guide prox-300 - product...

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