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Post Processing Guide

Projet_MJP_2500w_Front.jpg  

ProJet® MJP 2500W / IC

 

Post Processing Guide

 

p/n 33-D127 Rev E

 

Original Instructions

Please refer back to http://infocenter.3dsystems.com/projetmjp2500w/post-processing-guide for the most up-to-date post processing guide

Important Safety Information

Safety Symbols and Definitions

ELECTRICAL SHOCK HAZARD: High voltage electricity is accessible in the vicinity of this sign or behind the access panel. High voltage can cause severe burns or death, as well as fires. Access panels are for service only and should be opened only by certified service personnel or trained maintenance personnel.

HOT SURFACE HAZARD: A hot surface is accessible in the vicinity of this sign or behind the access panel. Avoid contact. Hot surfaces can cause burn injury or fire. Allow surface to cool before touching. Access panels are for service only and should be opened only by certified service personnel or trained maintenance personnel.

HARMFUL IRRITANT WARNING: Indicates that skin or eye irritation could result while exposed to a chemical composition.

CAUTION: Indicates the possibility of loss of data or damage to equipment.

WARNING: Indicates the possibility of injury or death to personnel

WEAR GLOVES: Wear the appropriate gloves when required. Heat gloves are necessary when touching surfaces that may be hot to ensure burns don’t occur.
Note.png

NOTE: A note signifies important information but not information of a critical content.

 

First Aid and Protective Equipment

The following paragraphs provide general first aid procedures and recommendations for protective equipment to minimize the risks from material exposure. If professional medical attention is necessary, take the Global Harmonized Standards/Safety Data Sheet (GHS/SDS) for the exact material involved to the attending physician.

Skin Contact

If molten material gets on skin, cool rapidly with cold water.

Eye Contact

Immediately flush eyes with plenty of water for at least 15 minutes. Get medical attention if symptoms persist.

Fume Inhalation

Move affected person to fresh air. If respiratory irritation occurs, if breathing becomes difficult seek medical attention immediately.

Ingestion

Ingestion is unlikely. If ingested, drink plenty of water and seek immediate medical attention. Do not induce vomiting.

 

Material Disposal

  • To find out facility disposal requirements, contact a local waste disposal provider. (Local environmental regulatory agency should have a list of qualified providers.) You will need to give disposal service provider a copy of the part material GHS/SDS (Global Harmonized Standards / Safety Data Sheets). SDS information regarding the part and support material can be found at the following links. VisiJet® M2 Cast SDS, VisiJet® M2 ICast & VisiJet® SUW SDS.
  • 3D Systems assumes no liability or responsibility for proper disposal of part material. Proper disposal of part material is the sole responsibility of the user.
  • For proper Isopropyl alcohol (IPA) disposal, please refer to the manufacturers Safety Data Sheet (SDS).

 

Health Hazards

Inhalation/Ingestion

  • Under normal operation, inhalation is not an expected route of entry.
  • Ingestion - Ingestion may cause nausea, diarrhea and/or stomach pain. 
  • VisiJet® M2 Cast, M2 ICast and VisiJet Wax Jewel Red is non-toxic if ingested.
  • Hazardous decomposition products: Carbon dioxide, carbon monoxide and other toxic fumes can be released at high temperatures or upon burning.

Handling Finished Parts

  • Finished parts can be handled or disposed of the same as standard household wax products. This material is not intended for and cannot be used for medical implant, food or drink handling applications.

Hygienic Practices

  • Appropriate hygienic practices should be followed, including washing with soap and water before meals, breaks, smoking, applying cosmetics, using toilet facilities, and after work. Ensure a convenient washroom location is provided with access to soap, water, and disposable paper towels.

 

Material Handling

Emergency (GHS/SDS)

Chemtrec USA (800) 424-9300; Europe +1-703-527-3887

M2_Cast_VisiJet Wax Material Carton Label-New Logo.png

Packaging Inspection

The material cartridges are packaged in shipping cartons. Upon receipt of material shipments, inspect cardboard carton exterior for signs of damage and leakage. If leakage is observed, DO NOT open carton, and contact 3D Systems’s Technical Support Hotline. If no leakage is observed, keep the material cartridges in their cartons and store until material is needed.

 

Regulatory Information

  • EU regulations
    EINEC/ELINCS/NLP: All materials are listed
    REACH Annex XVII: None listed
  • US FEDERAL
    TSCA: All materials are listed on the TSCA Inventory or are not subject to TSCA requirements:
    California Proposition 65: This product does not contain chemicals which are known to the state of California to
    cause cancer, birth, or any other reproductive defects.
    Australian regulations
    SUSDP, Industrial Chemicals Act 1989:
    Australian Inventory of Chemical Substances, AICS: Listed
    Japanese regulations
    Chemical Risk Information platform (CHRIP):....Listed
    Industrial Health and Safety Law....Article 57-2
    Hazardous material....not applicable
    Organic solvent poison prevention rule....not applicable
    Ordinance on prevention of hazard due to specified chemical substances....not applicable
    Lead Poisoning Prevention Rule....not applicable
    Poison and Deleterious Substance Control law....not applicable
    PRTR and Promotion of Chemical Management law (PRTR Law).... no listed components
    Fire Services Act....not applicable
    Explosives Law....not applicable
    High pressure gas safety law....not applicable
    Export Trade Control Order....not applicable
    Waste Disposal and Public Cleaning Law....applicable. Before disposal, consult an approved waste disposal operative to ensure regulatory compliance.

Spilled Material

  • Spills of material are HIGHLY UNLIKELY, and should NOT occur in normal operation of the 3D printer system. If a leak occurs, it is an indication of a serious 3D printer system malfunction.
  • Spills of support material can be cleaned without use of protective gear, and disposed of as office trash. 
  • Promptly remove spilled material, dispose of waste material, and clean up materials per local regulatory requirements. Suspend use of the 3D printer system until you contact 3D Systems Technical Support for a service visit to determine and repair the source of the leak.
  • If material is molten, allow it to freeze before clean up. Scrape the material loose from the floor if necessary and vacuum or sweep the solid material into a closed container. Place material in an appropriate container for disposal.
  • Consider avoiding placement of the 3D printer system over carpeting, or consider use of barriers to avoid the possibility of carpet damage if spills were to occur.

Waste Removal

See Material Disposal

 

Material Storage

  ProJet® MJP 2500W ProJet® MJP 2500 IC
Material (Part/Support)

VisiJet® M2 Cast (Part)

VisiJet® M2 SUW (Support)

VisiJet® M2 ICast (Part)

VisiJet® M2 IC SUW (Support)
VisiJet® Wax Jewel Red (Part)
Shelf Life 2 Years 2 Years 2 Years 2 Years
Climate Cool, dry area with adequate ventilation
Temperature Range 60°F (16°C) to 80°F (27°C)
Maximum Storage Temp 95°F (35°C)
Note.png

NOTE: For optimal results, keep stored cartons closed and sealed until material cartridges are ready for use.

 

Recertification Date

Always check material “Recertification Date” before use. Do not load material cartridges into 3D printer system if cartridge date has expired. When printer detects an expired cartridge, it aborts the build and rejects the cartridge. If a job is printing when the cartridge expires, it will try to continue to complete the job. If the next cartridge is expired, it won’t use it.

Support (white) material must be loaded in the left side of material drawer. Part (gray) material cartridges must be loaded in the right side of material drawer. Before loading cartridges into 3D printer system, inspect the cartridges for signs of damage or leakage. Do not load a damaged or leaking cartridge. Dispose of material cartridge according to local regulations.

IMG_3820.JPG

Storing a Partially Used Material Cartridge

To store a partially used Material Cartridge, tighten vent cap and store it upright and not on it's side to keep vent cap from clogging.

Material Storage

Material should be stored in their original containers, according to the guidelines given in the GHS/SDS included with the material.

VisiJet M2 Cast or Wax Jewel Red with VisiJet Support Wax Remover (VSWR)

The purpose of this guide is to discuss the various methods on how to post process VisiJet® M2 Cast with VSWR. This part material will be only be available for use in the ProJet® 2500W. Also included in this manual is safety information and material handling information.

Note.png
 

 NOTE: While the pictures within the section primarily display M2 Cast material Wax Jewel Red material may be post-processed in the same manner.

 

Small or Delicate Parts

Magnetic Stirrer Hot Plate Method

This procedure is a general guideline to help the customers process their printed VisJet® M2 Cast and VisJet® Wax Jewel Red parts with VSWR. Your results may vary slightly from the below procedure. Before proceeding with this method, 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 following all local safety procedures and regulations.

 

Items Needed:

  • Magnetic hotplate stirrer
  • Silicone net or a 3D printed Acrylate basket
Note.png

Note: A scalable .stl basket file can be found here: Acrylate Circular Basket.STL. This .stl file can be sized to fit your glass container using the 3DSprint. This .stl file is recommended to be printed on a Acrylate printer only. Do not print this .stl file using VisiJet® M2 Cast or Wax Jewel Red material.
  • Borosilicate glass (Pyrex) container with lid/cover.
  • Safety goggles
  • Nylon hold-down netting and wire or cord or plastic rods for hanging parts
  • Nitrile gloves
  • VisiJet Support Wax Remover (VSWR)

 

 

  1. Confirm that there is a clean build plate that has been placed in the freezer for a minimum of 15 minutes prior to step 2.
Note.png

NOTE: For small delicate parts, it is recommended to use the cold plate method to remove build parts off the build plate.
caution.png

CAUTION: WAX PARTS ARE VERY DELICATE AND MAY CRACK IF LEFT IN THE FREEZER FOR AN EXTENDED PERIOD OF TIME. 

 

IMG_3821.JPG

  1. Place the build platform on top of the cold blank build plate as shown. Keep freezer door open.

IMG_3824.JPG

  1. Within a couple of minutes, you will hear crackling sounds. This is the sound of a parts separating from the build plate. Carefully touch each part to confirm the build part has separated from the build plate. Larger pieces will take a bit longer than smaller ones. Remove build plate from freezer when all parts have released, and allow to warm to room temperature.

IMG_3828.JPG

  1. Put on safety goggles, and a pair of Nitrile gloves for the remainder of this procedure.
  2. Turn on your magnetic stirrer hot plate to 95° F (35°C). If your hot plate does not have an exact temperature setting, then use a thermometer. Adjust the heat dial until 95° F (35°C) is achieved.
caution.png

Caution: Parts will lose detail/melt if cleaning at temperatures exceeding 95° F ( 35°C).
  1. Fill an approved glass container with VisiJet Support Wax Remover VSWR. Place on hot plate and cover with the lid to avoid evaporation. 
Note.png

NOTE: As soon as the first part touches the VSWR, you will start to create an VSWR and Wax mixture. At some point this will become saturated depending on how many parts and how much support is on them. When it seems like the parts are taking too long to process, replenish the container with fresh VSWR.

IMG_1.jpg

Note.png NOTE: Confirm part(s) have reached room temperature from freezer before placing in basket. Frozen/cold part(s) that are processed will crack due to thermal shock.
  1. The density of the wax parts is less than the density of the VSWR, so the parts will float and move around uncontrollably if not constrained. This may result in damaged parts and incomplete support wax removal. Some soft plastic netting or mesh can be used to keep the parts submerged. Thin flexible wire, plastic rods, or cord work best for rings and objects with holes. Mounting holes for parts can be made with a very fine tip soldering iron. Take care to avoid accidentally melting the part material. One could also use a sharp tool to chip away a hole, but we do not recommend this technique as it often breaks the printed part into pieces.
IMG_2.jpg IMG_3.jpg

 

  1. Carefully suspend desired part(s) inside the basket. Do not double stack parts.
IMG_4.jpg IMG_5.jpg
  1. Remove the lid from the container. Gently lower the basket in the container. Confirm parts are completely submerged with enough solvent above to cover the entire part if and when it floats upward against the restraint. What is pictured is just one example of the many ways to suspend parts.

IMG_6.jpg

  1. Turn on stirrer to a low/medium setting (100-200 RPM) so that there is a nice smooth circulation in the container. If VSWR is splashing out of the container, turn your settings down.
  2. Replace lid facing upside down on top of basket. This will help reduce evaporation

IMG_7.jpg

  1. Observe your part every 5 minutes to see the progress of the support material dissolving.
  2. The lid was removed from the top of the basket after 8 minutes. You can clearly see the support material dissolving away.

IMG_8.jpg

Note.png Note: Depending on geometry of part(s), saturation of wax in solvent (cloudy appearance) and agitation, results will vary moderately on the amount of time the support wax is removed from the build part.

 

  1. Once your part(s) looks visually free of support material, turn stirrer off and remove basket.

IMG_9.jpg

  1. Place the basket into a 2nd warm VSWR bath 77-86°F (25-30°C) to remove any residual support material off part. Swirl the basket around manually for 10-20 seconds.
  2. Place part(s) into a warm plain water bath 77-86°F (25-30°C) to remove the slightly oily VSWR from part. Swirl part around manually for about 60 seconds or until all VSWR is removed.
  3. Remove basket and place on dry paper towels.
  4. Carefully remove part(s) from basket and allow them to air dry. Parts are very delicate, so handle with care.
  5. A finished ring is shown below. As you can see there is a white coloration. This is a result of slight etching of the build wax. This will have no affect on casting.

last original photo_step 19.png

 

 

Ultrasonic Cleaner Method

 The below procedure is a general guideline to help the customer process their printed VisJet® M2 Cast or Jewel Wax Red parts with VisiJet Support Wax Remover (VSWR) in a Ultrasonic Cleaner. Your results may vary slightly from the below procedure. Before proceeding with this method 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 following all local safety procedures and regulations.

 

Items Needed:

  • Ultrasonic cleaner
  • Silicone net or a 3D printed Acrylate basket
Note.png

Note: A scalable .stl basket file can be found here: Acrylate Rectangular Basket.STL. This .stl file can be sized to fit your ultrasonic cleaner using 3D Sprint. This .stl file is recommended to be printed on a Acrylate printer only. Do not print this .stl file using VisiJet® M2 Cast or Jewel Wax Red material.

 

  • Safety goggles
  • Nylon hold-down netting and wire or cord or plastic rods for hanging parts
  • Nitrile gloves
  • VisiJet Support Wax Remover (VSWR)
  1. Confirm that there is a clean build plate that has been placed in the freezer for a minimum of 15 minutes prior to step 2.
Note.png

NOTE: For small delicate parts, it is recommended to use the cold plate method to remove build parts off the build plate.
caution.png

CAUTION: WAX PARTS ARE VERY DELICATE AND MAY CRACK IF LEFT IN THE FREEZER FOR AN EXTENDED PERIOD OF TIME. 

IMG_3821.JPG

  1. Place the build platform on top of the cold blank build plate as shown. Keep freezer door open.

IMG_3824.JPG

  1. Within a couple of minutes, you will hear crackling sounds. This is the sound of a parts separating from the build plate. Carefully touch each part to confirm the build part has separated from the build plate. Larger pieces will take a bit longer than smaller ones. Remove build plate from freezer when all parts have separated from build plate.

IMG_3828.JPG

  1. Put on safety goggles, and a pair of Nitrile gloves for the remainder of this procedure.
  2. Fill the ultrasonic cleaner with VisiJet Support Wax Remover to the maximum fill limit for your cleaner. Cover with lid and set temperature to 86°F (30° C).

IMG_3753.JPG

Note.png NOTE: Confirm part(s) have reached room temperature from freezer before placing in basket. Frozen/cold part(s) that are processed will crack due to thermal shock.
  1. Carefully place desired part(s) into a basket. Metal baskets will retain more heat and have the potential to melt or deform delicate parts.  A silicone net or a plastic sieve/colander/basket is preferred. The density of the wax parts is less than the density of the VSWR, so the parts will float and move around uncontrollably if not constrained. This may result in damaged parts and incomplete support wax removal. Some soft plastic netting or mesh can be used to keep the parts submerged. Thin flexible wire or plastic rods work best for rings and objects with holes. Mounting holes for parts can be made by using a very fine tip soldering iron. Take care to avoid accidentally melting the part material.
IMG 1.jpg IMG 2.jpg

 

IMG 3.jpg

  1. Before lowering the basket into the ultrasonic cleaner, confirm the VSWR is at 86° F (30° C) temperature using a thermometer. The ultrasonic cleaner will rise in temperature during use, so monitoring the temperature throughout the cleaning process is highly recommended for optimal part processing.
  2. Slowly lower the basket into the ultrasonic cleaner. Confirm parts are completely submerged.
Note.png

NOTE: As soon as the first part touches the VSWR, you will start to create an VSWR and Wax mixture. At some point this will become saturated depending on how many parts and how much support is on them. When it seems like the parts are taking too long to process, replenish the container with fresh VSWR.

IMG 4.jpg

  1. Replace lid and turn on the Ultrasonic agitator.

  2. Observe your parts every 5 minutes to check the progress of the support material removal and make sure parts are still restrained.

Note.png

Note: Depending on geometry of part(s), saturation of wax in solvent (cloudy appearance) and agitation, results will vary moderately on the amount of time the support wax is removed from the build part.
  1. Once the parts look free of support material, turn off agitator and remove basket from cleaner.
  2. Place the basket into a 2nd warm VSWR bath 77-86°F (25-30° C) to rinse any residual support material off parts. Slowly swirl the basket around manually for 10-20 seconds.
  3. Place part(s) into a warm plain water bath 77-86°F (25-30° C) to remove the slightly oily VSWR from part. Swirl part around manually for about 60 seconds or until all VSWR is removed.
  4. Remove part(s) from warm water rinse and place on dry paper towels.
  5. Finished processed parts below. As you can see there is a white coloration to the parts. This is a result of slight etching of the build wax. This will have NO affect on casting.

IMG_3747.JPG IMG_3744.JPG

Large or Bulky Parts

Ultrasonic Cleaner Method

 This procedure is a general guideline to help the customer process their printed VisJet® M2 Cast or Jewel Wax Red parts with VisiJet Support Wax Remover (VSWR) in a large ultrasonic cleaner. Your results may vary slightly from the below procedure. Before proceeding with this method, 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 following all local safety procedures and regulations.

 

Items Needed:

  • Hotplate 
  • Large ultrasonic cleaner
  • Safety goggles
  • Nitrile gloves
  • Heat resistant gloves
  • VisiJet Support Wax Remover (VSWR)

 

  1. Put on safety goggles and a pair of Nitrile gloves while operating the Ultrasonic cleaner.
  2. Fill the ultrasonic cleaner with VSWR to the maximum fill limit for your cleaner. 
  3. Cover with lid and set temperature to 86°F (30°C).

pic 1.jpg

  1. For large bulky parts, use the hot plate method to remove build parts from the build plate. The thermal shock from a freezer may cause cracking and breakage.
  2. Place build plate with build part onto hotplate.
  3. Turn on the hotplate between 175°-195° F (80°-90° C).
Heat.png Caution: Hot plate is extremely hot and will cause build plate to become too hot to handle with Nitrile gloves. Use protective heat-resistant gloves when performing this step.

pic 2.jpg

  1. Within a few moments the support wax will begin to melt. Carefully touch each part(s) to see if it starts to slide across the build plate. Larger pieces will take a bit longer than smaller ones. Once a part has released, remove it from the build plate and place on waxed paper or crinkled aluminum foil or similar non-stick surface. Turn off the hotplate when done. Quickly wipe up molten wax on plate to avoid run off and spills.

pic 3.jpg

  1. Carefully place the part(s) onto a plastic pattern basket/wire rack. The density of the wax patterns is less than the density of the VSWR, so the parts will float and move around uncontrollably if not constrained. This may result in damaged parts and incomplete support wax removal. Some soft cargo netting or plastic mesh can be used to keep the patterns submerged.

pic 4.jpg

  1. Before lowering the part(s) into the ultrasonic cleaner, remove cover and confirm the VSWR is at the recommended 86°F (30°C) temperature using a thermometer. The ultrasonic cleaner will slightly rise in temperature during the cleaning process so monitoring the temperature throughout the cleaning process is highly recommended for optimal part processing.
  2. Place part(s) in Ultrasonic Cleaner.
  3. Replace cover and turn on ultrasonic agitator.
  4. Observe your part(s) every 5-10 minutes to check the progress of the support material removal and make sure part(s) is still restrained.

pic 5.jpg

Note.png

NOTE: As soon as the first part touches the VSWR, you will start to create a VSWR and Wax mixture. At some point this will become saturated depending on how many parts and how much support is on them. When it seems like the parts are taking too long to process, replenish the tank with fresh VSWR.

 

  1. The part below was removed from the Ultrasonic cleaner after 10 minutes. You can clearly see the support material dissolving away from the purple build material (M2 Cast).
Note.png

Note: Depending on geometry of part(s), saturation of wax in solvent (cloudy appearance) and agitation, results will vary moderately on the amount of time the support wax is removed from the build part.

IMG_3729.JPG

  1. Once the part(s) look free of support material, turn off agitator and remove part from Cleaner and place on dry paper towels.
  2. Place part(s) into a 2nd VSWR bath 77-86°F (25-30° C) to remove any residual support material from part. Swirl part(s) around manually for 20-30 seconds.
  3. Place part(s) into a warm plain water bath 77-86°F (25-30° C) to remove the slightly oily VSWR from part. Swirl part(s) around manually or rinse under warm water for about 60 seconds or until all VSWR is removed.
  4. Remove part(s) from warm water rinse and place on dry paper towels.
  5. Finished processed part below. As you can see there is a white coloration to the part. This is a result of slight etching of the build wax. This will have NO affect on casting.

pic 7.jpg

 

Display Parts

If you do not like the white surface appearance on your part, you can return it to all purple to make it aesthetically pleasing.

Items Needed:

  • Spray gun _ A spray gun with IPA may be used to make displays part more vibrant in color and lessen the appearance of any white surfaces
  • 99% > Isopropyl Alcohol (IPA)
  • Baby Oil
Note.png

NOTE: Keep in mind that this oiling step is only for display parts. Oiled parts will not cast well.

  1. Make a small mixture of IPA and Baby Oil in the bottom of the paint can. Mix by volume, 70% IPA, 30% baby oil. The two liquids have very different densities and will separate over time, make sure to mix it thoroughly before use.

  2. Hold the part approximately 10 inches away from the spray nozzle before applying the coating. For best results it is recommended to apply 3-4 light coatings with a light mist each time. Do not oversaturate the parts.

  3. Allow the part to thoroughly dry for the best color vibrancy.

  4. If the color results are not satisfactory apply an additional coating.

When To Change Solvent Bath

Throughout processing of 2500W or 2500 IC printed parts the solvent bath will eventually become saturated with wax and no longer be as effective at removing support wax material. 3D Systems recommends you do not exceed 400-450 grams of support wax per gallon of VSWR. To know when to change your bath for optimal performance, and ease of disposal, follow the procedure below.

Items Needed:

  • Scale
  • Tracking Document

 

  1. Weigh your parts after de-bulking. Note this mass somewhere, and process parts like normal.
  2. Once parts are completely air dry, weigh the parts again.
  3. Note the difference between the before and after masses to know how much support wax you have added to your cleaning tank.
  4. Due to temperature fluctuations you may experience differences in the amount of support wax you are able to dissolve for a set time.
  5. Dispose of the used bath once you have dissolved 400-450 grams of support material per gallon of VSWR.

Cleaning the Print Platform

Any time parts are processed, it is a good practice to clean the print platform and re-insert it into the printer. Follow these steps for cleaning the platform.

Items Needed:

  • Cut resistant gloves
  • Paper towels
  • 99% Isopropyl Alcohol (IPA)
  • Razor blade/putty knife

 

  1. Put on cut resistant gloves.
  2. Use a flat razor blade or putty knife to scrape any excess support material off of the platform. Be careful not to scratch the black coating on the platform.
  3. Spray the platform with IPA and wipe with paper towels.
  4. When cleaning the print platform always clean both sides.

NOTE: The print platform should be clean and at room temperature before installing and using it in the printer.

VisiJet® M2 Cast or Wax Jewel Red with IPA

The purpose of this guide is to discuss the various methods on how to post process VisiJet® M2 Cast or Wax Jewel Red with IPA. This part material will be only be available for use in the ProJet® 2500W. Also included in this manual is safety information and material handling.

Note.png

NOTE: While the pictures within the section primarily display M2 Cast Material, Wax Jewel Red materail may be post-processed in the same manner.

 

Small or Delicate Parts

Magnetic Stirrer Hot Plate Method

This procedure is a general guideline to help the customer process their printed VisJet® M2 Cast or Wax Jewel Red parts. 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 following all local safety procedures and regulations. 

caution.png

CAUTION:  If you are using IsoPropyl Alcohol (IPA), ensure that your magnetic hotplate stirrer is properly rated to use flammable solvents. Failure to do so could present a fire hazard.

 

Items Needed:

  • Magnetic hotplate stirrer
  • Silicone net or a 3D printed Acrylate basket
Note.png

Note: A scalable .stl basket file can be found here: Acrylate Circular Basket.STL. This .stl file can be sized to fit your glass container using 3DSprint. This .stl file is recommended to be printed on a Acrylate printer only. Do not print this .stl file using VisiJet® M2 Cast or Wax Jewel Red material.
  • Borosilicate glass (Pyrex) container with lid/cover.
  • 99%> Isopropryl Alcohol (IPA)
  • Safety goggles
  • Respirator mask
  • Nitrile gloves

 

 

  1. Confirm that there is a clean build plate that has been placed in the freezer for a minimum of 15 minutes prior to step 2.
Note.png

NOTE: For small delicate parts, it is recommended to use the cold plate method to remove build parts off the build plate.
caution.png

CAUTION: WAX PARTS ARE VERY DELICATE AND MAY CRACK IF LEFT IN THE FREEZER FOR AN EXTENDED PERIOD OF TIME. 

 

IMG_3821.JPG

  1. Place the build platform on top of the cold blank build plate as shown. Keep freezer door open.

IMG_3824.JPG

  1. Within a couple of minutes, you will hear crackling sounds. This is the sound of a parts separating from the build plate. Carefully touch each part to confirm the build part has separated from the build plate. Larger pieces will take a bit longer than smaller ones. Remove build plate from freezer when all parts have separated from build plate.

IMG_3828.JPG

  1. Put on safety goggles, an air respirator and a pair of Nitrile gloves for the remainder of this procedure.
  2. Turn on your magnetic stirrer hot plate to 35° Celsius. If your hot plate does not have an exact temperature setting, then use a infrared thermometer. Adjust the heat dial until 35° Celsius is achieved.
caution.png

Caution: Parts will lose detail/melt if cleaning at temperatures exceeding 35° Celsius.

IMG_3690.JPG

  1. Fill an approved glass container with 99%> Isopropyl Alcohol (IPA) and leave at least 1” of space from the top of the container.  Place on hot plate and cover with the lid to avoid evaporation. 
Note.png

NOTE: As soon as the first part touches the IPA, you will start to create an IPA and Wax mixture. At some point this will become saturated depending on how many parts and how much support is on them. When it seems like the parts are taking too long to process, replenish the container with fresh IPA.

IMG_3741.JPG

  1. Carefully place desired part(s) into bottom of basket. Do not double stack parts.
Note.png

NOTE: Confirm part(s) have reached room temperature from freezer before placing in basket. Frozen/cold part(s) that are processed will crack due to thermal shock.

IMG_3736.JPG IMG_3740.JPG

  1. Remove the lid from the container. Gently lower the basket in the container. 

IMG_3742.JPG

  1. Turn on stirrer to a low/medium setting so that there is a nice smooth circulation in the container. If IPA is splashing out of container, turn your settings down.

IMG_3691.JPG

  1. Replace lid facing upside down on top of basket. This will help reduce evaporation.

 IMG_3743.JPG

  1. Observe your part every 30 seconds (+/-) to see the progress of the support material dissolving. 

IMG_3693.JPG

  1. This part was removed from the basket after 2 minutes. You can clearly see the support material dissolving away from the build material (M2 Cast). 

IMG_3696.JPG

Note.png Note: Depending on geometry of part(s), saturation of wax in alcohol (cloudy appearance) and stirrer speed, results will vary moderately on the amount of time the support wax is removed from the build part.
  1. Once your part(s) looks visually free of support material, turn stirrer dial to "0" and remove basket. Place basket onto a dry paper towel.

IMG_3711.JPG

  1. Secure lid on container and turn off magnetic hot plate if no additional parts will be further processed.
  2. Place the basket into a 2nd IPA bath (room temperature) to remove any residual support material off part. Swirl the basket around manually for no more than 10 seconds.
  3. Remove basket and place on dry paper towels.
  4. Carefully remove part from basket and allow them to air dry. Part are very delicate, so handle with care.
  5. Finished processed rings below. Below is  there is white residue left on the rings. This is evaporated IPA. This will have NO affect on casting.

IMG_3744.JPG

 

Ultrasonic Cleaner Method

 This procedure is a general guideline to help the customer process their printed VisJet® M2 Cast or Wax Jewel Red parts in a Ultrasonic Cleaner. 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 following all local saftey procedures and regulations.

 

Items Needed:

  • Small ultrasonic cleaner
  • Silicone net or a 3D printed Acrylate basket
Note.png

Note: A scalable .stl basket file can be found here: Acrylate Rectangular Basket.STL. This .stl file can be sized to fit your ultrasonic cleaner using the 3DSprint. This .stl file is recommended to be printed on a Acrylate printer only. Do not print this .stl file using VisiJet® M2 Cast or Wax Jewel Red part material.
  • 99%> Isopropryl Alcohol (IPA)
  • Safety goggles
  • Respirator mask
  • Nitrile gloves
  1. Confirm that there is a clean build plate that has been placed in the freezer for a minimum of 15 minutes prior to step 2.
Note.png

NOTE: For small delicate parts, it is recommended to use the cold plate method to remove build parts off the build plate.
caution.png

CAUTION: WAX PARTS ARE VERY DELICATE AND MAY CRACK IF LEFT IN THE FREEZER FOR AN EXTENDED PERIOD OF TIME. 

IMG_3821.JPG

  1. Place the build platform on top of the cold blank build plate as shown. Keep freezer door open.

IMG_3824.JPG

  1. Within a couple of minutes, you will hear crackling sounds. This is the sound of a parts separating from the build plate. Carefully touch each part to confirm the build part has separated from the build plate. Larger pieces will take a bit longer than smaller ones. Remove build plate from freezer when all parts have separated from build plate.

IMG_3828.JPG

  1. Put on safety goggles, an air respirator and a pair of Nitrile gloves for the remainder of this procedure.
  2. Fill the ultrasonic cleaner with 99%> Isopropyl Alcohol(IPA) to the maximum fill limit for your cleaner. Cover with lid and set temperature to 30° Celsius. 

IMG_3753.JPG

  1. Carefully place desired part(s) into a non-metal basket. Metal baskets will retain more heat and have the potential to melt or deform delicate parts.  A silicone net or a 3D printed Acrylate basket is preferred.
Note.png

NOTE: Confirm part(s) have reached room temperature from freezer before placing in basket. Frozen/cold part(s) that are processed will crack due to thermal shock.

IMG_3718.JPG

  1. Before lowering the basket into the ultrasonic cleaner, confirm the IPA is at the recommended 30° Celsius temperature using a thermometer. The ultrasonic cleaner will slightly rise in temperature during the cleaning process so monitoring the temperature throughout the cleaning process is highly recommended for optimal part processing.
  2. Slowly lower the basket into the ultrasonic cleaner. Confirm parts are completely submerged.
Note.png

NOTE: As soon as the first part touches the IPA, you will start to create an IPA and Wax mixture. At some point this will become saturated depending on how many parts and how much support is on them. When it seems like the parts are taking too long to process, replenish the container with fresh IPA.

IMG_3720.JPG

  1. Replace lid and turn on the Ultrasonic agitator.

  2. Observe your part(s) every 20 seconds (+/-) to see the progress of the support material dissolving. This will happen relatively quickly. 

Note.png

Note: Depending on geometry of part(s), saturation of wax in alcohol (cloudy appearance) and agitation speed, results will vary moderately on the amount of time the support wax is removed from the build part.
  1. Once the part(s) look free of support material, turn off agitator and remove basket from cleaner and place on dry paper towels.
  2. Place the basket into a 2nd IPA bath (room temperature) to remove any residual support material off part. Slowly swirl the basket around manually for no more than 10 seconds.
  3. Remove basket and place on dry paper towels.
  4. Carefully remove the delicate part(s) from basket and allow them to air dry. Part(s) are very delicate, so handle with care.
  5. Finished processed part(s) below. As you can see there is white residue left on the part(s). This is a combination of evaporated IPA and the dried surface of the wax. This will have NO affect on casting.

IMG_3747.JPG IMG_3744.JPG

Large or Bulky Parts

Ultrasonic Cleaner Method

 The below procedure is a general guideline to help the customer process their printed VisJet® M2 Cast or Wax Jewel Red parts in a large ultrasonic cleaner. 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 following all local safety procedures and regulations 

 

Items Needed:

  • Hotplate 
  • Large ultrasonic cleaner
  • 99%> Isopropryl Alcohol (IPA)
  • Safety goggles
  • Respirator mask
  • Nitrile gloves
  • Heat resistant gloves

 

  1. Put on safety goggles, an air respirator mask and a pair of Nitrile gloves while operating the Ultrasonic cleaner.
  2. Fill the ultrasonic cleaner with 99%> Isopropyl Alcohol(IPA) to the maximum fill limit for your cleaner. 
  3. Cover with lid and set temperature to 30° Celsius.

Ultrasonic Cleaner.gif

  1. For large bulky parts, it is recommended to use the hot plate method to remove build parts off the build plate.
  2. Place build plate with build part onto hotplate pad.
  3. Turn on the hotplate between 175 -195° F (80°- 90° C ).
Heat.png Caution: Hot plate is extremely hot and will cause build plate to become to hot to handle with Nitrile gloves. Use protective heat-resistant gloves when performing this step.

IMG_3698.JPG

  1. Within a few moments the support wax will begin to melt. Carefully touch each part(s) to see if it starts to slide across the build plate. Larger pieces will take a bit longer than smaller ones.  Once all the part(s) have released, turn off the hotplate and remove each part(s) off the build plate and place on a wax paper. 

IMG_3700.JPG

  1. Before lowering the part into the ultrasonic cleaner, confirm the IPA is at the recommended 30° Celsius temperature using a thermometer. The ultrasonic cleaner will slightly rise in temperature during the cleaning process so monitoring the temperature throughout the cleaning process is highly recommended for optimal part processing.
  2. Remove cover and place part(s) in Ultrasonic Cleaner. 
  3. Replace cover and turn on ultrasonic agitator.
  4. Observe your part every minute (+/-) to see the progress of the support material dissolving. 
Note.png

NOTE: As soon as the first part touches the IPA, you will start to create an IPA and Wax mixture. At some point this will become saturated depending on how many parts and how much support is on them. When it seems like the parts are taking too long to process, replenish the vat with fresh IPA.

IMG_3705.JPG

  1. The below part was removed from the Ultrasonic cleaner after 3 minutes. You can clearly see the support material dissolving away from the build material (M2 Cast). 
Note.png

Note: Depending on geometry of part(s), saturation of wax in alcohol (cloudy appearance) and agitation, results will vary moderately on the amount of time the support wax is removed from the build part.

IMG_3729.JPG

  1. Once the part(s) look free of support material, turn off agitator and remove part from Cleaner and place on dry paper towels.
  2. Place part(s) into a 2nd IPA bath (room temperature) to remove any residual support material off part. Swirl part around manually for no more than 10 seconds.
  3. Remove part(s) from 2nd IPA bath and place on dry paper towels.
  4. Finished processed parts below. As you can see there is white residue left on the parts. This is evaporated IPA. This will have NO affect on casting.

IMG_3750.JPG

Display Parts

If you do not like the white surface appearance on your part, you can return it to all purple to make it aesthetically pleasing.

Items Needed:

  • Spray gun _ A spray gun with IPA may be used to make displays parts more vibrant in color and lessen the appearance of any white surfaces.
  • 99%> Isopropyl Alcohol (IPA)
  • Baby Oil
Note.png

NOTE: Keep in mind that this oiling step is only for display parts. Oiled parts will not cast well.

  1. Make a small mixture of IPA and Baby Oil in the bottom of the paint can. Mix by volume, 70% IPA, 30% baby oil. The two liquids have very different densities and will separate over time, make sure to mix it thoroughly before use.

  2. Hold the part approximately 10 inches away from the spray nozzle before applying the coating. For best results it is reccomened to apply 3-4 light coatings with a light mist each time. Do not oversaturate the parts.

  3. Allow the part to thoroughly dry for the best color vibrancy.

  4. If the color results are not satisfactory apply an additional coating.

When To Change IPA Bath

Throughout processing of 2500W or 2500 IC printed parts the solvent bath will eventually become saturated with wax and no longer be as effective at removing support wax material. 3D Systems recommends you do not exceed 400-450 grams of support wax per gallon of IPA. To know when to change your bath for optimal performance, and ease of disposal, follow the procedure below.

Items Needed:

  • Scale
  • Tracking Document

 

  1. Weigh your parts after de-bulking. Note this mass somewhere, and process parts like normal.
  2. Once parts are completely air dry, weigh the parts again.
  3. Note the difference between the before and after masses to know how much support wax you have added to your cleaning tank.
  4. Due to temperature fluctuations you may experience differences in the amount of support wax you are able to dissolve for a set time.
  5. Dispose of the used bath once you have dissolved 400-450 grams of support material per gallon of IPA.

Cleaning the Print Platform

Any time parts are processed, it is a good practice to clean the print platform and re-insert it into the printer. Follow these steps for cleaning the platform.

Items Needed:

  • Cut resistant gloves
  • Paper towels
  • 99%> Isopropyl Alcohol (IPA)
  • Razor blade/putty knife

 

  1. Put on cut resistant gloves.
  2. Use a flat razor blade or putty knife to scrape any excess support material off of the platform. Be careful not to scratch the black coating on the platform.
  3. Spray the platform with isopropyl alcohol (IPA) and wipe with paper towels.
  4. When cleaning the print platform always clean both sides.

NOTE: The print platform should be clean and at room temperature before installing and using it in the printer.

VisiJet M2 ICast with VisiJet Support Wax Remover (VSWR)

This purpose of this guide is to discuss the various methods on how to post process VisiJet® M2 ICast with VisiJet Support Wax Remover (VSWR). This part material will be only be available for use in the ProJet® 2500IC. 

Facility Equipment Requirements for Post Processing VisiJet M2 ICast with VSWR

Some considerations when purchasing post processing equipment:

 

Facilities Description Details
Table Space for wax removal and part handling Typical sizes: 48” x 30”
Table space for wax removal and part handling Typical sizes: 48” x 30”
Flammable liquid storage container Allocate floor space: Various sizes depending on usage

Power drops

Expect multiple 15A circuits. Depends on equipment—consult manufacturer’s documentation.
Safety Precautions Have equipment in place in accordance with all local/state/federal regulations.

 

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.

Layout with solvent callout.jpg

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.

Magnetic Stirrer Hot Plate Method

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.png

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.

IMG_2790a.jpg

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

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.

 

  1. (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.
IMG_2791a.jpg   IMG_2793a.jpg
  1. (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.
  2. (HD). Wipe up excess support wax from build plate while still warm—this makes plate cleaning easier.
  3. (HD). Replace heat resistant gloves for cut resistant gloves.
  4. (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.png

NOTE: Removing the bulk of the support material during this step will help the solvent bath last longer and be more effective.
_1440606a.jpg   _1440590a.jpg
1.jpg 2.jpg
Note.png

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.

SS_HDF1.jpg

 

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.

Note.png 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.

SS_HDF2.jpg SS_HDF3.jpg SS_HDF4.jpg

 

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.

SS_HDF5.jpg SS_HDF6.jpg SS_HDF7.jpg

 

SS_HDF8.jpg SS_HDF9.jpg SS_HDF10.jpg

 

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

SS_HDF11.jpg SS_HDF12..jpg SS_HDF13.jpg

 

Note.png 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.

  1. Put on safety goggles and a pair of nitrile gloves for the remainder of this procedure.
  2. 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.png

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.
  1. 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.png

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.

_1440614a.jpg

  1. 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.
  2. 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.
HDF_NEW PART 1.jpg HDF_NEW PART 2.jpg

 

  1. 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.png

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.

 

HDF_NEW PART 3.jpg

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

NOTE: The time it takes to dissolve support material depends on pattern geometry, wax content of bath, and agitation/stirrer speed.
  1. 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.

HDF_NEW PART 4.jpg

  1. 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.
  2. Place lid on container and turn off magnetic hot plate if no additional patterns will be further processed.
  3. Rinsing and drying of patterns can be done by two different methods:
Note.png

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:

1st 35 °C VSWR Bath

(Hotplate #1)

→

2nd 35 °C VSWR Rinse Bath

(Hotplate #2) (a)

→

35 °C Water Rinse

(b)

→

Air Dry

(c)

    

Single Hotplate Method:

1st 35 °C VSWR Bath

(Hotplate #1)

→

35 °C Water Rinse

(a)

→

Air dry and Cool To Room Temperature

(b)

→

2nd Room Temperature VSWR Rinse Bath

(c)

→

Room Temperature Water Rinse

(d)

→

Air Dry

(e)

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

IMG_2802a.jpg

 

VisiJet® M2 ICast with IPA

This purpose of this guide is to discuss the method on how to post process VisiJet® M2 ICast with IsoPropyl Alcohol (IPA). This part material will be only be available for use in the ProJet® MJP 2500 IC. 

Facility Equipment Requirements for Post Processing VisiJet M2 ICast with IPA

Some considerations when purchasing post processing equipment:

 

Facilities Description Details
Table Space for wax removal and part handling Typical sizes: 48” x 30”
Table space for wax removal and part handling Typical sizes: 48” x 30”
Flammable liquid storage container Allocate floor space: Various sizes depending on usage

Power drops

Expect multiple 15A circuits. Depends on equipment—consult manufacturer’s documentation.
Safety Precautions Have equipment in place in accordance with all local/state/federal regulations.

 

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.

Layout with solvent callout.jpg

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.

Magnetic Stirrer Hot Plate Method

caution36.png

CAUTION:  If you are using IsoPropyl Alcohol (IPA), ensure that your magnetic hotplate stirrer is properly rated to use flammable solvents. Failure to do so could present a fire hazard.

 

The below procedure is a general guideline to help the customer process their printed VisiJet® M2 ICast 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.png

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
  • 99%> Isopropyl Alcohol (IPA)
  • Clean water at 35 °C and room temperature (from tap or other heating source)
  • Safety goggles
  • Nitrile, heat resistant and cut resistant gloves
  • For (HD) Patterns _Heat gun/holding fixture
  • For (HDF) Patterns_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.

IMG_2790a.jpg

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

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.

 

  1. (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.
IMG_2791a.jpg   IMG_2793a.jpg
  1. (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.
  2. (HD). Wipe up excess support wax from build plate while still warm—this makes plate cleaning easier.
  3. (HD). Replace heat resistant gloves for cut resistant gloves.
  4. (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.png

NOTE: Removing the bulk of the support material during this step will help the solvent bath last longer and be more effective.
_1440606a.jpg   _1440590a.jpg
1.jpg 2.jpg
Note.png

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.

SS_HDF1.jpg

 

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.

Note.png 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.

SS_HDF2.jpg SS_HDF3.jpg SS_HDF4.jpg

 

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.

SS_HDF5.jpg SS_HDF6.jpg SS_HDF7.jpg

 

SS_HDF8.jpg SS_HDF9.jpg SS_HDF10.jpg

 

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

SS_HDF11.jpg SS_HDF12..jpg SS_HDF13.jpg

 

Note.png 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.

  1. Put on safety goggles and a pair of nitrile gloves for the remainder of this procedure.
  2. 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.png

NOTE: Remember to perform this section in a well ventilated area or a hood. Consult your suppliers MSDS for IPA and have proper fire suppression, and follow applicable local or company specific rules/guidelines for handling flammable liquids.
  1. Place an approved stainless steel container onto hotplate with 99%> Isopropyl Alcohol (IPA) 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.png

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

_1440614a.jpg

  1. Turn on magnetic stirrer to a medium setting so that there is a nice smooth circulation in the container. If the IPA is splashing out of the container, turn your settings down. Speed will need to be adjusted based on bath size.
  2. Place plastic pattern basket/wire rack into bath. Leave enough room so the magnetic stir rod cannot interact with the basket.
Note.png

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 attracted to the metal rack.

 

_1440616a.jpg

  1. Carefully place de-bulked patterns onto the submerged basket. Do not double stack patterns.

_1440620a.jpg

  1. Place lid loosely onto IPA bath to help reduce evaporation. Do not seal the container.
  2. Check patterns every 3-5 minutes to see progress of support material dissolving.
Note.png

NOTE: The time it takes to dissolve support material depends on pattern geometry, wax content of bath, and stirrer speed.
  1. This pattern was removed from the IPA bath after 5 minutes. You can clearly see the support material dissolving away from the build material.
3.jpg 4.jpg
  1. 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.
  2. Place lid on container and turn off magnetic hot plate if no additional patterns will be further processed.
  3. Rinsing and drying of patterns can be done by two different methods:
Note.png

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:

1st 35 °C IPA Bath

(Hotplate #1)

→

2nd 35 °C IPA Rinse Bath

(Hotplate #2) (a)

→

35 °C Water Rinse

(b)

→

Air Dry

(c)

    

Single Hotplate Method:

1st 35 °C IPA Bath

(Hotplate #1)

→

35 °C Water Rinse

(a)

→

Air dry and Cool To Room Temperature

(b)

→

2nd Room Temperature IPA Rinse Bath

(c)

→

Room Temperature Water Rinse

(d)

→

Air Dry

(e)

Double hotplate method (preferred method):

  1. Place basket into a 35 °C clean IPA rinse bath. Rinse patterns for 30 seconds.
  2. Remove basket from clean IPA 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 IPA rinse. Rinse patterns until residual wax is removed.
  4. Remove basket from clean IPA rinse and place into room temperature clean water. Rinse patterns for 30 seconds.
  5. Remove basket and allow patterns to air dry.
  1. A finished processed pattern is shown below. There is white residue left on the finished patterns. This is normal.

IMG_2802a.jpg

 

Alternative Solvents

Alternative Solvents:

Solvents other than VisiJet Support Wax Remover (VSWR) can be used for post processing your 2500 IC printed patterns. Isopropyl Alcohol (IPA) is one of the most effective solvents for the removal of M2 IC SUW material—it’s inexpensive, readily available, but highly flammable. If IPA is not available, or undesired for use, you can also use the following solvents:

  • Polypropylene Glycol (PPG).
  • Polyethylene Glycol (PEG).
  • Tripropylene Glycol Methyl Ether (TPM).

 

Considerations when using alternative solvents:

  • Parts will float. Use mesh plastic material to hold your parts firmly to your post processing basket.
  • Parts will have oil residue. Rinse thoroughly with a warm soapy water. Follow with a clean warm water rinse.
  • The time it takes to remove the support material will increase.
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