Latest revision as of 12:16, 10 March 2020

ZORTRAX 3D PRINTER

Zortrax M200

Zortrax is a Polish manufacturer of 3D printers and filaments for SMB market and rapid prototyping for industries, including robotics and automation, architecture, industrial design, engineering, aviation, industrial automation. Zortrax machines work with dedicated software, firmware and filaments.

Technology

Zortrax manufactures Layer Plastic Deposition (LPD) technology. The technology is using three-dimensional data to create three-dimensional model in layer after layer process.

Technical specifications

M200

• Build volume: Length: 200mm, Width: 200mm, Height: 180mm
• Layer resolution: 90-400 microns
• Minimal wall thickness: 400 microns / optimal-800 microns
• Nozzle diameter: 0.4 mm (0.016 in)

M200 Plus

• Build volume: 200 x 200 x 180 mm (7.9 x 7.9 x 7.1 in)
• Material diameter: 1.75 mm (0.069 in)
• Layer Resolution: 90 – 400 microns
• Minimal Wall Thickness: 400 microns
• Nozzle diameter: 0.3 mm (0.012 in), 0.4 mm (0.016 in), 0.6 mm (0.024 in)

Health & Safety

Emissions testing from polymer filament desktop 3D printers found that some plastic filament materials, when heated, were found to release chemicals “known to be hazardous to health”, such as styrene and isocyanates. These printers emit many particles that can potentially enter the airways and lungs and should only be operated when enclosed by a hood with a filtered ventilation system to reduce particle emission rates by 97%.

Zortrax materials

MATERIALS

Zortrax Materials

Layer Plastic Deposition is a technology in which printer is melting thermoplastic material (filament) in the extruder and apply it precisely on heated platform layer after layer. Zortrax M200 dedicated printing materials are: Z-ABS, Z-ULTRAT, Z-GLASS, Z-HIPS, Z-PCABS, Z-PETG, Z-ESD, Z-ASA Pro, Z-PLA Pro, Zortrax M300: Z-HIPS, Z-PETG, Z-GLASS, Z-ESD, Z-ASA Pro, Z-PLA Pro and Zortrax Inventure - Z-PLA, Z-PETG, Z-SUPPORT.

• Z-ULTRAT: Z-ULTRAT is a versatile materials that lets you prototype models with features of products manufactured using injection moulding technology, all in-house. The strong, stable, and time-resistant material is available in a wide range of colours. Applications: functional prototypes end-use parts casing prototypes for testing end-use casing parts for low volume production prototypes of consumer products mechanical parts simulating properties of elements made in injection moulding elements required to be durable and stable over time

• Z-HIPS: Use Z-HIPS to significantly reduce warping and visibly shorten the time you’re spending on post-processing. The material has a unique mat structure that absorbs light and reduces the visibility of minor flaws. It’s great for printing bigger part, housing or architectural prototypes. Applications: models with large, flat surfaces architecture mockups casing elements for testing end-use casing parts for low volume production prototypes of consumer products prototypes of mechanical parts

• Z-GLASS: Translucent structures. Its light-transmitting surface makes it applicable in automotive, industrial design, and architecture projects. Applications: concept models that are to imitate glass or translucent plastic functional prototypes of translucent objects translucent decorative elements parts required to be resistant to salts, acids, alkalis, and solvents

• Z-PETG: Durable material. It’s highly resistant to salts, acids, and alkalis. The models will have a glossy surface that is also resistant to impact, time, and UV light. Applications: parts required being resistant to salts, acids, alkalis, and solvents machine components elements requiring resistance to greases and oils packaging prototypes prototypes of mechanical parts

• Z-PCABS: Z-PCABS emerged from combining two durable materials. Therefore it’s durable and impact resistant, suited for producing casings. It’s also resistant to temperatures, UV lights, and chemicals. The resistance made it a great material for automotive. Applications: consumer electronics casings automotive parts parts required to be resistant to temperature structural components

• Z-ABS: For printing concept models, mockups, gadgets, or figurines. Choose from a wide range of colours to catch the attention to your project. Applications: concept models gadgets and figurines display models models with moderate functional and testing properties

External Materials

• PLA: Polylactic acid is the quintessential material for 3d printing, thanks to its ease of use through deposition. It is recommended to begin in this type of manufacturing technology with this material. A great variety of colours exist and complex geometries can be achieved without great difficulty. The finish is slightly glossy or semi-matte.

Printing is carried out at temperatures ranging between 195º and 220° C, depending on the supplier of the mate­rial and printing speed. A layer fan is required to build overhangs. It easily attaches to the glass, and if you work at a hotbed temperature ranging 45º C-55º C, no product is required to ensure this adherence. The mechanical properties are average, but presents a certain fragility in parts requiring deformation, from a tempe­rature of about 50 °, the parts can present it. It is dissolved in caustic soda.

• ABS: Acrylonitrile Butadiene Styrene is one of the most widely used materials in 3d printing, and makes up for some of the weaknesses of the PLA. Printing with ABS is more complex and requires some attention. ABS is not recom­mended for inexperienced users. The variety of colours is also very high and the finish is semi-matte or matte.

The ABS is printed at temperatures between 210º C and 240º C depending on the supplier of the material and prin­ting speed. The ABS performs better with overhangs, and needs less air into the fan layer (excess air can be harmful). Adherence to the platform is weaker than with the PLA, due to material shrinkage on cooling, and often requires adhesive coating despite working with a hotbed temperature of 70 ° C. If the geometry of the piece to be printed has a too large base, is further promotes adherence problem due to the large lift effect that occurs at the opposite ends of the workpiece (known as warping).

• Filaflex: Filaflex is a flexible material that comes in different colors.

Requires the use of a 0.6 mm nozzle. Speed 10mm/s Temperature 235ºC Hodbed 40ºC

WORKFLOW

STL File Preparation

STL is the standard file type used by most additive manufacturing systems. STL is a triangulated representation of a 3D CAD model. The triangulation (or poly count) of a surface will cause faceting of the 3D model. The parameters used for outputting a STL will affect how much faceting occurs. You cannot build the model smoother than the STL file. If the STL is coarse and faceted the physical 3D printed model will be coarse and faceted as well. However, the smoother/ less faceted your surface is, (the higher the poly count or triangulation) the larger your file. 3D printing can only accept a certain file size; therefore it’s important to find a balance between your model, its desired surface, and the 3D printing process of your choice.

Important: STL files are suitable for 3D printing only if the models they describe are “watertight”, that is, they do not contain holes or gaps. To check to see if your mesh is watertight, follow the steps below:

   1. Convert file to MESH
      -Select Object
      -Convert to Mesh by typing command 'MESH'
      -Select Polygon Count > The higher the polygon count, the smoother the surface finish
   2. Check the MESH for any errors
      -Type 'CHECKMESH' to check mesh object for errors and problems, which include:
        • Degenerate faces - Fix with the CullDegenerateMeshFaces command.
        • Zero length edges - Zero-length edges typically are the result of degenerate faces. Fix with the CullDegenerateMeshFaces command.
        • Non-manifold edges - Use the CullDegenerateMeshFaces command and then fix with the ExtractNonManifoldMeshEdges command.
        • Naked edges - Naked edges can cause problems with rapid prototyping.
          Use the ShowEdges command to help find them or set the display mode to paint them a different color.
          Try the FillMeshHole, FillMeshHoles, or MatchMeshEdge commands to remove naked edges.
          If the mesh is still open, try the WELD Command.
          The Weld command will merge adjacent triangle points when 180 angle tolerance is set
        • Duplicate faces - Fix with the ExtractDuplicateMeshFaces command.
        • Faces with reversed normals. Fix with the UnifyMeshNormals command.
        • Disjoint pieces - Fix with the SplitDisjointMesh command.
        • Unused vertices - Unused vertices do not usually cause a problem, and there are no commands to for removing them in Rhino.
          Specific details on these commands can be found in the Rhino Help file.
   3. Once the mesh is watertight, it is ready to be exported.
      -File > Save As
      -Select File Type as STL
      -Select File Name > Save
      -Select Binary
      -As for the other settings, always select the standard options
      -Click OK

Z-SUITE Software Manual

Zortrax Z-SUITE software is created specifically for Zortrax machines. Z-SUITE allows opening a .stl, .obj or .dxf file and set printing preferences. It is the only 3D printing software in which users are able to convert 2D files into 3D models and cut models directly in Z-SUITE software. It is dedicated for both Windows and Mac users. Zortrax developed an application for storing and downloading 3D models - the Zortrax Library. It is available in both Z-SUITE and online. Before starting, download the Z-SUITE here: http://support.zortrax.com/downloads/

1. Printer Selection: On Z-Suite start screen, select the model of the printer you are going to use.
2. Adding a Model: Use + icon or use drag and drop option to upload a model. You may do so with models saved in an .stl or an .obj format. Select a model and click OPEN.
3. Editing a Model: There are several options to manipulate or edit your model in Z-suite including Splitting, Rotating, Resizing, Moving, or Duplicating a model, all of which can be found on the left-hand side of the window.
4. Preparing to Print: If your model is ready to be printed, click “Print.” Set printing options: PROFILE/LAYER THICKNESS/SPEED/INFILL which are explained below.
5. Print Settings:
   1. Normal Settings

      Layer thickness: choose the height of one layer: 0,09mm/0,14mm/0,19mm/0,29mm/0,39mm (depending on the material). Finer layers provide better surface quality but make printing more time- and material-consuming.

      Quality (previously Speed): HIGH/NORMAL. High quality gives better looking prints but increases the printing time.

      Infill: Choose the model infill: MAXIMUM/HIGH/MEDIUM/LOW. All four types of infill are presented in the picture on the right. MAXIMUM infill allows printing with the highest strength level. But the larger infill, the more time and material is needed for such a print.

      Support: Select the angle at which the support structure is generated. 20° is the default option. It means that for all hanging parts of the model the support structure is generated at a 20° angle.

      Support Lite: Choose this option to generate the support structure without the outer perimeter. Support lite consumes less material and it is easier to remove.

      Print Cooling: You can choose the fan speed which cools down the model that is being printed. Cooling is not useful for big prints without any thin parts, whereas high cooling is better for small and thin prints. We recommend leaving the default option – AUTO. The printer will adjust the fan speed accordingly.

   2. Advanced Settings

      Seam: It allows you to choose the starting point of every new layer (normal or random)

      Surface Layers: If you aim at achieving a thicker finishing of the model, use this function. It helps you to choose the amount of layers at the top and at the bottom

      Offset: this option helps to correct the internal and external dimensions of a model (in millimeters). It is possible to modify outer contours and holes dimension, however, only in the X and Y axis.

      Infill Advanced:

      -MESH Prints the model with 0% infill with horizontal surfaces (top and bottom) and the walls

      -SHELL Prints the model with 0% infill and no top and bottom surface layers. This option allows to choose the amount of the model wall. If you want the bottom layer to be printed, check the BOTTOM surface layer box while choosing SHELL infill.

      -There is a SPIRAL MODE available with SHELL option. If you choose this option, your model will be printed with no seam.

6. Saving the Z-Code: Once the .zcode has been generated, your model is ready to be saved on the SD card. Information about your print: profile, layer thickness, infill as well as an estimated print time and material usage will be shown at the bottom of the screen. Save your .zcode on a hard drive or directly on the SD card by clicking “Save to print” button. Insert the SD card into the printer and start printing.

Type of infill

LARGE PRINTS The problem of warping is frequent with large prints. Bigger models often shrink and that’s why they do not stick to the platform while printing. Additionally, it is better to choose low density of infill (medium or light) or, if low density is problematic, choose mesh option. For large prints with no precise details the optimum layer thickness is 0,19mm or 0,29mm.

PRINTING SMALL OBJECTS Very small objects require some additional options such as the appropriate FAN SPEED and LAYER THICKNESS. Set the lowest possible layer thickness and the additional FAN SPEED to 80-100%.

PRINTING MOVEBLE PARTS While printing movable parts, it is important to keep proper spaces between particular parts. The minimum space requirement is 0.4mm for these kinds of prints.

M200/M200 Plus User Manual

1. Save your model onto the Zortrax SD Card (M200) or onto the Zortrax USB Stick (M200 Plus)
2. Insert the SD Card/USB Stick on the appropriate machine
3. To change the material, unload and load the material by selecting "Material" option from the menu. To unload the material, select the “Unload the material” option. To load the material, select “Load the material” option. When the display shows the message “Insert new material,” insert the end of the material into the extruder and push the knob. Once the M200 finishes loading the material, it is ready to print. Remove the material remains using tweezers.
4. Select the model. To choose the model for printing, select the “Models” option from the main menu. Select the model in either the .zcode format file (M200) or .zcodex (M200 Plus) and confirm by pushing the knob. The printing procedure will begin automatically. The display will show information about the extruder heating level. Once the heating has been completed, the M200 will start printing. The bar on the display shows the progress of the print.
5. When it’s done, heat the platform.
6. Detach the model with the spatula tool and remove the model.
7. Use pliers or a scalpel to remove the support structure from your model.

Maintenance

• Maintenance Guide

Downloads

• mecanizado de precision
• | 10 Basic Repair Functions