Some considerations when purchasing post processing equipment:

Here is a generalized layout which may be applicable. This is only one example and should only be used as a reference. Install and use equipment in accordance with all local/state/federal regulations.

Solvent Reclamation:

Distillation of used solvent can be an economical and environmentally friendly choice when post processing 2500 IC printed parts. Solvent waste is generated when the support material is removed from your printed parts. This waste has to be disposed of in a manner which meets all local/state/federal regulations. Commercially available distillation units may be used to distill the solvent back into a usable form. Consider researching and purchasing a distillation unit to reuse the solvent needed to post process 2500 IC printed parts.

The below procedure is a general guideline to help the customer process their printed VisiJet® M2 ICast with (VSWR) pattern. Your results may vary slightly from the below procedure. Before proceeding with the procedure, confirm you have the following items in place. Also, make sure to perform this procedure in a well ventilated room or under a ventilation hood with proper fire suppression.

NOTE: Wax patterns are fragile and should always be handled and processed with care. Expect a slight learning curve in developing the best techniques for working with these patterns. Please consult the [Best Practices] for more information about methods of handling and processing printed patterns.

Items Needed:

• (1 or 2) Magnetic hotplate stirrer
• (2) Large stainless steel reservoir
• (1 or 2) Reservoir for clean water
• (2) Plastic pattern holding basket/ wire rack
• VisiJet Support Wax Remover
• Clean water at 35 °C and room temperature (from tap or other heating source)
• Safety goggles
• Nitrile, heat resistant and cut resistant gloves
• Heat gun/holding fixture
• Spatula, butter knife, plastic ruler, or equivalent with thickness 0.020 inch to 0.060 inch (0.5 mm - 1.5 mm)
• Wax carving kit
• Paper towels

For Patterns printed in HD Mode, Use steps HD1 through HD8. For Patterns printed in HDF Mode, see steps HDF1 through HDF8.

1. (HD). Place build plate on heat gun fixture with heat gun positioned below build plate.

2. (HD). Put on heat resistant gloves.
3. (HD). Turn heat gun on and apply heat to build plate, occasionally moving heat gun to different portions of the build plate.

NOTE: Heat gun method works best for plates which have multiple patterns. If there is only a single pattern on the plate (especially if large) then it may be more advantageous to use a hot plate.

4. (HD). Patterns will begin to melt around edges. At this point carefully try to remove pattern(s) from build plate. Larger patterns will take longer to remove. Small patterns will quickly melt and will have to be removed swiftly so the build wax is not damaged.

5. (HD). Place patterns on parchment paper/crumpled aluminum foil/non-stick sheet. Once all patterns have been removed from the plate, turn off the heat gun.
6. (HD). Wipe up excess support wax from build plate while still warm—this makes plate cleaning easier.
7. (HD). Replace heat resistant gloves for cut resistant gloves.
8. (HD). Standing over a trash can or catch tub, carefully break away support structure. Wax carving kits are useful for reaching hard to get places & for blind holes. Care should be taken when using wax carving tools as they can easily damage build material and/or the operator.

NOTE: A good rule of thumb is to remove 25-50% support wax by hand. This should only take a few minutes.

1. (HDF). Place Build Plate on flat surface. You may wish to use a drop cloth or tarp under the plate to make it easier to clean up stray pieces of crumbled support wax after it has been removed from the build plate.

2. (HDF). Put on Nitrile gloves.

3. (HDF). Take a spatula or similar dull flat tool and gently push on the bottom of the white support columns on the build plate until they break away. There is only a thin 0.2 inch (5 mm) layer of support beneath the build wax, so be certain your tool is not too thick or else you may damage patterns.

TIP: If you start with the fragile verification wall, you will gain experience and learn how much force is needed to break away the sparse support wax structure.

4. (HDF). Move the tool further and further under the pattern and also to the left and right to break all the support wax connections to the build plate. The pattern will loosen and drop down a small amount.

5. (HDF). Carefully remove the pattern from the build plate and place on a soft smooth surface, such as a tarp or tray covered with a lint-free towel.

6. (HDF). Repeat step HDF4 and HDF5 to remove all the remaining patterns.

7. (HDF). Standing over a trash can or disposable waste container, gently brush away the support structure using you fingers or small tools such as a soft bristle brush. Wax carving kits, Q-tips, wooden coffee stirrers, and plastic cable ties are useful for reaching hard to get places and for blind holes. Caution should be used when using wax carving tools as they can easily damage build material and / or the operator. Rapid, aggressive motions can result in small rice-like pieces of support wax flying everywhere. Take care to contain the spread of broken support pieces, as wax bits on floors are very slippery.

8. (HDF). A final surface cleanup may be done with soft brushes, mild scrubbing pads, ultra fine steel wool, extra fine sandpaper, etc.

NOTE: Removing the majority of the support material during this step will help the solvent bath last longer and be more effective. It is usually very easy to remove more than 90% of the support wax by hand in a few minutes.

If the patterns are acceptable for use at this stage, there is no need for further cleaning in solvent baths.

9. Put on safety goggles and a pair of nitrile gloves for the remainder of this procedure.
10. Turn on magnetic stirrer hot plate to 35° C. If your hot plate does not have an exact temperature setting, then use an infrared or probe thermometer. Adjust the heat dial until 35 °C is achieved.

NOTE: Remember to perform this section in a well ventilated area or a hood. Consult your suppliers SDS for VSWR, and follow applicable local or company specific rules/guidelines for handling flammable liquids.

11. Place an approved stainless steel container onto hotplate with VisiJet Support Wax Remover and have at least 1” of space from the top of the container. Place lid on container to help reduce evaporation. Place magnetic stir rod into container.

NOTE: Aluminum foil works well as a lid to reduce VSWR evaporation during pattern processing. Do not seal the container with a tight fitting lid.

12. Turn on magnetic stirrer to a medium setting so that there is a strong, smooth circulation in the container. If the VSWR is splashing out of the container, reduce the RPM. The stirrer speed will need to be adjusted based on size of open spaces in the rack, part geometry, and bath size.
13. Carefully place de-bulked patterns onto a plastic pattern basket/wire rack. The density of the wax patterns is less than the density of the VSWR, so the patterns will float and move around uncontrollably if not constrained. This may result in damaged patterns and incomplete support wax removal. Some soft plastic netting or mesh can be used to keep the patterns submerged.

14. Insert the basket/rack into the bath. Leave enough room so that the magnetic stir rod cannot interact with the basket. Place the temperature probe off to the side of the bath.

NOTE: If using a wire rack, be sure that it does not come close to the magnetic stir rod as this will cause the rod to be attach to the metal rack and cease stirring.

15. Place lid loosely onto VSWR bath to help reduce evaporation. Do not seal the container.
16. Check patterns every 5-10 minutes to monitor progress of support material removal.

NOTE: The time it takes to dissolve support material depends on pattern geometry, wax content of bath, and agitation/stirrer speed.

17. This HDF pattern was removed from the VSWR bath after 15 minutes. You can clearly see that much of the support material has been dissolved away.

18. Once your pattern(s) look visually free of support material, turn stirrer dial to “0”/off and remove basket. Place basket onto a dry paper towel.
19. Place lid on container and turn off magnetic hot plate if no additional patterns will be further processed.
20. Rinsing and drying of patterns can be done by two different methods:

NOTE: Patterns are delicate, so handle with care. Large changes in temperature can cause thermal cracking of these patterns so ensure they do not undergo a large temperature shift in a short time.

Double hotplate method (preferred method):

1. Place basket into a 35 °C clean VSWR rinse bath. Rinse patterns for 30 seconds.
2. Remove basket from clean VSWR rinse and rinse in 35 °C clean water. Rinse patterns for 30 seconds.
3. Remove basket and allow patterns to air dry.

Single hotplate method (alternative method):

1. Place basket in 35 °C clean water. Rinse patterns for 30 seconds.
2. Remove basket and allow patterns to cool to room temperature.
3. Place basket into room temperature VSWR rinse. Rinse patterns until residual wax is removed.
4. Remove basket from clean VSWR rinse and place into room temperature clean water. Rinse patterns for 30 seconds.
5. Remove basket and allow patterns to air dry.

21. A finished processed pattern is shown below. There is white residue left on the finished patterns. This is normal.