FDM 2000 Introduction

F2000-2

About This Manual

Purpose

Procedures

About This Manual

Purpose
The purpose of this manual is to provide you with the necessary information to operate and maintain the Stratasys FDM 2000. This manual complements the procedures covered by the Stratasys training program. However, it does not serve as a substitute for hands-on learning. It also functions as an integral part of the complete documentation for your Stratasys system configuration.

Organization
This manual contains three main sections: 1) 2) Introduction Procedures (how to information) This section contains FDM 2000 usage, maintenance, and troubleshooting procedures. The usage section describes modeling and manual operations (see How This Manual is Organized on page F2000-4). The maintenance section covers daily cleaning, cleaning the FDM head, and periodic maintenance. The troubleshooting section covers basic problem resolution. 3) Reference (What is it? information) FDM 2000 concepts such as Fused Deposition Modeling are covered here. This section also describes the FDM 2000 controls, hardware, and the recommended road parameters for Stratasys modeling materials.

Conventions
The caution symbol indicates important information that should be read carefully. Cautions and warnings appear in bold typeface. The notepad symbol can indicate any of the following: a shortcut additional information about a feature or topic the situation in which you might choose to use a feature

This information appears in italics. Text to be entered at a prompt is indicated in a bold typeface, and may contain the subscripted caret (^) symbol, which represents when a space must be entered.

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Organization

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All of the Stratasys product documentation uses letter designated page numbers (appendices use lower case letters). You may find references within this manual to page numbers in other Stratasys documentation. The letter designations are as follows: TTraining Manual QQuickSlice Manual F1650- FDM 1650 Manual F2000- FDM 2000 Manual F8000- FDM 8000 Manual AApplications Manual UUtilities Manual GGlossary NNotes mMaterials Appendix SEInstallation Appendix Export/Import Appendix (Software) (FDM Hardware) (FDM Hardware) (FDM Hardware)

(Appendices) (Appendices) (Appendices)

The documentation included with your FDM system is dependent upon your FDM system configuration.

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About This Manual

How This Manual is Organized

Procedures

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About The FDM 2000 Overview

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About the FDM 2000

Overview of the Process
There are four main parts to the Stratasys modeling system: Slicing Software (see slicing software manual for description) Computer Workstation (see slicing software manual for description) FDM 2000 Modeler Modeling Materials

FDM 2000
The FDM 2000 uses Fused Deposition Modeling TM (FDM) to turn computeraided design (CAD) geometry into models that can be used for design reviews, manufacturability studies, investment casting patterns, and marketing. The FDM 2000 features the Break Away Support System (BASS), allowing the designer to create models with greater speed and precision. The support tip extrudes a material that supports any overhanging portions of the models geometry. When the model is completed, the support is easily broken off leaving behind the final product. The FDM 2000 is a bench-top unit standing forty-five and one half inches high with a 26 x 36 inch footprint. Because it requires no exhaust hood or other special facilities, it can be placed next to a designers CAD workstation.

Each CAD file is converted to an STL format. The STL file is read into Stratasys slicing software called QuickSlice. QuickSlice breaks the model into individual slices, with each slice representing one layer of material. Quickslice then generates tool paths to fill the slices. These toolpaths form the SML file. After slicing an STL file and creating a Stratasys Modeling Language (SML) file, the SML file is downloaded to the FDM Hardware for modeling.

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About The FDM 2000 Overview

Procedures

In the FDM Hardware, the FDM head moves in two horizontal axes across a foundation and deposits a layer of material for each slice. The material is heated by the FDM head so it comes out in a semiliquid state. The successive layers fuse together and solidify to build up an accurate, three-dimensional model of the design. For more information on this process, see Fused Deposition Modeling under Concepts in the Reference section of this manual. Overall tolerance is 0.005" in the X, Y, and Z axes. Actual results depend on the model.

Materials
The FDM 2000 is capable of using a variety of inert, nontoxic materials:
l l l

ICW06 Investment Casting Wax P400 ABS ABS Plastic P500 ABSi High Impact ABS Plastic

It is extremely important to keep ABS and ABSi completely dry. Each material comes wound on a spool in the form of a filament approximately 0.070" in diameter, so it is both easy to load and easy to store.

Storage
The Stratasys materials may be stored at normal room temperature. Humidity must be eliminated when using ABS and ABSI. Exposing the filament material to temperatures outside normal office temperatures may cause the filament to fracture. Stratasys recommends storing ABS and ABSI spools in dry boxes, like the dry box on the back of the FDM 2000. These materials also can be stored inside two plastic bags. Enclose a bag of desiccant with the spool. Place the plastic bags in a closed cabinet or vacuum sealed environment. This is to protect them from dust, bumps, nicks, and moisture. Handle the spools of material with care. Sudden or abrupt impacts to material spools may cause the filament to fracture. (See the Technical note enclosed with each P400 ABS , P400 RG, and P500 ABSi spool for further information.)

Investment Casting Wax

Stratasys investment casting wax allows the operator to take an STL file from a CAD model through the Stratasys modeling process and create a wax pattern. Forming and dewaxing a shell mold is done rapidly using normal investment casting procedures. No special burnout is required. Using this material streamlines the model-making process and helps you get your products to market faster. The low ash content and low viscosity level of the wax leave a residue-free cavity. (See the Materials Appendix for more information about Investment Casting Wax.)

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P400 ABS Plastic

This tough plastic is an acrylonitrile-butadiene-styrene based material which produces sturdy prototypes. P400 ABS allows you to make models much more similar to the desired final product than was possible with previous modeling materials. (See the Materials Appendix for more information about P400 ABS.)

P500 ABSi Plastic

P500 ABS is a medium grade, high impact strength ABS plastic. This tough plastic meets all FDA USP Class VI requirements and can be gamma sterilized with negligible discoloration. (See the Materials Appendix for more information about P500 ABSi.) For more information about these materials, see the Materials Appendix in the back of your FDM System documentation.

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About The FDM 2000

BASS

Procedures

Break Away Support System (BASS)

The FDM 2000 uses the unique Break Away Support System (BASS). BASS uses a second nozzle to extrude the support material. The supports are designed to prop up the overhanging portions of the part during modeling. The supports detach easily, making the finished product look better with minimal post-modeling finishing.

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About The FDM 2000

Supports

F2000-9

Support Sets
For best use of the FDM 2000s BASS system, the .sml file must be made correctly. The layer of support making direct contact with the model must be part of a set designated strictly for supports. The sets designated for this in QuickSlice are Support, SupportFace, and SupportFast. (See Creating Supports and Creating Sets in the QuickSlice manual). ABS, and ICW06 have specific release materials associated with them. Stratasys recommends making the entire support from the release material. The support slices default to raster curves only. (It is possible to change the roads to be contour or contour and raster, but Stratasys recommends using raster fills exclusively). The Support, SupportFace, and SupportFast sets all use the alternate or release material.

Finishing The Part

After the model is made, the supports must be detached without removing any of the part. If the support toolpath is the same color as the part toolpath, the operator can still determine the difference by visually inspecting the .sml file. A support region has wide gaps between the roads, and a part region might have no gap between the roads. A significant advantage in using the BASS system becomes obvious when you take the part out of your FDM 2000. Not only is the finished part of better quality than a part made without the BASS system, but the supports come off easily and cleanly. This greatly reduces the time required to manually finish the part. (See pages 3-5 in the Applications manual). You can usually determine the difference between the support and the part by the amount of space between the roads in each layer. Rasters are aligned in support curves.

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About The FDM 2000

Usage

Procedures

The FDM System

Changing the FDM Head (page F16-21)

Setting Modeling Temperatures (page F16-25)

Changing the FDM Tip (page F16-25)

U s a g e

Changing Spools of Material (page F16-28)

Replacing the Foam Foundation (page F16-32)

2 0 0 0

Slicing 3D STL File (see QuickSlice manual)

Creating Sets (see QuickSlice manual)

F D M

Generating Roads/Tip Path (see QuickSlice manual)

Creating an SML File (see QuickSlice manual)

Sending an SML File to the FDM 2000 (see QuickSlice manual)

Positioning the FDM Head (page F16-35)

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About The FDM 2000 User Information

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Capabilities
With the FDM 2000, you can create models in; modeling envelope sizes of up to 10 inches x 10 inches x 10 inches a variety of wall thicknesses (road widths) ranging from .0103 inches to .0396 inches slice resolutions (road heights) of .007, .010 and .014 inches investment casting wax, ABS and ABSI plastic

Requirements
User
It is highly recommended that all users complete Stratasys FDM Hardware/ QuickSlice training to ensure they obtain the necessary skills to operate the Stratasys equipment. Contact Stratasys Training department for details.

Space
The FDM 2000 uses 26 x 36 inches of bench-top space. If you are not purchasing a Stratasys table, make sure the table you use can support 500 lbs. Two to three feet of space behind the FDM 2000 are needed for clearance when opening the back door to change the spools of material. With a Stratasys table or any other table on casters, space can be minimized by pushing the FDM 2000 flush to the wall (within 1 to 2 inches), and then rolling the FDM 2000 away from the wall to change the filament.

Other
The FDM 2000 operates on normal office electrical power (one 20-amp line) and within the temperature and humidity ranges of an ordinary office environment. No special provisions are required for noise or vibration with the FDM 2000.

Items Included
All necessary hardware is included with the FDM 2000. Cabling to connect it to the workstation varies somewhat depending on the type of workstation.

Installation
Installation is available for your FDM 2000.

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Procedures

FDM 2000 Procedures

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About The FDM 2000

Calibration

F2000-13

Calibration
To make good parts, the tips must be calibrated correctly. Improper calibration can cause a misaligned part, or even displace a support from its proper XYZ position. It is necessary to calibrate the tips each time the head is changed. Stratasys recommends recalibration before every part to ensure the best results. Proper calibration allows the FDM 2000 to toggle between the modeler tip and the support tip, so the current tip in use is placed at the precise XYZ coordinate of the previous tip in use. Having one tip lower than the other prevents the unused tip from damaging the part. As an example, if a part is made with both modeling and release material, the FDM 2000 switches between the modeling tip for modeling material and support tip for release material. If the last position of the modeling tip before the FDM 2000 switches to release material is X=1.0, Y=1.3, Z=2.0, the head and Z-stage need to be calibrated so the modeling tip is moved out of the way, and the support tip is positioned at X=1.0, Y=1.3, Z=2.0. When the FDM 2000 switches back to the modeling tip, the support tip is moved out of the way and the modeling tip is placed at the last XYZ coordinate used by the support tip. The XY offset is the distance the head must move along the X and Y axes to place the new tip at the correct XY coordinate. The Z offset is the distance the Z-stage must be raised or lowered to change between the modeling tip and the support tip so each layer of material is placed at the correct Z level. The factory default value is 0.030", but might be slightly different when measured and calibrated by the operator.

The above graphic shows the support tip in use. It is offset slightly lower than the modeler tip. For modeling material, the modeler tip would be lower than the support tip.

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About The FDM 2000

Calibration

Procedures

Road Width Calibration

If your FDM modeler is not extruding the correct road widths, follow these steps to check the road widths and change it, if necessary. QuickSlice 5.0 contains a flow compensation feature that requires you to recalibrate the modeler. Recalibrated modelers are not compatible with files made in versions of QuickSlice prior to 4.0a. To run a pre-4.0a on a modeler calibrated for 5.0, it is necessary to recreate the SML file from the existing STL or SLC file. 1) 2) 3) Load filament into the FDM 2000 using the procedure on page F2000-32. Open the /strata/standard/2000 directory (or QuickSlicev50.qs for Windows NT.) Run the appropriate file for the material loaded in the FDM 2000. For ABS enter: For ICW06 enter: 4) 5) Measure the roads with a caliper. Part roads built with a 0.012" or 0.016" tip should measure 0.030." Adjust the road width if necessary. a) b) c) d) Press Space231 on the keypad control. Press 2 for ABS family main material or 1 for any other main material. Press Enter. Enter a value on the keypad. The numbers represent a percentage. Larger numbers increase the road width. Smaller numbers decrease the road width. Press Enter to accept the new value. Press Space239 on the keypad control. Press 8 for ABS family alternate material or 7 for any other support material. Press Enter. Enter a value on the keypad. The numbers represent a percentage. Larger numbers increase the road width. Smaller numbers decrease the road width. Press Enter to accept the new value. ssend^rc12abs.sml ssend^rc12icw.sml

e) f) g) h) i)

j) 6)

Repeat steps three through five until the road widths are properly calibrated.

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About The FDM 2000

Calibration

F2000-15

T12 and T16 Tip Offset Calibration

Following is the sscal procedure for calibrating an FDM 2000 upgrade. It differs from the ssxyz procedure by its use of a floating decimal, and a measured Z amount. It also requires the operator to enter -a at the beginning of the command string instead of at the end when using append mode. The sscal program uses the following parameters: [-h] [-v] [-a] show help message (optional) show version (optional) append input values to current values (optional mode)

It is easier to calibrate the FDM 2000 using the append mode. [-d] X_offset Y_offset Z_offset [port_id] use default values (optional) X offset distance Y offset distance Z offset distance port ID (a or b) (default a)

Example: sscal ^-a ^.001 ^-.001 ^.002 ^ a The example above adjusts the X offset 0.001 inches in the positive X direction, 0.001 inches in the negative Y direction, and 0.002 inches in the positive Z direction.

The following calibration procedure is for P400 ABS and a 0.012 inch tip. 1) 2) Download the calibration file /strata/standard/2000/cb12abs.sml to the modeler. The modeling material is made with a 0.03 inch road width. The release material is made with a 0.02 inch road width. The release material roads should lie directly on the center of the model material roads. Enter the new offset values through the sscal script. (See page F2000-17 for examples.) Repeat steps 1-3 until the support material is properly centered on top of the modeling material and the Z thickness is correct for the part (0.010 inches for the part in this file).

3) 4)

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About The FDM 2000

Calibration

Procedures

The observation must be made using a magnifier such as a microscope or a jewelers eyepiece. Z thickness must be measured with a caliper or micrometer. The Z layer must be peeled away from the calibration box to measure the Z thickness.

The above graphic represents a model of a correctly calibrated box for X and Y. The release material layer, represented by the thick black box, is 0.020" thick. The modeling material layer, represented by the lightly shaded area, is .030" thick. The release layer is 0.005" from both the inner and outer edges of the modeling material.

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Calibration

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Examples: sscal^ -a .001^.005^ -0.010^a

l

This command moves the support tip relative to its current offset values. It moves the support material offset 0.001 in the positive X direction (to the operators right when facing the front of the machine), 0.005 in the positive Y direction (away from an operator facing the front of the Machine), and 0.010 in the negative Z direction (thinner). The modeler is connected to port a. This command moves the support tip offset 0.001 in the negative X direction (to the operators left when facing the front of the machine), 0.005 in the negative Y direction (towards an operator facing the front of the machine), and 0.010 in the positive Z direction (thicker). The modeler is connected to port a. This command moves the support tip to an absolute coordinate. It moves the offset to the position X= -1.125, Y= 0.005, and Z= 0.030. The modeler is connected to port a. This sets the offset variables to default values. The modeler is connected to port b. The default values are X=-1.125, Y=0, Z=0.060.

sscal^ -a -.001 ^-.005^0.010^a

l

sscal^ -1.125^.005^.030^a
l

sscal^-d^b
l

An error message might occur during tip calibration. Below are some of the possible error messages along with the correct way to resolve the problem. Warning: You need to enter an X offset value. (or Y or Z)
l

Include an X, Y, and Z value (absolute or append) with the sscal script. The sscal script exits. Include a port id, either a or b. The sscal script exits.

Warning: the port_id must be either a or b.

l

Warning: the port_id ($SS_PT) needs to be conditioned for FDM hardware.

l

Condition the port with the ssport script. The sscal script exits.

Warning: there is a ssend for the port_id $SS_PT.

l

There is already a Stratasys script using the port^$SS_PT.

The sscal script exits.

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Procedures

T10 Tip Offset Calibration

Following is the sscal procedure for calibrating an FDM 2000. This procedures requires you to enter -a at the beginning of the command string when using append mode. The sscal program uses the following parameters: [-h] [-v] [-a] show help message (optional) show version (optional) append input values to current values (optional mode)

It is easier to calibrate the FDM 2000 using the append mode. [-d] X_offset Y_offset Z_offset [port_id] use default values (optional) X offset distance Y offset distance Z offset distance port ID (a or b) (default a)

Example: sscal ^-a ^.001 ^-.001 ^ .002 ^a The example above adjusts the X offset 0.001 inches in the positive X direction, 0.001 inches in the negative Y direction, and 0.002 inches in the positive Z direction. The following calibration procedure is for P400 ABS and a 0.010 inch tip. 1) 2) Download the calibration file /strata/standard/2000/cb10abs.sml to the modeler (or QuickSlicev50qs for Windows NT). The modeling material is made with a 0.01 to .03 inch road width. The support material is made with a 0.006 to .03 inch road width. The release material roads should lie directly on the center of the model material roads. Enter the new offset values through the sscal script. Repeat steps 1-3 until the support material is properly centered on top of the modeling material and the Z thickness is correct for the part (.007 inches for the part in this file).

3) 4)

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The observation must be made using a magnifier such as a microscope or a jewelers eyepiece. Z thickness must be measured with a caliper or micrometer. The Z layer must be peeled away from the calibration box to measure the Z thickness.

The above graphic represents a model of a correctly calibrated box for X and Y. The release material layer is represented by the thick black box, the modeling material layer is represented by the lightly shaded area. The release layer is 0.005" from both the inner and outer edges of the modeling material.

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About The FDM 2000

Calibration

Procedures

Creating a Calibration Box

The operator can create a calibration box manually with QuickSlice 4.1. Use the procedure detailed below and select the modeling tip size. QuickSlice defaults to a 0.012 inch tip. Calibration boxes built with a 0.016 inch tip require the operator to select the tip size in QuickSlice.

1) 2) 3)

Open a Unix shell window. Enter: qs Double click on the QuickSlice icon.

The Sun workstation goes directly to the QuickSlice window. 4) 5) 7) 8) 9) Place the cursor in the Files menu. Double click in the Open field with the left mouse button. Enter: /strata/standard/calbox.ssl Click OK in the Files menu. Click the arrow next to the Modeler field in the System Setup panel.

10) Select 2000 by clicking it with the left mouse button. 11) Click the arrow next to the Material field in the System Setup panel. 12) Select the material loaded in the FDM 2000. 13) Click the Roads icon with the left mouse button. 14) Click the File pull-down menu. 15) Click Save As. 16) Click SML to save the file as an SML file. 17) Double click in the Save field. 18) Name the file to indicate a calibration box for that material and place it in a user directory. (Example calxyz_p400.sml.) 19) Click OK to save the new calibration file. 20) Click the File pull-down menu with the left mouse button. 21) Click Exit with the left mouse button. 22) Click Yes.

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Calibration

F2000-21

23) Log in as a superuser. 24) Move the file into the /strata/standard/2000 directory. 25) Run the file using the ssend command string. Remember to use the file you just created instead of any previously existing calibration file.

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Usage Modeling Operations

Procedures

FDM 2000 Usage

Modeling Operations
When changing the FDM head or tip, the Z stage platen should be lowered at least 6 inches below the FDM head and the FDM head should be positioned toward the front of the modeling envelope. The front door to the FDM 2000 must be open when changing the FDM head, tip, or foam foundation. Press Pause or Stop to unlock the front door. (The FDM 2000 interlock feature prevents access through the front door until the Pause or Stop buttons are pressed.) This illustration shows the proper positions of the FDM head and front door.

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Usage Modeling Operations

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Changing the FDM Head Removing an FDM Head from the FDM 2000
If the FDM tip temperature is above 50 C (122 F), insulating gloves must be worn to avoid direct skin contact with the FDM head and tip. 1) Press the UNLOAD button on the control panel keypad to unload the modeling material. Wait 5 seconds and press UNLOAD again to stop unloading material. Repeat step 1 for the support material. Turn off the power to the FDM 2000 by pressing the black O button on the upper right corner of the FDM 2000. Using caution, unplug the screw-on connector from the right side of the FDM head. The FDM head is attached to the carriage and back plate. Unlatch the draw latches from the carriage.

2) 3) 4) 5)

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Procedures

Be very careful not to touch the hot FDM tips or the FDM head. Always wear heat resistant gloves. 6) 7) After both latches are detached, swing the FDM head to the right until the inside of the head is completely visible. Lift up the FDM head to detach its upper hinges from the back plates lower hinges.

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Attaching an FDM Head to the FDM 2000

1) 2) Make sure both draw latches are hanging freely on the FDM head. With the FDM head positioned as indicated in the illustration on page F2000-22, line up and drop into place the FDM heads upper hinges with the lower hinges of the back plate. Reattach the FDM head to the back plate and carriage: a) b) c) 4) 5) Swing the FDM head to the left until it touches the back plate. Line up the FDM head so the dowel pin on the top of the FDM head fits in its corresponding hole on the bottom of the carriage. Latch the left and right draw latches to the carriage.

3)

Using caution and making sure the pins line-up, connect the screw-on cable connection to the side of the FDM head Turn on the power to the FDM 2000 by pressing the white l button on the upper right corner of the FDM 2000. If the power is already on, turn it off and then back on so the temperature controllers can reset themselves. Check the liquefier temperature control to make sure it is running in automatic mode (the red light on the Auto/Man button should be off.) If the red light is on, press the Auto/Man button twice to turn it off. Call Stratasys Customer Support for further instructions.

6)

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Usage Modeling Operations

Procedures

Removing Backflow from the Head

If power is completely cut off from the FDM 2000, the cooling fan also shuts off at the same time. This happens whenever the FDM 2000 is unplugged. It also occurs during a power outage. If the FDM 2000 remains off for more than one hour because of one of these reasons, any filament remaining in the head can back up out of the liquefier and harden, preventing further flow. If a plug occurs, the operator should take the following steps to unplug the head. 1) 2) 3) 4) Unlatch the head using the procedure starting on page F2000-25. Open the head and snip the filaments. Lift the head off the hinges. Pull the head away from the back plate and allow it to rest on the bottom shelf of the FDM 2000.

It might be helpful to lower the Z stage platform before removing backflow.

5)

Remove the motor block if necessary.

The tweezers supplied by Stratasys can often be used to remove excess material without removing the motor block. It might be necessary to unclip the cable for easier access to the set screws. The operator must remember to reclip the cables before reattaching the head to the back plate. a) b) 6) 7) Use an Allen wrench to remove the cap screws holding the motor down. Lift the motor block away from the head and set it aside.

Carefully cut away the excess material with the cutting tool supplied by Stratasys. Replace the motor block. a) b) Place the motor block into the head so the two dowel pins under the motor lock in place. Insert the cap screws and tighten them to a snug seal with an Allen wrench.

8)

Close the head and start a filament load procedure. Be careful to keep tension on the filaments while closing the head, so they do not kink.

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Setting Modeling Temperatures

The temperature control graphic does not necessarily contain the recommended temperatures for the modeling tip, support tip, and modeling envelope. Always check the white label on the side of the material spool and set the controls for the temperatures specified there. 1) Set the liquefier and envelope temperatures on the control panel using the temperature adjustment buttons.

2)

Close the front door to the modeling envelope when using materials that require envelope temperatures higher than ambient.

Changing the FDM Tip

Before proceeding, make sure; 1) the Z stage platen is at least 6 inches below the FDM head. 2) the FDM head is mounted to the FDM 2000 . 3) the liquefier is heated to the correct temperature.

Removing an FDM Tip From the FDM Head

1) Unscrew the FDM tip with the tip wrench.

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Usage Modeling Operations

Procedures

Avoid direct skin contact with the hot FDM head and tip. Always wear heat resistant gloves. Make sure the tips are at the recommended modeling temperature before removing them. This prevents the threads on the tip from stripping. ABS tips have an o-ring placed on top of the tip. (See graphic on next page.) Make sure the o-ring is removed with the tip. 2) Place the FDM tip in a location where it can cool. Once the FDM tip has cooled, return the tip to its holder.

Attaching FDM Tips to the FDM Head

Make sure the FDM tip is designated for use with the currently mounted FDM head and loaded material. 1) 2) 3) Check the tip to make sure it is clean and has no nicks or scratches. Any residue of material will be melted out in step five. Place a bead of anti-seize lubricant on the threads and distribute evenly around the tip. Place the o-ring into the groove on top of the tip if necessary. ABS tips must have the o-ring in place. Be careful not to strip the tip threads. Wear heat resistant gloves to avoid direct skin contact with the hot FDM head and liquefier opening. 4) Partially screw on the FDM tip and allow it to heat up to the liquefier temperature. a) b) Start the FDM tip by screwing it into the liquefier. Do not screw the tip all the way into the liquefier.

5)

Wait for the actual temperature reading on the liquefier temperature control (Watlow) to reach the set temperature. Tighten the FDM tip very slowly with the tip wrench until it is seated firmly against the liquefier opening. If the FDM tip has been used before, some material might come out of the tip. If no material comes out of a used FDM tip, it might have been screwed on too quickly. This causes the liquefier to plug. See page F2000-43 for instructions on how to clean the FDM head.

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5) 6) 7)

Wait for the actual temperature on the liquefier temperature control to reach the set temperature. Press the LOAD button once on the control panel and wait for material to come out of the FDM tip. Press the Load button once to toggle it off.

Before Proceeding
Each tip is designated for use with only one material. Never use a tip for a material other than the one you select for that tip.

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Usage Modeling Operations

Procedures

Changing Spools of Modeling Material Removing an Empty Spool of Material

1) 2) 3) 4) 5) Press UNLOAD on the keypad for the modeling tip to begin the unloading process. Allow the machine to run for 10 seconds and then open the head. Pull the filament out from the front of the machine. Press UNLOAD on the keypad to end the unloading process. Repeat steps 1-4 for the support tip if necessary.

Removing a Mounted Spool of Material

1) 2) 3) Press the UNLOAD button on the keypad to unload material in the FDM 2000. Open the back door of the FDM 2000. Open the dry box door by unlatching the latches. Do not force filament out from the head. 4) 5) 6) 7) Press UNLOAD on the keypad to end the unloading process. Turn the mounted spool counterclockwise to wrap the remaining material onto the spool. Pull the spool with both hands to remove it from the mount. Store the spool according to the specifications for its material.

ABS must be stored with desiccant in sealed plastic bags.

Mounting a Spool of Material

If you are switching from ABS to wax, make sure to wait for the envelope to cool to the designated temperature for that wax. If you are using ABS, make sure to place the desiccant bags in the dry box. 1) 2) Inspect the wheels, spools, tips, and head before starting each model. Tighten the tips to prevent ooze and seam defects.

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3) 4) 5) 6)

Inspect the material carefully. Make sure it is free of kinks and nicks. If you are using ABS, make sure to take a spool from a sealed bag. Inspect the spool. Make sure it is wrapped tightly without any tangled or overwrapped material. Undo any tangles or overwraps. Cut off any kinks or nicks with a sharp knife. Using both hands, press the spool with the filament wound clockwise onto the mount until it locks into place. Make sure the spool does not rest on its tension ball. If you are loading ABS, open the head and insert the filament seals using the tool supplied by Stratasys. Press the LOAD button. Feed the filament gently into the guide hole on the bottom of the sensor block (do not force it), while continuing to unspool filament, until you feel it being pulled into the FDM head. Allow it to feed until filament comes out past the open part of the head.

7) 8) 9)

10) If you are loading ABS, adjust the filament seals so they just barely cause resistance with the filament.

Do not tighten the seals beyond contact resistance. 11) Cut the filament to a square edge with a sharp knife, and push it back until only 1/8 inch is sticking out from the rear portion of the head. 12) Feed the filament into the head from the rear until the motor pulleys grab it. 13) Make sure filament is coming out of the FDM tip. 14) Inspect the flow. It may sputter if there is a blockage or other problems. If filament does not begin coming out of the tips within 20 seconds, turn off the load, open the head, and check for anything that might prevent filament from flowing through the tip. 15) Press the LOAD button to stop loading material. 16) Clean the tips with a steel brush. 17) Back up the spool until the filament is taut. 18) Close the dry box door and secure it with the latches. 19) Close the back door.

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Enabling the Auto Shutoff

The FDM 2000 is equipped with an Auto Shutoff feature. Turning this feature on causes the FDM 2000 to turn itself off after completing a model. The cooling fan will remain on for 30 minutes to prevent backflow. To enable the Auto Shutoff feature:
l

Press the AUTO SHUTOFF button once. The green AUTO SHUTOFF LED lights indicating the feature is in use.

The Keypad Display Panel

To disable the AUTO SHUTOFF feature:
l

Press the AUTO SHUTOFF button once. The green AUTO SHUTOFF LED turns off, indicating the feature is no longer in use.

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If the modeler is left idle for several hours with material loaded, the material may back up and form a hard ring around the filament, or buckle, preventing further flow. This is called backflow. To help prevent this, make sure your liquefier is always up to the recommended material temperature before you load, and always make sure the filament is loaded before you place a new nozzle on the FDM 2000 head. When not using the modeler for more than a day, it is best to unload the material and lower the temperature.

Dry Filament Measurement Procedure (Ooze Test)

When using P400 ABS plastic, it is important to make sure the filament is dry for the material to model properly. The test is as follows: 1) 2) 3) 4) 5) 6) 7) Set the modeling liquefier to the recommended modeling temperature. Use a 0.012 inch tip. On the keypad, press the LOAD button and let it run for 60 seconds. Press LOAD again to stop the flow. Wait exactly 20 seconds and wipe the tip. Leave the flow off for 10 minutes. Measure the length of the ooze. Repeat steps 1 through 6 for the support material.

Totally dry filament has less than 0.25 inches of ooze after 10 minutes. Filament is acceptable with less than 0.50 inches of ooze after 10 minutes. Do not use wet filament. Filament must be dried in a vacuum drying machine. The vacuum dryer must be capable of maintaining 20 mm Hg pressure and 175o F.

Drying P400 ABS Filament

1) 2) 3) Set the vacuum dryer to 20 mm Hg. Preheat the material to 175o F. Place the material in the vacuum dryer for 2-3 hours. Spools can be sent to Stratasys for drying. Contact your sales representative or call Stratasys Customer Support.

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