This purpose of this document is to discuss the types of materials that will be available for use in the ProJet® 5500X and to help you determine which material works best for your application. Also included in this manual is safety information, material handling, and post processing instructions.

The materials currently available for use in the ProJet 5500X are:

• VisiJet® CR-CL, Rigid Clear Build Material

• VisiJet® CE-NT, Elastomeric Natural Build Material

• VisiJet® CR-WT, Rigid Whte ABS-like Build Material

• VisiJet® CE-BK, Elastomeric Black Build Material

PART MATERIAL SAFETY

Users of the 3D printer system should be informed of potential hazards of part material prior to working with a 3D printer system, or performing duties which may result in exposure to uncured part material, such as removal and disposal of empty material bottles and waste bag.

DISPOSAL

• Disposal of fully cured part material produced by the 3D printer system is not subject to regulations of any known agency worldwide.
• Uncured part material waste is classified as regulated, and in some areas hazardous, and may require special packaging, transportation and disposal. Waste bags filled with VisiJet support and part materials and the material bottles may be disposed of according to your local codes. The disposal of partially cured or uncured part material must comply with all local, state, and federal environmental safety regulations.  Applicable part material “waste” includes bottles (empty or full) and waste bags. Any cleaning materials used to clean up spilled uncured part material should be disposed of in compliance with local, state, and federal environmental safety regulations.
• Do not contaminate drains, soil or surface waters with this material or its container. Reduce waste by attempting to utilize product completely.  Dispose of this container and its contents in accordance with all local, state, and federal regulations. Do not reuse or refill.
• Support Material, cured or uncured, is not hazardous.

To find out facility disposal requirements, contact an approved waste disposal provider. Your local environmental regulatory agency should have a list of qualified providers. You will need to give disposal service providers a copy of the part material Global Health and Safety sheets, and possibly other forms included in the Appendix of your VisiJet Post Processing Guide, such as Waste Profile Worksheet and SNUR (Significant New Use Regulation - U.S. only). A report will be provided, indicating disposal requirements, as well as a quotation for regularly scheduled pickups. If assistance is needed locating a waste disposal provider, or completing a waste disposal form, contact 3D SystemsTechnical Support Hot line.

3D Systems assumes no liability or responsibility for proper disposal of uncured part material. Proper disposal of uncured material is the sole responsibility of the user.

Health Hazard/Irritant

CAUTION: Uncured 5500X VisiJet part material is a sensitizer. Skin or eye irritation could occur when exposed to the chemical composition of the material. Any chemical may exert harmful effects if it contacts or enters the body. VisiJet part material is a sensitizer and irritant.

Skin Sensitiztion: Uncured 5500X VisiJet part material is a snesitizer.  Slin or eye irritation could occur when exposed to the chemical composition of the material.

• Uncured material is a sensitizer and can cause allergic reactions if it contacts skin without protective gloves and sleeves. To avoid sensitization, do not allow uncured material to contact skin. Consult the GHS sheets for specific information about the sensitization potential.
• Once sensitized, a severe allergic reaction may occur when subsequently exposed to very low levels.

Ingestion: Uncured 5500X VisiJet part material is toxic if ingested.

• Uncured material is toxic if ingested. Uncured material must not be present where food and drink are stored, prepared, or consumed and must not be ingested. After handling materials, wash hands with soap and cold water before consuming or preparing food.

Inhalation: Under normal operation, inhalation is not an expected route of entry.

Contact With Uncured Material: Employees should be alerted to clean and rinse off any contacted surface promptly in order to prevent further contamination. Ensure a convenient washroom location is provided with access to soap, water, and disposable paper towels.

Handling Finished Parts: Finished (cured) parts can be handled or disposed of the same as standard household plastic products. VisiJet parts are not recyclable. VisiJet materials are not intended for, and cannot be used for medical implant or food or drink handling applications.

Exposure Control: The 3D printer system has a variety of built-in engineering controls which are designed to prevent operator exposure. Do not try to change or disable these controls.

Appropriate hygienic practices should be followed, including washing with soap and cold water before meals, breaks, smoking, applying cosmetics, using toilet facilities, and after work.

MATERIAL HANDLING

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

Packaging Inspection: VisiJet materials are supplied in bottles. These bottles are packaged with cardboard packing material inside the shipping carton. Upon receipt of material shipments, inspect cardboard carton exterior for signs of damage and leakage. If leakage is observed,  DO NOT open carton, contact 3D Systems Certified 3D Systems Service Provider. If no leakage is observed, store shipping carton until material is used.

Building: If uncured material is observed on the part or platform after build, this is an abnormal condition, and is an indication the 3D printer system requires servicing by 3D Systems or an authorized servicing reseller. Assume any liquid or paste-like material is part material. Do not directly touch uncured part material without protective gloves and protective sleeves. Discontinue use of the 3D printer system, pending service by a 3D Systems Technical Support Representative or your servicing reseller.

Flammability and Combustibility: Do not expose materials to heat at or above 230°F (110°C), flames, sparks, or any source of ignition.  Though the U.S. Department of Transportation does not consider VisiJet materials a “flammability hazard,” they do classify them “combustible” based on flash points.  For more information on VisiJet material flash points and combustibility, see the VisiJet Post Processing Guide.

PERSONAL PROTECTION EQUIPMENT

Skin Protection: Performing some procedures in this manual will exposure the user to uncured part material. To prevent contact, wear a chemically resistant apron or lab coat, protective sleeves (Tyvex) and chemically resistant protective gloves. Nitrile gloves are recommended.  Do not use Latex gloves.  For some procedures, heat resistant gloves are required. Where a “heat resistant glove” is referenced, 3D Systems recommends wearing a thermal liner with a nitrile glove worn over the liner. The thermal liner must be capable of withstanding temperatures up to 90 degrees C.

Eye protection: In the event of a leak or spill of uncured part material, wear safety glasses with side shields to provide eye protection.

Respiratory protection: Because of the 3D printer system’s built in engineering controls, respiratory protection is not necessary during normal operation. A NIOSH-approved (or equivalent) dust mask is recommended when dry sanding cured material parts

FIRST AID MEASURES

General Information: Ensure that eyewash stations and safety showers are close to the workstation location.  In case of inhalation: May cause respiratory irritation. Move affected person to fresh air.  If respiratory irritation occurs or if breathing becomes difficult, seek medical attention immediately.

In case of skin contact: May cause irritation or sensitization by skin contact , including redness and/or swelling. Immediately flush skin with plenty of cold water. After the area has been thoroughly rinsed, use soap and cold water to cleanse the area. Remove contaminated clothing and shoes.  Get medical attention if symptoms occur. Wash clothing before reuse.

In case of eye contact: Irritating to eyes. Causes redness, swelling and pain. Immediately flush eyes with plenty of water for at least 15
minutes. Remove contact lenses immediately. Get medical attention if symptoms persist.

In case of ingestion: Irritating to mouth, throat and stomach. If ingested, drink plenty of water and seek immediate medical attention. Do not induce vomiting.

Self-protection of the first aider: Put on appropriate protective equipment (see section 7). Move exposed person to fresh air. Remove contaminated clothing and shoes

ECOLOGICAL INFORMATION

Ecotoxicity: The aquatic toxicity of the product is unknown; however based on components, it is predicted that uncured part material may be harmful to aquatic organisms or cause long-term adverse effects in the aquatic environment. Prevent contamination of soil, drains and surface waters.

REGULATORY INFORMATION

VisiJet support material has no known regulatory requirements.

In the U.S., uncured material is subject to special EPA disposal regulations and record-keeping requirements. “Uncured 5500X VisiJet material” includes any part material bottles (empty or full) and waste bag, and about half of the material in a waste bag is uncured part material. For complete disposal regulation details, see the VisiJet Post Processing Guide.

In the U.S., the following disposal records must be kept for five years after the date of disposal:

• The quantity of part material received (new or “virgin”).
• The name and address of the shipping location (the “responsible party” - generally your waste disposal service provider).
• The quantity of part material shipped (disposed). For further information, see the VisiJet Post Processing Guide.

For assistance, contact 3D Systems Technical Support.

SPILLED VISIJET MATERIAL

Spills of material are highly unlikely and should NOT occur in normal operation of the 3D printer system.

The first priority is to protect users from inadvertently touching material. Spills of support material can be cleaned without use of protective gear, and disposed of as office trash. Handling uncured part material requires use of gloves, protective sleeves and other personal protective equipment to ensure no direct contact with uncured part material. If you don’t know which material it is, assume it to be uncured part material, and handle accordingly with the recommended personal protective equipment.

Promptly clean up spilled material, dispose of clean up materials and waste material per local regulatory requirements. Discontinue use of the 3D printer system, and contact 3D Systems Technical Support for a service visit to determine and repair the source of leakage.

Small spills of uncured liquid part material can be cleaned up using disposable towels, non-reusable rags, or absorbing materials such as sawdust, clay, diatomaceous earth, or activated charcoal. If spilled material is hot (liquid), wait until cools and gels before wiping up. After wiping up the spill, wipe surface with denatured or isopropyl alcohol and clean thoroughly with soap and water.

Advise the service provider involved of the spilled material, and provide other material information prior to contact with the material. Advise them of disposal requirements for part material and clean-up products if part material (uncured) is the spilled material.

Tools contaminated with part material should be cleaned prior to reuse. Solvents such as denatured alcohol or Isopropyl Alcohol (IPA), are normally required to clean equipment and tools. Wash with soap and water to remove any traces of excess part material or solvent. Contact solvent suppliers for information on proper handling of solvents if used for clean-up.

WASTE REMOVAL.

WARNING: UNCURED PART MATERIAL IS A SENSITIZER. SKIN OR EYE IRRITATION COULD OCCUR WHEN EXPOSED TO THE CHEMICAL COMPOSITION OF THE MATERIAL.

Wear protective gloves and protective sleeves before removing any waste product from the 3D printer system. Be careful not to spill, drop, or expose others to these materials - particularly part material bottles or waste bag. Dispose of all waste material appropriately per local regulatory requirements.

• Open waste drawer.
• Remove the waste bag from the waste bag holder by lifting the waste bag straight up and out of the waste drawer.
• Seal bag and dispose according to your local regulatory guidelines.
• Replace new waste bag by reversing the previous process. Close waste drawer after waste bag is installed

NOTE: For optimal results, keep stored cartons closed, and do not open until bottle is ready for use.

Always check bottle’s expiration date before loading. Do not load bottles into 3D printer system if they are about to expire. When 3D printer system detects an expired bottle, it aborts the build and rejects the bottle if the expiration date has expired for support material or more than one year past the expiration date for part material.

NOTE: When storing material bottles that have been used but still contain material, do not place the bottles on their side; stand bottles in the upright position. Also, in the case where bottles containing material are removed from the MDM and are still warm, the bottle must be stored with the cap vented. If the warm bottle is not vented, the wax will contract during cooling and the bottom of the bottle may flatten.  This will prevent the bottle from re-engaging in the MDM.

Support material bottles must be loaded in the left side material delivery module. The part material bottles must be loaded in the right material delivery module. Before loading material bottles into the 3D printer system, inspect bottles for signs of damage or leakage. Do not load a damaged or leaking bottle. Dispose of them according to local regulations.

The photopolymers used in stereolithography may be hazardous if handled improperly. Repeated skin contact with materials may cause sensitization. Consult the manufacturer’s Global Harmonized Standards/Safety Data Sheet (GHS/SDS) for information on specific materials. For further information on this and related topics, consult the 3D Systems – Materials website at http://www.3dsystems.com/support/materials/msds.

After the part(s) completed the printing process, there are steps that must be followed before it can be considered finished. Follow these steps to remove the build Support Wax from the part(s). An optional oven is also available for post porcessing, please refer to ProJet MJP Finisher Oven for detailed instructions.

Supplies Needed

• Paper Towels / Absorbent Pads
• Nitrile Gloves
• Insulating Gloves
• Safety Glasses
• Protective Clothing (lab coat, protective sleeves)

Equipment and Tools Needed

• Two MJP EasyClean warmer units capable of heating to 100°C (212°F)
• Fine wax removal fluid (such as EZ Rinse-C or mineral oil)

Steps for Post Processing a Part

1. When a part is finished printing the platform will raise and the platform clamps will release. Lift the entire platform off of the printer.

2. Place the platform of parts in a freezer for approximately 10-20 minutes depending on part geometries. This will cool the parts and enable them to separate easily from the platform.

NOTE: Placing the print platform on a metal surface as shown here speeds up the cooling time

3. Pre-warm the MJP EasyClean units for both bulk and fine wax. The units will take approximatley 30 minutes minimum at room temperature to warm up.

​ Turn on both warmer units

​ Turn the Bulk Wax unit control knob to 10 (99°C)

​ Turn the Fine Wax unit control knob to 6 (70°C)

​NOTE: Keeping units set to 5 when not in use will significantly reduce warm up time for Bulk Wax Removal.

4. Check the water level in each warmer units reservoir. If the water level is not at the fill mark, add more water now.

NOTE: Refilling the reservoir with warm water will significantly reduce the unit warm up time.

5. Fill the 2/3 pan in the Fine Wax Removal unit with wax removal fluid (EZ Rinse-C, Mineral Oil, etc.) so that it is 1/3 to 1/2 full.
6. Place the covers back on warmers
7. When parts have been separated from platform place them in the strainer basket and put the strainer in the Bulk Wax removal system, with the bulk wax system heated to 10. Close cover and leave in the bulk wax system for approximately 15 to 20 minutes after steam is being generated. The actual melt time will depend on the size of the part and how much support wax is present. For best part quality, remove parts from Bulk Wax removal system as soon as the bulk wax is visualy removed from part.

  NOTE: Ensure parts are not stacked on top of one another, a lasting impression may be made from one part to another.

8. Carefully lift cover off of warmer directing the steam away from yourself. 

CAUTION: Steam can cause burns. Use precaution when lifting lid off of warmer.

 NOTE: Water condenses on the inside of the cover. Take care to prevent hot water from dripping out of the system. Prevent hazards by wiping up any water that escapes the unit.

9. Wearing insulating gloves, use the strainer basket removal handles to pick basket up. With the strainer still over the wax catch pan, tilt it to the corner to allow liquid wax to drain away. You may want to shake gently to remove remnants of bulk wax.

10. Place the strainer basket with your parts in the fine wax removal systems 2/3 pan. This pan should be 1/2 to 2/3 full of fine wax removal fluid (such as EZ Rinse-C or Mineral Oil). Ensure dial is set to 6.

11. The hooks on each handle are inserted into the two slots on each side of the strainer. This allows the strainer basket to be lifted without the user having to touch the hot surfaces or liquids. When strainer has been moved, and user is done with handles, remove them and store somewhere close for the next application. Do not leave the handles in the warmer.

NOTE: Be careful not to overflow the liquid. If parts are not completely submerged, either add more of the liquid used in the fine wax removal system or plan on rotating the parts.

12. Close cover and leave basket in fine wax removal for no longer than 15 minutes. 
13. For best part quality, remove parts from Fine Wax removal system after 15 minutes not to exceed 30 minutes. Shake parts to remove excess liquid, remove from MJP EasyClean system, and rinse in warm soapy water and gently wipe parts dry with a paper towel/absorbent pad or allow them to air dry. 

14. Parts are now ready to use.
15. Remove the bulk wax 2/3 pan from the warmer unit and pour the molten wax and water mixture into a bucket. Allow wax to cool and solidify. Once cool, the wax may be removed from the bucket and put in normal trash. Pour the remaining water down the drain in accordance with local regulations.

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:

1. 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.
2. Spray the platform with isopropyl alcohol (IPA) and wipe with paper towels.
3. 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.

Below is a quick reference flow chart for post processing of parts: