Differences

This shows you the differences between two versions of the page.

--- form2sop [2020/08/28 17:31] – furst
+++ form2sop [2021/04/27 17:39] (current) – furst
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-=====Form 2 Training SOP=====
+=====Form 2/3 Training SOP=====
 Last edited: Furst (8/28/20)
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-Name
+Name (Last, First)
 !
 Group or Company
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-Signature
+Signature (First, Last)
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 ====Overview:====
-  * This training provides an introduction to using and operating the Form 2 SLA 3D printers including:
+  * This training provides an introduction to using and operating the FormLabs SLA 3D printers including:
     * File Types
     * Software
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       * Cleaning Build Tanks
       * Troubleshooting
-  * The Form 2 is a 3D printer that uses SLA (stereolithography) to make a part. In SLA, a laser beam is directed into a tank of photoreactive resin, which hardens to form a layer of the part. The first layer adheres to the build platform, and each following layer adheres to the previous one. The finished part will be suspended upside-down above the resin tank. It has a build volume of 145 × 145 × 175 mm (5.7 × 5.7 × 6.9 in).
+  * The Form 2/3 is a 3D printer that uses SLA (stereolithography) to make a part. In SLA, a laser beam is directed into a tank of photoreactive resin, which hardens to form a layer of the part. The first layer adheres to the build platform, and each following layer adheres to the previous one. The finished part will be suspended upside-down above the resin tank. It has a build volume of 145 × 145 × 175 mm (5.7 × 5.7 × 6.9 in).
   * The Form Wash is an automated washer that bathes the printed part in IPA (isopropyl alcohol) to wash off residual resin.
   * The Form Cure is a chamber that exposes a printed part to UV light to finish the curing process. This is referred to as ‘post-curing.’
-  * Remember to enter job information into the 3D print job log!
+  * Remember to enter job information into FBS!
 ====Safety====
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   * Care must be taken to prevent contaminating other areas with liquid resin - use containers to transport build platforms or parts that still have liquid resin on them.
   * Dispose of resin contaminated gloves and other objects in the yellow hazardous waste bin in 2442.
 ====Job Setup====
 **On The Computer:** \\
-  * On the desktop computer near the Form 2 printers, open the PreForm software from the start menu.
+  * On the desktop computer near the Form 2/3 printers, open the PreForm software from the start menu.
 {{:tools:form2:logo.png?75|}}
   * To start a new print, click File > New
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 {{:tools:form2:diagram.png?600|}}
 **On the Printer: ** \\
-  * Press the button on the Form 2 to confirm the print
+  * Press the button on the Form 2/3 to confirm the print
   * After the print is completed, slide out the build platform with the part attached and place it into a plastic bin with absorbent pad to catch any resin spill.
   * Close the orange cover
@@ Line 115: / Line 114: @@
       * Slide a removal tool under the angled edge of the part’s base to separate it from the build platform.
   * Lift the cover of the Form Cure. Place the part in the center of the turntable.
-  * Select the curing time and temperature. Curing settings are dependent on which resin is
+  * Select the curing time and temperature. Curing settings are dependent on which resin is used.
-used.
   * Refer to the webpage “Form Cure Time and Temperature Settings” through the Formlabs website for resin specific information. A longer cure time (up to an hour) will slightly increase the tensile strength of the part.
   * Press ‘Start’
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 **Post Processing:**
   * Use snips or tweezers to break support material off of the part. Be careful when finishing delicate parts to avoid breaking off small features.
-  * Use abrasives such as sandpaper and files to remove marks left by touchpoints until the
+  * Use abrasives such as sandpaper and files to remove marks left by touchpoints until the surface is satisfactory.
-surface is satisfactory.
 **Replacing an empty resin cartridge with a full one of the same type:**\\
 More information on the resin system and changing a cartridge can be found on the webpage
 “Formlabs Resin Tank Information” through the Formlabs website.
+Both the resin cartridges and build platforms are cross compatible with both the Form 2/3 as well as the newer Form 3 3D printers however the build tanks are not interchangeable. Types of resins are distributed between the Form 2/3 and Form 3 based on frequency used as well as which benefit from the low force SLA process employed by the Form 3 and should not be swapped without consultation with the staff.
   - Remove the empty resin cartridge:
     - Close the vent cap at the top right of the resin cartridge to prevent resin from spilling out once removed
-    - Hold the cartridge handle and lift to remove from the Form 2. Store the cartridge upright with the valve cover installed to protect storage surfaces from resin.
+    - Hold the cartridge handle and lift to remove from the Form 2/3. Store the cartridge upright with the valve cover installed to protect storage surfaces from resin.
   - Insert a new resin cartridge:
     - Shake and rotate the new resin cartridge to ensure that the resin is mixed thoroughly.
     - Align the cartridge with the opening at the back of the printer. Push down on the cartridge handle until the top of the cartridge is level with the printer.
     - Press open the vent cap to ensure the resin tank can fill correctly
+**New build tanks should be marked off when a new resin cartridge is put into rotation. This allows us to keep track of the wear on the build tanks and troubleshoot the printers more easily. Each new build tank is marked with a countdown of the number of liters remaining. Continue to numbers off the list as new resin tanks are put into use.**
-**Switching a printer from one type of resin to another**\\
+====Switching a printer from one type of resin to another====
 More information on the resin system and changing a cartridge can be found on the webpage
 “Formlabs Resin Tank Information” through the Formlabs website. This includes videos and
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   - Remove resin cartridge:
     - Close the vent cap at the top right of the resin cartridge to prevent resin from spilling out once removed.
-    - Hold the cartridge handle and lift to remove from the Form 2. Store the cartridge upright with the valve cover installed to protect storage surfaces from resin.
+    - Hold the cartridge handle and lift to remove from the Form 2/3. Store the cartridge upright with the valve cover installed to protect storage surfaces from resin.
   - Remove the resin tank
     - Hold the front tabs of the resin tank
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   - Cover the resin tank and store on the left side of the fume hood
   - Insert the resin tank for the resin that you plan to use
-    -  Lift the Form 2 orange cover. Use the tank grips to hold the Resin Tank LT, with the wiper resting inside the tank. If the tank contains resin, cover the tank with the plastic lid to align the wiper and minimize the risk of spills during insertion.
+    -  Lift the Form 2/3 orange cover. Use the tank grips to hold the Resin Tank LT, with the wiper resting inside the tank. If the tank contains resin, cover the tank with the plastic lid to align the wiper and minimize the risk of spills during insertion.
     - Align and insert the four small feet of the resin tank into the corresponding slots in the tank carrier on the printer.
-    - Hold the front tabs and carefully push the tank until the tank feet lock into the slots on the tank carrier. Check the touchscreen display to confirm that the Form 2 detects the tank. The Form 2 will only detect the tank when the tank is fully inserted.
+    - Hold the front tabs and carefully push the tank until the tank feet lock into the slots on the tank carrier. Check the touchscreen display to confirm that the Form 2/3 detects the tank. The Form 2/3 will only detect the tank when the tank is fully inserted.
   - Lock the wiper blade
     - Align and insert the wiper foot into the wiper mount.
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   - Replace build platform
   - Make sure that all of the resin tanks are correctly labeled.
+**New build tanks should be marked off when a new resin cartridge is put into rotation. This allows us to keep track of the wear on the build tanks and troubleshoot the printers more easily. Each new build tank is marked with a countdown of the number of liters remaining. Continue to numbers off the list as new resin tanks are put into use.**
+====Maintenance====
+  * Cleaning resin tank interior
+    * Use the scraper from the finish kit to inspect the resin and the elastic layer. Starting from the top corner, gently scrape from top to bottom across the elastic layer.
+    * Check for the following issues that may lead to print failures or any excessive wear that requires replacing the tank:
+      * cured resin on the elastic layer
+      * debris or failed prints in the resin
+      * settled pigment on the elastic layer
+      * punctures, cuts, or gouges in the elastic layer
+      * excessive “clouding” or wear in the elastic layer
+  * Filtering Resin
+    *  Use a filter to remove any debris or small bits of cured resin floating in the tank. Clean, debris-free resin helps avoid print failures, which may damage the tank.
+  * Cleaning the tank window
+    * Never use IPA on the acrylic tank window (it will cause cracks).
+    * If dust, fingerprints, and/or contamination are present, clean the clear acrylic tank window with NOVUS No. 1 and a clean microfiber cloth. The clear acrylic tank window is located on the underside of the resin tank. Apply 1-2 full sprays of NOVUS No. 1, and wipe using long, sweeping strokes top to bottom and across the tank window. Fold the microfiber cloth after each swipe to prevent dust and debris from scratching the acrylic.
 -----
+====Form 2/3 Quick Review====
+Tool Lead:    \\
+Contact: andrewfurst@ucsb.edu      \\
+====Safety Concern====
+  * Lab coat and gloves must me used when handling resin
+  * Anything with uncured resin must be transported within a container to avoid spilling
+====Safe Operation Procedures Review====
+  - Check resin cartridge and tank, make sure build material matches and is desired material.
+  - If resin is not desired material, disconnect wiper at build tank, remove build plate by sliding towards front of fume hood. Remove cartridge, cap valve on bottom and close valve on top of cartridge. Replace build tank, wiper, and cartridge with desired material.
+  - Launch Preform on Ultimaker computer
+  - Import desired STL
+  - Select "one click print" in the top left corner menu, change position, orientation, resolution and support as desired (note: that Preform will report on print ability of model, changing part rotation can affect print ability.
+  - Select print (orange button) from top left menu
+  - Select desired printer
+  - Press button on Formlabs printer to start print
+====Post Processing====
+  - Excess resin should be removed from the build tray and part with IPA over a waste container.
+  - Place build tray and part in the Form Wash for 20 to 30 minuets (part can be placed individually within basket if necessary
+  - Allow 30 minuets for IPA to evaporate before placing part in Form Cure
+  - Set Form Cure time and temperature based on resin type, place part within form cure, wait for time to elapse
+====Maintenance====
+  * Switching resin types
+    * Close breather valve on resin cartridge
+    * Remove the resin cartridge by pulling straight up on the handle behind the form labs printers
+    * Cap the cartridge valve using the included orange tap and cap
+    * Remove the wiper by pulling straight out towards the front of the fume hood.
+    * Pull the resin tray out of the printer by pulling firmly straight out toward you
+    * Lift the wiper and resin tray out simultaneously, and carefully place on resin shelf within fume hood.
+    * Cover resin tray with black plastic cover and label
+    * Replace resin tray with clean or desired resin tank. Push tank and wiper firmly back toward the Form 2/3 until it clicks into place
+    * Replace resin cartridge and open valve