Z402C User Manual

Z402C System User Manual
November 2001
ZTM402C 3D Color Printer

User Manual
Z Corporation
Software Version 5.1.40
Copyright©2001 Z Corporation Part Number 09501

Z402C System User Manual Z Corporation
Table of Contents:
1 YOUR Z402C SYSTEM ................................................................................................5
1.1 INTRODUCTION ....................................................................................................5
1.1.1 OVERVIEW ..................................................................................................................5
1.1.2 HOW IT WORKS ......................................................................................................6
1.2 PRINTING A PART OVERVIEW............................................................................9

1.2.1 STEP 1: IMPORTING THE FILE ..................................................................................9
1.2.2 STEP 2: PREPARING THE 3D PRINTER ...............................................................9
1.2.3 STEP 3: PRINTING THE PART ...............................................................................9
2 THE ZCORP SYSTEM SOFTWARE..........................................................................10

2.1 RECOMMENDED SYSTEM.................................................................................10
2.2 INSTALLING THE ZCORP SYSTEM SOFTWARE .........................................10
2.3 MAIN WINDOW....................................................................................................11
2.4 TOOLBAR ............................................................................................................12
2.5 OPENING A FILE ................................................................................................12
2.6 NAVIGATING THROUGH THE BUILD AREA .....................................................14
2.6.1 VIEWING CROSS SECTIONS OF THE BUILD..........................................................14
2.7 TRANSFORMING THE PART .............................................................................15

2.8 GETTING INFORMATION ABOUT THE BUILD .............................................18
2.9 SAVING YOUR WORK ........................................................................................19
2.10 3D PRINT SETUP ................................................................................................19
2.10.1 RECOMMENDED SETUP PROCEDURE* ................................................................20
2.10.2 CHANGING POWDER PARAMETERS .....................................................................20
2.11 SETTING USER PREFERENCES.......................................................................21

2.12 SERVICE MENUS................................................................................................23
3 PREPARING THE Z402C SYSTEM TO PRINT.........................................................24
3.1 HARDWARE CONTROLS ...................................................................................24
3.2 PREPARING THE 3D PRINTER..........................................................................24
3.2.1 FILLING THE FEED BOX WITH POWDER................................................................25
3.2.2 RINSING THE CARWASH .........................................................................................27
3.2.3 CHECKING FLUID LEVELS ..................................................................................27
3.2.4 CHECKING OVERFLOW VACUUM BAG ..................................................................28
3.2.5 PUTTING THE MACHINE ONLINE ............................................................................28
www.zcorp-users.com 1
Z Corporation Z402C System User Manual
4 PRINTING THE PART ........................................................................................... 29

5 POST PROCESSING THE PART.............................................................................. 32
5.1 REMOVING THE FINISHED PART..................................................................... 32
5.2 DEPOWDERING THE PART............................................................................... 33
5.3 DRYING THE PART ............................................................................................ 33
5.4 INFILTRATING THE PART.................................................................................. 34
5.4.1 TO INFILTRATE THE PART USING RESIN: .............................................................34
6 ADVANCED USER FEATURES................................................................................ 35

6.1 ORIENTATION FOR SPEED............................................................................... 35
6.2 ORIENTATION FOR STRENGTH ....................................................................... 35
6.3 ORIENTATION TO PREVENT WARPING .......................................................... 35
7 MAINTENANCE ......................................................................................................... 36
7.1 CHANGING THE COLOR PRINT HEAD ........................................................ 36
7.2 CHANGING MONOCHROME PRINT HEADS .................................................... 41
7.3 FLUSHING THE BINDER .................................................................................... 44
7.4 GREASING THE FAST AXIS .......................................................................... 45
7.5 CHANGING BETWEEN COLOR AND MONOCHROME ADAPTERS ............... 46
7.6 LOGGING YOUR BUILDS................................................................................... 48
8 TROUBLESHOOTING ............................................................................................... 49
8.1 THE BINDER SOLUTION IS BEING APPLIED IN ERRATIC STRIPES............. 49
8.2 THE SYSTEM SOFTWARE FREEZES DURING USE ...................................... 49
8.3 THIN PLANAR PARTS ARE WARPING ......................................................... 49
8.4 NOTHING HAPPENS WHEN I TRY TO PRINT .............................................. 49
8.5 MY STARCH-BASED PARTS ARE UNUSUALLY “CAKEY” .............................. 50
8.6 PARTS ARE UNUSUALLY WEAK OR CRUMBLY ............................................. 50
8.7 PRINTER LOOKS LIKE IT IS PRINTING, BUT IS NOT LAYING DOWN BINDER50
9 Z402C SYSTEM DETAILS......................................................................................... 51
9.1 DESCRIPTION OF REAR I/O PANEL................................................................. 51
9.2 SYMBOLS USED................................................................................................. 52
9.3 SYSTEM SPECIFICATIONS ............................................................................... 53
9.4 MATERIAL STORAGE PRECAUTIONS ............................................................. 54
10 INDEX......................................................................................................................... 55
2 Z Corp Service (781)852-5050/(877)88-ZCORP

Table of Figures
Figure 1. The Printing Process............................................................................................................... 6
Figure 2: The Z402C System Shelling and Infrastructure Features....................................................... 7
Figure 3: Illustration of Z402C System Print Orientations ..................................................................... 8
Figure 4: The Main System Software Window ..................................................................................... 11
Figure 5: Carwash Detail ..................................................................................................................... 27
The Z Corporation Rapid Prototyping System is manufactured under patent license to be used for the
fabrication of appearance parts and facsimile prototypes. Other uses may be restricted; contact Z
Corporation for further information.
Our equipment is designed to be used by design engineers and other professionals in the production
of early-stage 3D appearance parts. Our equipment is not to be used to produce, either directly or
indirectly, medical or other products that may require precise dimensions or tolerances to ensure the
safe and effective operation of such products. You agree to indemnify, defend and hold Z
Corporation and its officers, directors and employees harmless from and against any and all claims,
losses, damages, costs and expenses resulting from any use of our equipment other than for the
production of early-stage appearance parts.

1 YOUR Z402C SYSTEM
1.1 INTRODUCTION
1.1.1 OVERVIEW
This Z402C 3D Color Printer Manual will speed you along the path towards quickly and
inexpensively building parts. The manual contains the following sections:
1. Introduction. This section will give you an overview of the principles behind the Z402C
System, familiarize you with the terminology we will use to describe the Z402C System
and introduce you to some of the features of this manual. This section concludes with an
outline of the three quick and easy steps to printing parts.
2. Z Corporation System Software. This section will guide you through the features of the
Z Corporation System Software.
3. Preparing the Z402C System to Print. This section will guide you through putting
powder, binder solution and washer fluid in the Z402C 3D Printer, and preparing the
system to print a part.
4. Printing a Part. This section describes the steps of actually printing the part.
5. Post Processing a Part. This section guides you through removing your printed part,
removing any excess powder and infiltrating the part with resin to improve strength and
finish.
6. Advanced User Features. This section will help you get the maximum performance out
of your Z402C System.
7. Maintenance. This section contains instructions for keeping your Z402C 3D Printer in
proper condition through regular preventative maintenance.
8. Troubleshooting. This section offers some troubleshooting tips.
9. Index.
1.1.2 HOW IT WORKS
The Z402C System is based on the Massachusetts Institute of Technology’s patented 3DP (3D
Printing) technology.
The System Software first converts a three-dimensional design built using 3D CAD (and saved in
VRML or STL format) into cross-sections or slices that can be between 0.003” – 0.009” thick.
The Z402C 3D Printer then prints these cross-sections one after another from the bottom of the part
to the top.
Inside the Z402C 3D Printer there are two pistons (see Figure 1.) The feed piston is represented in
the diagrams below on the left and is shown in the ‘down’ position filled with powder. The build piston
is the piston on the right, shown below in the ‘up’ position. Also represented in the diagrams is the
roller (drawn as a circle) and the print assembly (drawn as a square.) On the Z402C printer, the
roller and the print assembly are mounted together on the gantry which moves horizontally across the
build area.
To begin the 3D printing process, the Z402C System first spreads a layer of zpTM series powder in
the same thickness as the cross section to be printed. The Z402C print heads then apply a binder
solution to the powder causing the powder particles to bind to one another and to the printed cross-
section one level below. The feed piston comes up one layer and the build piston drops one layer.
The Z402C System then spreads a new layer of powder and repeats the process, and in a short time
the entire part is printed.
Step 1: As the gantry traverses left Step 2: The roller spreads a thin Step 3: The roller discharges
to right, the roller collects powder. layer of powder over the build excess powder down the powder
piston. overflow chute.
Step 4: As the gantry traverses Step 5: The feed piston moves up

right to left, the print head prints one layer, the build piston moves
the part cross-section. down one layer, and the process is
repeated.
Figure 1. The Printing Process

The Z402C System employs several techniques to quickly build parts. First, binder solution is applied
in a higher concentration around the edges of the part, creating a strong “shell” around the exterior of
the part. Within parts, the Z402C Printer builds an infrastructure by printing strong scaffolding within
part walls with a higher concentration of binder solution. The remaining interior areas are printed with
a lower saturation, which gives them stability, but prevents over saturation, which can lead to part
distortion.
Other interior areas

Interior infrastructure printed at lower
printed at a higher saturation saturation
Exterior walls printed at

higher saturation.
Figure 2: The Z402C System Shelling and Infrastructure Features
After printing, the part is removed from the powder bed, depowdered and dried. The part can then be
infiltrated with wax, resin, or other materials to increase strength and durability. You will have the part
in your hands and can start improving your design within the same day—usually within hours.
Because the powder layers support the structures being printed above, the Z402C System prints
parts without support structures and can print parts with complex geometries.
There are several important features of the Z402C System that will help you print the best parts for
your intended purpose.
Part Placement. The System Software will automatically place the parts within the build box to
maximize build speed, the most important criteria for the majority of our users. The software
positions the parts with the smallest dimension in the z (vertical) axis. In addition to part placement,
the following other characteristics should be considered.
Strength. The ultimate strength of the part will be somewhat affected by its orientation within the
build box. The part will be strongest along the y-axis and the x-axis and less strong along the z-axis.
This is because the cross sections are printed in continuous strips along the y or the “fast” axis (the
print heads direction of travel), bands across the x or the “slow” axis (the gantry direction of travel)
and laminated layers along the z-axis. (See figure 3 below.) This discussion only applies to
untreated parts; once parts are infiltrated, they uniformly take on the strength characteristics of the
infiltration material.
z-axis Less Strong
x-axis
Strong
y-axis
Strong
Figure 3: Illustration of Z402C System Print Orientations
Accuracy. The accuracy of the system depends on the materials you choose. You can employ the
anisotropic scaling feature in the software to adjust for expected shrinkage and bring your parts into
true scale. For more information, please see Section 2.10.1 Changing Powder Parameters.

1.2 PRINTING A PART OVERVIEW

Printing a part using the Z402C 3D Printer is fast, easy, clean and fully compatible with an office
environment. This manual will show tips on how to print the most challenging parts, but for most
purposes printing a part is as simple as 1-2-3.
1.2.1 STEP 1: IMPORTING THE FILE
OPENING A FILE – Upon launching the Z Corporation System Software, you will be presented with
the ‘Open’ dialog box. Select the file you wish to print. The ZCorp System Software allows you to
open a variety of monochrome and color file formats including STL, PLY, SFX, VRML (WRL), BLD,
ZEC, ZBD and ZCP files. The System Software also allows you to move and scale your part, or pick
a color for monochrome (STL) files before printing.
1.2.2 STEP 2: PREPARING THE 3D PRINTER
Carefully following the steps outlined in Chapter 3, you can prepare the 3D printer in less than ten
minutes. You will put powder in the feed piston, and ensure fluid levels are correct and that the
powder overflow bin is empty.
1.2.3 STEP 3: PRINTING THE PART
The Z402C 3D Printer prints most parts in minutes and prints even the largest parts in a few hours.
You may then remove the part, depowder any excess powder and, if desired, dry and infiltrate the
part with wax or other materials to give the part the desired strength and finish. The post-processing
phase takes less than ten minutes for small parts and only an hour or so for the most massive parts.
Once you have completed these steps you are ready to start using parts to improve design,
communicate with other departments and reduce the time it takes you to get new products to market.
2 THE ZCORP SYSTEM SOFTWARE
2.1 RECOMMENDED SYSTEM

Before you can begin building parts, you must install the Z Corp System Software on your
computer. The system that we recommend for best performance with our System includes:
• Personal computer using a 600 MHz Pentium III chip, AMD Athlon, or higher
• Microsoft Windows* NT 4.0 or Windows 2000 Professional operating system
• 256 MB of RAM or more
• True Color Graphics
• 1024 X 768 pixels (or better)
• Graphics card accelerated for OpenGL
• Virtual Memory of 1 GB
2.2 INSTALLING THE ZCORP SYSTEM SOFTWARE

1. Close any open applications on your computer, make sure Windows NT 4.0, or 2000
Professional system is running and insert the CD into your CD-ROM drive.
2. If the installer does not start automatically, double-click on your CD-ROM drive and then double-
click on the ‘Setup.exe’ icon. This will start the setup sequence. If you have not closed all active
programs, the setup will give you an opportunity to do so.
3. Read the licensing agreement carefully.
4. Select destination directory. The program will prompt you for a selection and will offer
C:\Program Files\Z Corporation as the default directory.
Choose your installation preference: typical, compact or custom. Once you have made your
selection, it may take several minutes for installation to occur. When complete, you will be returned
to your main window. If you encounter any problems during installation, please contact the Z
Corporation Service Department at (781)852-5050, (877) 88-ZCORP, or via email at
service@zcorp.com
1
WARNING: To avoid problems that may occur during printing, ensure that all screen savers and
your power management software are turned off on the computer driving the Z402C Printer. Most
screen savers and power management software can be turned off in the main Windows screen
settings. For additional instructions on how to disable your hardware and software power
management, please consult your computer hardware owner’s manual.
*Microsoft Windows is a registered trademark of Microsoft Corporation.

2.3 MAIN WINDOW
Task Bar
Top View
Cross-Sectional View
Front View
Layer Count Height from

base of
Build Box
Figure 4: The Main System Software Window
The System Software provides three views of the part in the Main Window.
• The top view presents the view of the part in the x-y plane from the top.
• The front view presents the view of the part in the x-z plane from the front of the build
area. The horizontal yellow line in the side view marks the level of the cross-sectional
layer being displayed in the cross-sectional view.
• The cross-sectional view displays exactly what the Z402C System will print in that layer.
Different window views can be resized for user convenience. To resize a window, place the pointer
over the border between views, left-click on the border and drag to create your preferred window
size.
2.4 TOOLBAR
Save Mirror Ten Layers Up
New 3D Print Copy Rotate One Layer Up Selection List
Open 3D Print Setup Translate Justify Ten Layers Down
Import Scale One Layer Down About
2.5 OPENING A FILE
Open. When you initially open the System

Software, you will be presented with an Open
dialog box. Select the file you wish to open.
You may open zbd, stl, bld, ply, zcp, sfx, zec, or
wrl files. The print volume when using the
Z402C System in color is 6 x 9 x 8 inches (155 x
225 x 200 mm.) When using the Z402C System
in monochrome, the build are is 8 x 10 x 8 (200
x 250 x 200 mm.)
File Formats:
zbd files are build files created by the Z Corp stl files are monochrome 3D model files
System Software. exported by several 3D CAD packages.
zcp files are Z Corporation color files. ply files are color 3D model files exported by
several 3D CAD packages.
zec files are files created by the previous
version of the Z402C System Software. sfx files are color 3D model files exported by
SolidView/Pro.
bld files are build files created by the previous
version of the Z402 System Software. wrl (also known as VRML) files are color
files that are exported by many 3D CAD
packages.

When importing VRML files you will be asked to

input mesh resolution and texture threshold
settings.
Mesh resolution is the number of facets in your

graphic primitive file. A graphic primitive file is
composed of facets that are made up of cones,
cylinders, and spheres as opposed to triangles.
The default is set at ‘40’. Setting the number
higher will increase the number of facets making
your file larger; lowering this number will reduce
the number of facets.
Texture threshold pertains to scan data and

FEA files. A value of ‘0’ will render every color,
thus, producing a large file. Increasing the
number will produce coarser rendering.
Choose Units. A dialog box will prompt you to

choose units (inches, centimeters, millimeters or
meters.) If you are using more than one type of
powder, you can also choose the powder type.
The System Software will select as a default the
largest units that will fit the part into the build
volume.
After you select the units, the System Software

will place the object into the build area in the
way that will minimize print time if you have
chosen this option under the ‘Preferences’
menu. For more information see Section 2.11.
Import. You may import multiple files into a

single build—each subsequent file will be placed
within the build area such that the objects will
not overlap. To insert additional files, choose
‘Import’ under the File menu. You may import
stl, ply, zcp, sfx, or wrl (VRML) files.
If the model has many facets, the fast rendering

option will be offered if you have chosen this
option under the ‘Preferences’ menu. This may
also be selected later under the ‘View’ menu.
If the imported file is rendered dark and no

slices show in the cross sectional view, the back
faces of the file are showing. The part will not
print properly in this orientation. To correct the
file, invert all normals. This feature is found
under the Edit menu.
Normals Inverted
Normals Corrected
2.6 NAVIGATING THROUGH THE BUILD AREA
2.6.1 VIEWING CROSS SECTIONS OF THE BUILD
The System Software offers you several ways to view cross sections:
To do this: Menu Command Toolbar Keyboard Shortcut
Move up one level Select ‘One Layer Up’ from ‘a’
the View menu
Move down one level Select ‘One Layer Down’ ‘z’
from the View menu
Move up ten levels Select ‘Ten Layers Up’ from Shift ‘a’
the View menu
Move down ten levels Select ‘Ten Layers Down’ Shift ‘z’
from the View menu

TECHNICAL TIPS….
When setting up your build area with multiple parts, place larger, bulkier
parts towards the bottom of the build box.
2.7 TRANSFORMING THE PART

First select your part(s). To select parts within the build area, click on the part with the left mouse
button. An yellow rectangle will appear around the part. To select multiple parts, hold down the Shift
key and select the parts you wish to modify. To de-select a single part, hold down the shift key and
click on the image of the part. To de-select all parts, click on an open area.
• Once opened or imported, parts can be

translated, rotated or scaled by percentage
or through anisotropic scaling factors, and
colored within the print area.
• To translate or move your parts within the

build area: Select parts within the print area,
click on the selected area and move with the
mouse.
You may also select parts using the ‘Entity

Selection’ option under the Edit menu. Click
on the part you wish to select. To choose
multiple parts, hold the Shift key and click on
additional parts.
There is also an icon on the toolbar for this

function.
• You may move the object more precisely by

choosing ‘Translate’ from the Transform
menu.
• To rotate the part, select the part and

choose ‘Rotate’ from the Transform menu.
In the dialog box, specify the plane and
degree of rotation you desire.
• You may also rotate using ‘Rotate in Active

View’. Choose the part you would like to
rotate in the view box you would like view
window you would like to rotate in (top
view, or front view.) The yellow box
surrounding the part will be highlighted in a
brighter yellow box in the view that you
have chosen. Then choose one of the
following options under the ‘Rotate in
Active View’ menu.
• To mirror a part, select the part and make a

copy. With the copied part selected,
choose ‘Mirror’ under the translate menu.
Choose the orientation you would like to
mirror.
• To scale the part, select the part and

choose ‘Scale’ from the Transform menu.
In the dialog box, you are given several
options. You may scale the object relative
to the dimensions in the imported file and
the units you initially selected by entering a
percentage in the ‘Relative’ box.
Remember to limit your selection to the
maximum limits of the build area 6 x 9 x 8
inches (150 x 225 x 200 mm) in color and 8
x 10 x 8 inches (200 x 250 x 200 mm) in
monochrome .

• To justify the part, select the part and

choose ‘Justify’ from the Transform menu.
You may justify the part to the left, right,
front, back or bottom of the build box.
Justifying the part, lets the software move
the part to the edge of the build box
optimizing your build area.
PLEASE NOTE: In the process of changing

the location or orientation of a part, you may
find that parts overlap in the build box or
exceed the boundaries of the build box. If
parts exceed the boundaries of the build box,
the System Software will alert you with an
error message and the part in question will
be outlined in red. To fix the problem, select
the part and either move it within the build
box or use the ‘Justify’ feature to bring the
part completely within the build box. If parts
overlap with each other in the build box, you
will NOT receive an error message; carefully
inspect the build box by checking the layers
of the build. This is done by pressing the A or
Z key to up each layer. Then correct part
overlaps before printing.
You may also add a color to your

monochrome stl part.
Selecting the part.
1. Choose Color option under the Edit menu.
2. Pick a color from the color pallet.
3. Click ‘OK’.
The part will be colored by an outer shell as

with all Z Corp. color parts.
PLEASE NOTE: Only monochrome

files (STL) may be colored. If you
select a color part, the software will
remind you that the color feature is
only available for monochrome files.
• To change anisotropic scaling factors

for a specified part, choose the part
and select the ‘Anisotropic Scaling’
option under the ‘Transform’ menu.
Enter your custom anisotropic scaling
factors for the x, y, and z axes. Click
‘OK’. These anisotropic scaling
factors will only affect the selected
part(s).
• To change anisotropic scaling factors

to affect the entire build, change the
powder parameters under the ‘3D
Print Setup’ menu. For more
information, see Section 2.10.1,
Changing Powder Parameters.
Please refer to the Powder Fact Sheet

provided with your case of powder for
recommended anisotropic scaling factors.
2.8 GETTING INFORMATION ABOUT THE BUILD

The System Software allows you to estimate the time required to print your build in color and
monochrome mode, the number of pixels the part will use and other statistics.
Select ‘Print Time Estimator’ from the File

Menu. The System Software will return a
dialog box with the estimated build time.
To calculate the surface area and volume of

the build, select ‘Calculate Part Statistics’ from
the View menu.

2.9 SAVING YOUR WORK

After you have imported the files, oriented parts and have set up your build to print, save your work
by selecting ‘Save As’ from the File menu. After you choose a name for your build, select ‘Save’ and
your work will be saved as a *.zbd file. A build file contains all of the modifications that you have
made to the parts and the settings you have selected from the build.
If you reopen and work on an existing build file, you can save your changes to the *.zbd file by either
selecting ‘Save’ from the File menu or choosing the save icon from the tool bar.
2.10 3D PRINT SETUP
The ‘3D Print Setup’ dialog box allows you to select a printer, choose a powder type, and change
powder parameters. This dialog box is found under the ‘File’ menu. It is also located as an icon
on your task bar.
2.10.1 RECOMMENDED SETUP PROCEDURE*
1) Select the Printer that you will be using. Choose ‘Select Printer’. You may choose any printer
that is connected by serial port. If the Printer is busy or offline, the option to select this printer
will not be available.
2) ‘Save Printer as Default’ enables you to save the chosen printer so that the software
remembers to use the settings for this printer when the software is reopened.
3) Choose ‘Powder Type’ by clicking on the list box. Save this powder type as the default
powder so that the printer will remember to use this powder for every print job unless
manually changed. If you would like to use a powder that is not the default, you may manually
change powder type by choosing from the ‘Powder’ list box.
PLEASE NOTE: *This is the recommended 3D Print Setup procedure. It is chronologically

structured to prevent any changes in values once they have been entered.
2.10.2 CHANGING POWDER PARAMETERS
The saturation settings for plaster-based powder are constant for all parts. Please refer to the Powder
Fact Sheet for recommended saturation values.
The default saturation values suggested by the software for starch-based powder are designed to
successfully print a majority of parts. You may, from time to time, choose to override these saturation
levels. Please refer to the Powder Fact Sheet for recommended saturation values.
In general, bulkier parts will print more successfully with a lower setting and delicate parts will print
better with a higher setting.
To change Powder Parameters for the chosen powder:
1. Click on the ‘Override…’ button.
2. Choose the unit of measure for layer thickness.

3. Choose a given layer thickness or to put in your own layer thickness, choose ‘Other.’
4. Shell Saturation values may be changed based on three factors – Binder/Volume Ratio (%),
Saturation Level (%), and Saturation. When changing any value corresponding to Shell
Saturation, the relative Core Saturation will also be changed.
5. Input the core saturation manually if needed.
6. Input Anisotropic Scaling factors for the chosen powder. These values may then be saved as
default values in the ‘3D Print Setup’ dialog box. This scaling will affect all parts in the build.
You may choose to assign anisotropic scaling factors for each model by using the
‘Anisotropic Scaling’ option under the Transform menu.
Anisotropic scaling operates as a simple multiplier. The shrinkage or expansion you experience may
differ from the norm because of humidity and temperature variations between operating
environments. The anisotropic scaling factors allow the printer to compensate for these differences.
2.11 SETTING USER PREFERENCES

You can change the default settings
for several software features by
selecting ‘Preferences’ from the Edit
menu.
• Units.
You may choose to have the measurements for your parts displayed in either inches or
millimeters. This will change the way part dimensions and layer thickness are displayed, but it
will not change the underlying dimensions on the part. You will still need to choose the proper
units when opening or importing a new file.
• Save slice data in ZBD files.
When a build file (ZBD) is saved, the slice information is discarded and the part is resliced
every time the file is opened. This is generally the best strategy for saving files; the file size is
significantly smaller, and because it is smaller, it will reopen faster. However, once the file is
opened, you will have to wait while the file reslices. If you wish to save slice data, check this
box.
• Orient imported parts for the fastest print times.
When this box is checked, parts are always rotated so that the smallest dimension of the part
occurs in the Z direction. Since build times are largely determined by the height of the part,
this arrangement produces the fastest build times. But if you are importing several parts that
need to be placed in a predetermined arrangement to each other, you can uncheck this box
and prevent the software from rotating the part.
• Offer fast rendering for parts larger than [ 100 ] thousand facets.
Large parts with many facets can be slow to draw on the screen. It is often convenient to
draw the parts using "Fast Rendering," which can be selected from the View menu. When an
file is larger than a certain threshold, before drawing the part for the first time, the software
will ask you if you prefer to use fast rendering. You can still choose to use photo-realistic
rendering.
If you have a very fast video display you may want to set the threshold higher, or even
uncheck the box. If your computer is slow to draw and refresh the screen, you can set the
threshold lower.
• Warn if entity is outside the build box.
If your part is outside the build area the boundary surrounding the part will be red. The
software also shows a dialog box reminding you that your part is outside the printable area.
You may turn this warning off by unchecking this feature.

2.12 SERVICE MENUS
The System Software allows you to draw information from the

Z Corporation 3D Printer and activate some printer functions.
• Get Piston Levels. (Shortcut Key: F1) To check the available powder in the Feed
Piston and the remaining room in the Build Box, Select ‘Get Piston Levels’.
• Squirt Squeegee. This feature applies to only the Z406 3D Printer.
• Prime Print Heads. (Shortcut Key: F3) This feature allows you to service the print
head if it is not printing well.
• Toggle Roller on/off. (Shortcut Key: F4) This allows you to activate the roller
independently for easy cleaning.
• Toggle Vacuum hi/low. (Shortcut Key: F5) This feature applies to the Z402 and
Z402C 3D Printers.
• Change Print Heads. This feature allows you to change the print heads, as
described in detail in Section 7.1 and 7.2.
• Flush Binder. This feature allows you to cycle fluid through the plumbing system,
which is useful in changing the binder color, as described in detail in Section 7.3.
• Report Capabilities. This feature allows you to view the capabilities of the Z
Corporation Printer connected to your computer.
• Stripe Test. This feature allows you to test the printing status of your print heads.
This feature applies to the all Z Corp Color 3D Printers.
• Upload New Firmware and Upload New Printer Configuration. This feature
allows you to upgrade the firmware that is in your 3D Printer. The Service
Department will provide you with required upgrades and instructions.
3 PREPARING THE Z402C SYSTEM TO PRINT
3.1 HARDWARE CONTROLS

The front control panel on the Z402C 3D Printer has the following features:
Feed Up/Down Buttons. Allows

users to raise or lower the Feed
Online Button. Enables
Box. A light tap raises or lowers
and disables local
one layer thickness; holding
control of the printer.
down causes continuous motion.
Spread Button. This button allows you to move the Build Up/Down Buttons. Allows
gantry from left to right. Moving the gantry left to users to raise or lower the Build
right allows you to spread powder over the Build Box. A light tap raises or lowers
Box. Holding down this button will result in one layer thickness; holding down
continuous spreading of powder. causes continuous motion.
3.2 PREPARING THE 3D PRINTER

If the machine is off, switch it on by pressing and releasing the Power ON/OFF Switch. The red
power light and yellow error light will turn on. Then, the Gantry will move slowly as it orients itself.
We recommend that you leave the machine on at all times—the printer will go into a low power ‘sleep’
mode after 90 minutes. In sleep mode the machine will exercise the print heads and other functions
during periods of inactivity to prevent clogging.
1. Wait for the green Online light indicating that the power-up procedure has completed.
The power up process should take just a few minutes.
2. Take the machine offline by pressing and releasing the Online Button.
3. Open the clear Top Cover to gain access to the build area.
TECHNICAL TIPS….
LEAVE THE MACHINE ON! This allows the printer to perform a periodic self maintenance.

3.2.1 FILLING THE FEED BOX WITH POWDER
1. Press and hold the Feed Down button until

the piston reaches the bottom of the Feed Box.
The piston will stop when it reaches the bottom.
2. Open a bag of fresh powder and carefully

place the bag upside down in Feed Box with the
edges of the open end of the bag touching or
slightly below the powder level.
3. Carefully withdraw the bag from the Feed

Box, allowing the powder to flow out. Twisting
the bag slowly as it is withdrawn helps powder
to emerge smoothly.
4. Grip the Powder Scoop and using a

stabbing motion, insert it repeatedly a few
inches into the loose powder to compact it.
Continue for about a 10-15 seconds until
the powder feels firm.
5. For each powder bag added to the Feed

Box, repeat steps 2, 3 and 4.
6. When Feed Box is filled to top, take the

Tamper and slowly press it onto the powder
surface. Be careful not to “slap” the Tamper
into the Feed Box, which will produce
airborne particles. About 10-15 pounds of
force will give a smooth, flat, and compact
surface. Failure to firmly pack Feed Box will
affect part quality.
7. Vacuum up any powder spilled on the Top

Deck.
8. Raise or lower the build piston until it is approximately one inch from the top. Pour powder into the
build piston and tamp down until the powder is even.
9. Close the cover and move the gantry left by pressing the spread button.
10. Raise the build piston until the level of powder is approximately an eighth of an inch above the
Top Deck.
11. Press and hold the Spread Button until a uniform bed of powder is formed in the Build Box. Make
sure powder is even throughout the Build Box.
TECHNICAL TIPS….
Keep powder containers closed when not in use to keep powder dry.
Scoop powder carefully to minimize airborne powder.
Make sure that you carefully vacuum up excess powder. It only takes a minute, and the tidier the machine is,
the less often it will need maintenance!
WARNING: Use only powder supplied by Z Corporation. Use of any other material may impact the
performance and/or safety of your Z402C System and will void warranty of equipment.

3.2.2 RINSING THE CARWASH
The Carwash cleans the nozzle array of the Print Head during printing. Rinse the Carwash
before and after each build.
Squeegee
Figure 5: Carwash Detail
To clean the Carwash:
1. Take the machine Offline.
2. Open the Top Cover.
3. Manually pull the print head forward, out of its parked position.
4. Rinse the Carwash, especially the Squeegee, with distilled water. This will
dissolve any dried deposits of powder. Never dry out the carwash area.
5. If there is any powder inside the gantry along the path of the print head, vacuum or wipe
it up.
6. Push the print head back to the parked position. Close the clear Top Cover.
3.2.3 CHECKING FLUID LEVELS
1. Open the doors at the bottom front of the machine.
2. Check the jugs on the left side. If the binder waste bottle on the left is three-
fourths full, empty it out. Binder waste should be treated in accordance with local
regulations. If the binder supply jug is approaching the bottom rim of the bottle,
replace it by unscrewing the top from the empty bottle and refastening the top to
a full binder solution bottle.2
3. Close the doors on the front of the machine. Do not run the printer with the doors open.
2 Store binder in a cool, dry place away from the sun. Keep tightly capped. Keep away from heat. Gloves and
safety glasses are recommended to avoid direct contact.
3.2.4 CHECKING OVERFLOW VACUUM BAG
Check the Powder Overflow Bag at the right side of the

machine. This bag must be replaced approximately once
per complete build volume. To replace the Powder
Overflow Bag:
1. Pivot down the slotted Bag Support Rails that seal the
Powder Overflow Bag against the Powder Chute.
2. Slide the bag out of the machine.
3. Vacuum off the Filter in the back of the Powder

Overflow Box.
4. Slide a fresh bag into the Bag Support Rails and push
it up against the top face of the Powder Overflow Box
so that the end of the Powder Chute passes into the
bag.
5. Puff out the bag manually so that it will inflate easily

when the door is sealed.
6. Close the front doors and latch them securely. The

right front door forms the seal on the Powder Overflow
Box, and the overflow vacuum system will not work
properly if the door is not closed.
3.2.5 PUTTING THE MACHINE ONLINE
Press the ‘Online’ button. The green ‘Online’ Indicator Light will illuminate. The Z402C 3D Printer is
now ready to print.
TECHNICAL TIPS….
Keep the Machine Clean!
Make sure that you have enough powder to complete the build. It is wise to always begin a build with a full
feed box.
CHECK THE OVERFLOW BIN! If the overflow bag becomes full, powder will back up through the system
and cause errors with your Printer.
CHECK FLUID LEVELS! Make sure you have enough fluid to complete the build. Make sure the waste bottle
is empty.
Keep your Z402C 3D Printer as clean as possible. The cleaner it is, the better it will function.

4 PRINTING THE PART
Before printing, double check the settings for your print job by choosing the ‘3D Print Setup’ option
under the File menu. Make sure the software has chosen the correct COM port. You also want to
make sure powder type and parameters are correct. For more information about changing this set-up,
see Section 2.10, 3D Print Setup.
1. Select ‘3D Print’ from the file menu or the

3D Print icon on the toolbar. The first
dialog box reminds you of the pre-print
checklist. Be sure to complete all steps
described in Section 3.
2. Select either entire build or the specific

range of layers that you would like to print. If
you wish to only print a particular cross-
sectional slice of your part, enter the range
of layers that you wish to print. If you wish to
use the delay timer feature, check the
appropriate box. You will then be asked to
enter how many hours in the future you wish
your build to begin.
PLEASE NOTE: Be sure your

computer’s clock is set correctly. The
timer will calculate start time based on
this clock.
3. If the Warning Window appears, recheck

either the powder available in the feed piston
or the build piston as instructed. After you
correct the problem, choose ‘’Remeasure.”
You may chose to print even when this
warning is given by pressing ‘Go Ahead’.
4. The Z402C System will commence printing

your part.
During printing, the Z402C System Software

will display the progress of the print and will
monitor the key operating characteristics of
the Z402C Printer.

5. After completion of your build, the System

Software will display a dialog box containing
information about print time, time completed,
and number of pixels used.
5 POST PROCESSING THE PART
5.1 REMOVING THE FINISHED PART

After the build is complete, remove the finished parts from the build box as follows:
1. Wait approximately ten to fifteen minutes to ensure that the uppermost layers of
the starch based model have had a chance to dry. With plaster-based models,
the models will be easiest to remove from the powder bed if left in the bed for an
30-60 minutes after printing before removing the model from the build bed.
Depending on wall thickness, plaster-based
models may take up to four hours to achieve
full strength.
2. Take the machine offline by pressing the

Online Button.
3. Move the Gantry to the Feed (left) end of the

deck by pressing the Spread Button.
4. Lift the Top Cover.
5. Vacuum up any powder spilled on the deck.
6. Place a tray on the deck to the right of the Build

Box.
7. Take a moment to look at the computer screen

and determine exactly where parts lie in the
build box.
8. Without raising the build piston, begin vacuuming powder out of the build box.
Hold the end of the hose on a 20° to 30° degree angle over the powder so the
hose inlet is 1/4” to 3/8” above the surface of the powder. This generates
enough of a draft to lift loose powder without shifting parts.
9. Vacuum powder away from the buried parts, and clean powder out of the
margins against the walls of the Build Box.
10. To gain access to the sides of the parts, raise the Build Piston by holding down
the Build Up button.
WARNING: When performing any vacuuming operation, use the vacuum provided as part of the
Z402C System. Vacuuming powder can generate static electricity, and use of a non-grounded
vacuum will create static charges, which may affect the operation of the Z402C System and harm
the operator.

5.2 DEPOWDERING THE PART

1. Place parts inside depowdering unit.
2. Using the compressed air system included in

the Depowdering Station, remove any excess
powder that remains in any concave surfaces.
TECHNICAL TIPS….
The air pressure on your Depowdering Station is adjustable. For bulky parts, turn the air
pressure up. For more delicate parts, turn the air pressure down.
5.3 DRYING THE PART

To infiltrate parts with wax, the parts must be hot and dry. Preheat part at 165 degrees Fahrenheit in
the Automated Waxer or in a drying oven, remembering that drying time and part wall thickness are
directly related. If the average wall thickness is ¼”, then the part should be in the drying oven for
fifteen minutes. If average wall thickness is ½” inch, the part should be in the drying oven for ½ hour.
Use the chart below as a guide.
Average Wall Thickness Drying Time
1/8 inch 8 minutes
1/4 inch 15 minutes
1/2 inch 30 minutes
1 inch or greater 60 minutes
For instructions on how to use the Automated Waxer, please refer to the Waxer User Manual.
5.4 INFILTRATING THE PART

The parts can be infiltrated with a variety of materials to produce a range of material
properties. As an early stage design tool, it may not be necessary to infiltrate the parts at all.
If you wish to use the parts for focus groups or to send to vendors, you may wish to infiltrate
with resin, a two-part epoxy or other material for greater durability and longer life. For
information on other possible infiltration materials call us at Z Corporation, or visit our website
at www.zcorp-users.com
5.4.1 TO INFILTRATE THE PART USING RESIN:
1. Read and understand the Safety Information on the resin container label.
2. Dry the part as outlined in Section 5.3, Drying the Part.
3. In a well-ventilated area, place the part on waxed paper or on another non-stick

surface.
4. Wear gloves to prevent the resin (and other things) from sticking to your fingers!
5. Apply a thin coat of resin to the entire part by gently squeezing the bottle and
letting the resin drip onto the part.
6. Once the entire part is coated, let it dry for 45 minutes to one hour. To stop the
part from sticking to the wax paper, pick it up and move it every ten minutes until
dry.
7. Once the part is dry, it can be sanded to improve the surface finish (250 grit
sandpaper works best). This operation should be performed while wearing a
dust mask.
8. To further improve the surface finish, the part can be waxed or painted. To wax
a part infiltrated with resin, the part must be heated at 165 degrees Fahrenheit
for one to three minutes before waxing.
PLEASE NOTE: Carefully read the Material Safety Data Sheet for resin before use.

6 ADVANCED USER FEATURES
6.1 ORIENTATION FOR SPEED

Parts oriented with their largest dimension along the y or “fast” axis (print heads direction of travel),
next longest along the x or “slow” axis (gantry direction of travel) and shortest dimension along the z-
axis will print the fastest.
Because speed is the most important feature for the majority of our customers, the System Software
will automatically position parts with the shortest dimension along the z-axis unless this feature is
disabled in the ‘User Preferences Dialog Box’ (See section 2.11).
6.2 ORIENTATION FOR STRENGTH

In Section 1.1.2, How it Works, we explain that part features that lie in the x-y plane will be stronger
than those aligned along the z-axis. If a part has a particularly delicate feature, especially one
shaped like a thin rod, you might find aligning that feature in the x-y plane to be most successful.
6.3 ORIENTATION TO PREVENT WARPING

Very thin planar part features printed in starch-based powder may warp if they dry unevenly or are
excessively heated (this problem will not occur with plaster-based powder). Thin, planar features
aligned along the z-axis will dry more evenly than those with thin planar features that lie flat along the
top of the build box. Also, be careful when drying parts with thin planar features in the drying oven.
We find that thoughtful positioning and limited drying time effectively control warping in starch-based
powder.
7 MAINTENANCE
Maintenance Steps Frequency
1. Change Print Heads When Needed
2. Flush Binder Bi-Weekly
3. Lubricate Fast Axis Weekly
4. Vacuum Filter After Every Build
5. Clean Carwash Before and After Each Build
7.1 CHANGING THE COLOR PRINT HEAD
WARNING: Do NOT touch or contaminate the gold contacts on either the print heads or
the carriage with your fingers. Avoid spilling binder on the contacts. If you do get binder or
anything else on the gold contacts, clean them with an alcohol swab.
If the print becomes faint or begins to print unevenly replace the print head as follows:
1. Make sure the printer is online and the top cover

is closed. From the ‘Service’ menu, select
‘Change Print Head’.
2. The front panel lights will flash rapidly and the

gantry and print head will move into position.

3. Although there are no serial numbers available

with the color print head used on the Z402C
System, we recommend that you input a series of
six numbers in the Serial Number box. These
numbers will be used when logging all builds
printed with this set of print heads. (We
recommend using the date as the series of
numbers.) The software will not accept letters or
symbols.
4. Wait for the printer to finish moving and the front

panel lights to change to slowly blinking. This
indicates that it is safe to remove the print head
from the carriage.
5. Open the top cover of the printer and place the

new cartridge on the top deck of the printer near
the carriage.
6. The Z402C 3D Printer uses a Canon BC-21e

color BJ print head. Remove the print head from
the packaging. Remove the two gray ink
cartridges labeled BCI-21 Color and BCI-21 Black
by pulling on the tabs at top of ink cartridge.
These should be discarded. They are not used by
the Z402C 3D Printer.
7. Lift the green lever and remove the old print head
from the carriage.
8. Lay it on the deck next to the new print head.
9. Slide the color binder reservoir out from the old

print head by pulling on the groove at the top of
the binder reservoir.
10. Immediately insert the color reservoir into the left

side channel of the new print head. The reservoir
should snap into place.

11. Repeat the same procedure, placing the clear

binder reservoir into the right side channel of the
new print head. Discard the old print head.
PLEASE NOTE: Make sure hoses are

not twisted. If the hoses bind up, they
may pull on the carriage and cause
premature print head failure.
12. Remove the orange tab and tape from the

bottom of the print head and discard.
13. Activate enclosed swab by removing the cap and

crushing the plastic casing.
14. Wipe the contact on the carriage.
15. Wipe the contacts on the print head.
PLEASE NOTE: Check again that the

hoses are not twisted. If the hoses bind
up, they may pull on the carriage and
cause premature print head failure.
16. Wait a few seconds for the alcohol to dry. Then,

insert the new print head into the carriage,
checking to make sure the tubes are not twisted.
Lower the green lever to latch the print head in.
17. Close the cover and press the ‘Feed Up’ button
once. The printer will rezero, and fill and prime
the print head automatically. After this fill cycle,
the machine will shut itself off and restart. The
cycle is complete when the machine comes
online. Press the ‘Done’ button on the System
Software dialog box.
18. Run a stripe test to ensure that all the jets and
colors are operating properly. Spread an even
layer of powder onto the build piston. Then select
the ‘Stripe Test’ option in the ‘Service’ menu.

19. If the stripe test does not print well all colors will
not look like a solid stripe. Choose the ‘Prime Print
Head’ option under the Service menu and then
run the stripe test again.
7.2 CHANGING MONOCHROME PRINT HEADS
WARNING: Do NOT touch or contaminate the gold contacts on either the print
heads or the carriage with your fingers. Avoid spilling binder on the contacts. If you
do get binder or anything else on the gold contacts, clean them with an alcohol swab.
1. The Printer should be online. From the

‘Service’ menu, select ‘Change Print
Head’.
2. Type in the number found on your print
head into the serial number box.
This number will be used to create a file
name for automatic data logging.
3. Make sure the Printer is online and the
top cover is closed. Press the ‘Start’
dialog box button to begin the process.
The front panel lights will flash rapidly and
the gantry and print head will move into
position.
4. Wait for the Printer to finish moving and

the front panel lights to change to slowly
blinking. This indicates that it is safe to
remove the print head from the carriage.
5. Remove the cap from the new print head.
The print head is filled with clear binder
for storage. Open the top cover of the
Printer and place the new cartridge on the
top deck of the Printer near the carriage.
6. Remove the old print head by lifting up on

the green lever. Take out the print head
and unscrew the blue retaining ring. Lift
the feed tubes out of the print head.
7. Without removing the fluid from the new

print head, insert the feed tube into the
new print head. Orient the fitting as
shown; try to avoid tangling the feed and
return tubes. Make sure the metal insert is
secure on the print head, then slide the
retaining ring down and gently screw it on.
8. Clean contacts on both the print head and

the carriage with the alcohol swab
provided with your print head.

9. Remove the orange cap and tape from

the face of the print head.
10. Insert the print head into the carriage.

Lower the green lever to secure the print
head.
11. Close the top cover and press the ‘Feed

Up’ button once. The Printer will rezero,
then fill and prime the print head
automatically. After this fill cycle, the
Printer will shut itself off and restart. Once
the Printer has come back Online, press
‘Done’ on the System Software dialog
box.
7.3 FLUSHING THE BINDER

If you will not be using your Z402C 3D Printer for more than two weeks, it is good practice to flush the
binder out of the fluid system with distilled water as follows:
1. Pour all the primary colored binders back into their

original containers.
2. Pour distilled water into the color binder reservoirs.
3. Then change the gallon of clear binder with

distilled water.
NOTE: If you will continue to use the printer in

monochrome mode, you do not need to replace
the gallon of clear binder with distilled water.
Replace the gallon only if the printer will not be in
use

4. With the printer online. Choose the ‘Flush Binder’

option under the ‘Service’ menu.
5. Press and hold the ‘Feed Up’ and ‘Build Up’ button
down together for approximately 30 seconds.
Once you hear a beep, remove your fingers from
the buttons. The Printer will flush the binder
automatically. Flush the binder for approximately
five minutes. Then press ‘Online’ to complete the
flush process.
REMEMBER: When printer is ready to be used again, refill the binder reservoirs with Z Corporation binder
and repeat the “flush” system process.
7.4 GREASING THE FAST AXIS

Over the coarse of printing, powder may adhere to the fast axis causing friction in the movement of
the carriage. Greasing the fast axis weekly will ensure the fast axis does not dry out and enable
smooth movement of the carriage.
1. Turn power off.
2. Remove print cartridge from the print head

holder by lifting green lever and removing print
cartridge. Do not remove feed line from
cartridge.
3. Push green lever back down to the secure

position.
4. Note the small circle in the center of the gray plate in the print head holder.
Insert head of grease tube into hole and apply one quick squeeze of grease
found in your tool box.
5. Move print assembly back and forth on gantry to evenly distribute grease. You
will be able to see the grease on the print assembly (fast axis) rail.
6. Replace print cartridge in the print head holder and secure by depressing green
lever.
7.5 CHANGING BETWEEN COLOR AND MONOCHROME ADAPTERS

1. Shut off the printer.
PLEASE NOTE: If printer will not be

used in color mode for a while,
flush the colored binder lines with
distilled water before shutting off
machine. For more information, see
Section 7.3, Flushing Binder.
2. Disconnect both screws from the color or

monochrome adapter. (Color adapter shown in
picture.)
3. Remove the print head from the carriage.

4. Take the color (or monochrome) print head and

store in a resealable bag. (Color print head shown
in picture.)
5. Take your monochrome (or color) adapter and

insert the two screws into the printer assembly.
(Monochrome adapter shown in picture.)
PLEASE NOTE: Do not

overtighten the screws.
6. Insert a NEW print head into the carriage and

secure by pushing down on the green lever.
7. Turn the power on and hold down the ‘Online’

button until the carriage moves. The printer will
emit two beeps and followed by another two
beeps when changing from color to monochrome.
If changing from monochrome to color, the printer

will emit two beeps followed by three beeps.
6. In the ZCorp System Software, choose “Change

Print Head” under the Service Menu. Enter the
serial number and click “Start.” Without changing
the print heads again, click “Done.” This will create
a new log file for the new print head.
7.6 LOGGING YOUR BUILDS

Automatic logging saves build job statistics to a text file when enabled. To record build date, time,
volume and other important information about your builds check the ‘Use Log File’ option in the 3D
Print dialog box.
Build Date Time Job Pixels Fed Prime DSize DSDEV Error Max Min Pre Vol Area Shell Core Thickness Name
9/17/2001 87 3.78e+008 50.00 14.00 132.49 39.91 13 80 77 77 5.37 66.72 2.25 1.00 0.0040 TNO_Color_Pallette_8.13.00.ply
9/17/2001 96 1.86e+008 19.00 12.00 82.05 11.66 0 81 75 75 2.36 23.68 2.25 1.00 0.0040 GREEN.ply
9/17/2001 46 6.14e+006 7.00 12.00 0.00 0.00 0 75 74 74 15.04 106.05 2.25 1.00 0.0040 Porsche_Color1 FANCY.ply
9/19/2001 105 1.87e+008 34.50 36.00 115.86 18.43 0 79 74 74 1.77 8.24 2.25 1.00 0.0040 grey_cylinder.ply
9/19/2001 2 1.12e+006 0.00 1.75 0.00 0.00 0 79 74 74 1.48 27.82 2.00 1.00 0.0040 Chain.stl
9/19/2001 45 9.95e+007 34.50 51.25 0.00 0.00 0 77 74 74 1.48 27.82 2.00 1.00 0.0040 Chain.stl
9/19/2001 86 1.26e+008 26.50 38.00 0.00 0.00 0 75 74 77 0.19 7.94 2.25 1.00 0.0040 bool5.ply
9/21/2001 140 6.49e+008 71.00 18.00 102.23 23.96 0 88 79 79 9.87 100.03 2.25 1.00 0.0040 2_TNO_Color_Palette.zec
Above is an example of the log file for the Z402C Printer. There is a log file for each COM port or
connection used. The log files can be found in the directory “C:\Z402 Records\Print Logs”. They are
tab delimited files for easy import into a spreadsheet.
The columns are as follows:

Build Date: The desktop computer’s date when the job was started.
Time: Time to complete printing in minutes.
Job Pixels: Total number of pixels fired during the job
Note: pixels are not logged for print head purging between jobs.
Fed: Approximately how much binder was fed during the job, in milliliters.
Prime Approximately how much binder was used for pressure priming the print heads.
Dsize Does not apply.
DSDEV Does not apply.
Error If the job was terminated with an error code, it will be recorded here.
Max The maximum head temperature during the last layer of the build.
Min The minimum head temperature during the last layer of the build
Pre The print head temperature just before printing a stripe.
Vol Part volume
Area Total printed area
Shell Shell saturation
Core Core saturation
Thickness Layer thickness
Name File name for the job.
In the Z402C Printer a new log file is started for each print head. The serial number inputted into the
‘Change Print Head’ dialog is used as part of the file name.

8 TROUBLESHOOTING
8.1 THE BINDER SOLUTION IS BEING APPLIED IN ERRATIC STRIPES

If the binder appears to be applied in fragmented stripes, check the following:
1. Rinse the squeegee clear of any debris.
2. Make sure binder supply is full.
If this does not correct the problem, your print heads may be worn out. Replace the print
heads as outlined above in Section 7.1 and 7.2.
8.2 THE SYSTEM SOFTWARE FREEZES DURING USE

Exit the System Software by pressing Ctrl-Alt-Delete and choosing End Task from the Task
Manager, then restart the software.
8.3 THIN PLANAR PARTS ARE WARPING

In general, warping is caused by uneven drying of parts. By adjusting print orientation and
drying time, warping can be minimized. You can take steps to ensure that drying is occurring
evenly by:
• Reorienting your part within the build box. If a thin planar surface of a part lies flat
along the top of the build box, the broad exposed area may dry unevenly and bow
towards the top. Reorient the part so that the thin planar surface lies perpendicular
to the top of the build box.
• Ensure that you are not over-drying the part. Reduce drying time to a minimum.
Refer to the guide in Section 5.3, Drying the Parts to select a drying time.
• Decreasing the layer thickness without proportionally changing the minimum and
maximum saturations will over-saturate the part causing it to warp and may also
cause individual layers to curl during printing.
8.4 NOTHING HAPPENS WHEN I TRY TO PRINT

• Is the serial cord connected properly?
Remove the cord and carefully reinstall ensuring that you tighten the screws only after
making sure that it is tight in the socket. Do NOT over tighten the screws.
• Are any of the lights on the control panel illuminated?
If the error and power light come on but nothing happens after that, shut the machine off and
turn it back on again. The machine should come online. But if it does not, please call the
Service Department.
8.5 MY STARCH-BASED PARTS ARE UNUSUALLY “CAKEY”
• Is the saturation too high?
If your parts (especially bulky parts) are unusually difficult to depowder, too much moisture
has moved from the part into the immediately surrounding powder. You may have the
saturation levels set too high for this type of part. Using a lower maximum setting will fix this
problem.
• Was the part left in the bed too long?
If the part is delicate and requires a higher maximum setting, it will be helpful to remove the
part from the bed as soon as possible after the completion of the build. Using the delay timer
feature will allow you to cause the build to end at a convenient time.
8.6 PARTS ARE UNUSUALLY WEAK OR CRUMBLY
• Is the data file known to be without errors?
If the *.stl file is not near perfect you will have problems printing the part. Open the file in the
Z Corp. System Software and inspect it layer by layer to ensure there are no gaps and the
part does not overlap other parts.
• Is there enough binder in the feed bottles?
When you start the build, a reminder box will pop up asking you to check if there is enough
binder in the feed bottles. If you plan to start a large build make sure binder bottles are full.
• Are the parts dry?
If plaster parts are not yet dry they may seem weak or crumbly. Allow more time for the part
to dry, or put it in an oven for 30 minutes at 120-140F. For plaster parts, this may be done
even before depowdering.
8.7 PRINTER LOOKS LIKE IT IS PRINTING, BUT IS NOT LAYING DOWN

BINDER
As you begin printing, carefully watch the Z402C Printer to see if it is printing normally. It may
be that the print head are not properly seated in the carriage. This can cause a bad
connection with the temperature sensor and the print head will overheat. Prolonged periods of
attempting to print without binder flow will damage the print head. You will need to replace the
print head.

9 Z402C SYSTEM DETAILS
9.1 DESCRIPTION OF REAR I/O PANEL

Power Input Diagnostic Diagnostic
Video Connector Keyboard Connector
Main Power Fuse Serial Input

Connection
Serial Port Connection: This is an RS-232 serial port for data transfer to and from the Z402C
System Software. The Z402C System uses 115k baud and has the same pin out as a standard PC
compatible computer. The connection to the Windows computer running the Z402C System Software
requires a 9 pin to 9 pin null modem cable (also known as a ‘laplink’ cable). This cable is supplied
with your Z402C System; if a replacement is required, order Z Corporation part #10267.
Diagnostic Connections (Video and keyboard): These connections are used while servicing your
Z402C System. Nothing should be connected to them in normal operation. The diagnostic video
connection is standard VGA output video. The keyboard connection is PS/2 style compatible.
9.2 SYMBOLS USED

The following symbols are used on the Z402C 3D Printer:
This is the international symbol for ‘standby power’. It is used on the Z402C 3D
Printer power switch. The Z402C 3D Printer is partially powered as soon as you
plug it in. The power switch is momentary contact and toggles the machine from
idle mode to full power on mode.
This is the international symbol for ‘warning’ or ‘caution’. It indicates the need to
consult your manual for further information. This symbol is in two places on the
Z402C 3D Printer.
1. It is used on the rear, lower left to call your attention to the fact that only
authorized personnel should open the Z402C 3D Printer rear cover. None of
the normal operation and maintenance procedures described in this manual
require you to remove this cover.
2. It is used on the front cover next to the handle to call your attention to the fact
that you should be careful not to drop the cover when closing it. Due to the
weight of the cover and the force of the air springs, it is possible to pinch or
strain a finger or hand if it were to get caught between the bottom of the cover
and the front slow axis rail.

9.3 SYSTEM SPECIFICATIONS
Z402C 3D Printer Dimensions: 29 x 36 x 42 inches high (74 x 91 x 107cm high)

Z402C 3D Printer Weight: 300 lbs. (136 kg)
Power Requirements and Operating Conditions at Site of Installation:

• Power Requirements: 115 or 230V (2.5 or 2 amps)
• Operating Conditions: 68 to 85ºF, 20 to 50% Relative Humidity, non-condensing.
Lithium Battery: Internal to the Z402C 3D Printer is a lithium coin cell type battery. This may be
any one of the following: Type: CR2032, either Maxell, Panasonic, Renata, Sanyo or Sony.
PLEASE NOTE: This battery is not in a user accessible area and is not user replaceable.
The expected lifetime of the battery is in excess of five years. Replacement will be handled
by your Z Corporation customer service representative.
FCC Notice: Note: this equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction manual,
may cause harmful interferance to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be required
to correct the interference at his own expense.
CENELEC Class A Warning: Note: this equipment has been tested and found to comply with
the limits for a Class A digital device, pursuant to EN 55022. Class A devices are for office
and light industrial environments, and are not generally suitable for home use.
WARNING: This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
9.4 MATERIAL STORAGE PRECAUTIONS

Binder Solution: Store in cool, dry place, away from sun. Keep tightly capped.
Powder: Store powder on pallets in a cool, dry, ventilated area away from sources of heat,
moisture, and incompatible materials. Keep containers tightly closed.
Wax: Keep containers closed when not in use. Store in a cool, dry, well ventilated area.
Resin: To extend shelf life store in cool (less than 5 degrees Celsius), dry, and dark place.
Shelf life for resin is 6 months.

10 INDEX
3 J
3D Print Setup, 19 Justify, 17
A L
Anisotropic Scaling, 21 Logging Your Build, 48
For Specified Part, 18
M
B Massachusetts Institute of Technology, 6
BLD Build Files, 12 Material Storage, 54
C O
Cakey Parts, 50 Opening a File, 12
Changing Adapters, 46
Changing Color Print head, 36
Changing Monochrome Print Heads, 41
P
Changing Powder Parameters, 20 Part infiltration, 34
Checking Fluid Levels, 27 PLY Files, 12
Choosing a Layer Thickness, 21 Post Processing, 32
Color, 17 Powder Overflow Bag, 28
Control Panel, 24 Prime Print Heads., 23
D R
Delay Timer, 30 Removing finished parts, 32
Depowdering Parts, 33 Report Capabilities, 23
Drying the Parts, 33 Rinsing the Carwash, 27
Rotate, 16
E
Estimating Time to Build, 18, 19
S
Saturation Values, 21
Save Powder Type as Default, 20
F Save Printer as Default, 20
Filling the Feed Box with Powder, 25, 26 Scale, 16
Flush Binder, 23 Select Parts, 15
Flushing the Binder, 44 SFX Files, 12
Shelling, 7
Speed, 35
G Spread Button, 32
Get Piston Levels, 23 Squirt Squeegee, 23
Greasing the Fast Axis, 45 STL Files, 12
Strength, 35
Stripe Test, 23
I Striping of Binder Solution, 49
System Specifications, 53
Importing a File, 13
T Z
Toggle Roller on/off, 23 Z Corp System Software, 10
Translate, 15, 16 3D Print Setup, 19
Troubleshooting, 49 Color Monochrome Parts, 17
Cross Section, 14
Estimating Build Time, 18, 19
U Fast Rendering, 22
Upload New Firmware, 23 Import, 13
Upload New Printer Configuration, 23 Justify, 17
User Preferences, 21 Logging Your Build, 48
Main Window, 11
Mirror, 16
V Opening a File, 12
Viewing Cross Section, 14 Orient Parts for Fastest Print Times, 22
VRML Files, 12 Part Statistics, 18
Importing, 13 Powder Parameters, 20
Mesh Resolution, 13 Rotate, 16
Texture Threshold, 13 Save Slice Data, 21
Scale, 16
Select Parts, 15
W Translate, 15, 16
Unit of Measure, 13, 21
Warping, 35, 49 User Preferences, 21
Weak Parts, 50 Installation, 10
WRL Files, 12 ZBD Build Files, 12
ZCP Files, 12
ZEC Files, 12

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Z402C System User Manual

ZTM402C 3D Color Printer

Software Version 5.1.40

Copyright©2001 Z Corporation Part Number 09501

1.1.2 HOW IT WORKS ......................................................................................................6

1.2 PRINTING A PART OVERVIEW............................................................................9

1.2.2 STEP 2: PREPARING THE 3D PRINTER ...............................................................9

1.2.3 STEP 3: PRINTING THE PART ...............................................................................9

2 THE ZCORP SYSTEM SOFTWARE..........................................................................10

2.7 TRANSFORMING THE PART .............................................................................15

2.10.2 CHANGING POWDER PARAMETERS .....................................................................20

2.11 SETTING USER PREFERENCES.......................................................................21

3.2.2 RINSING THE CARWASH .........................................................................................27

3.2.3 CHECKING FLUID LEVELS ..................................................................................27

3.2.4 CHECKING OVERFLOW VACUUM BAG ..................................................................28

3.2.5 PUTTING THE MACHINE ONLINE ............................................................................28

4 PRINTING THE PART ........................................................................................... 29

6 ADVANCED USER FEATURES................................................................................ 35

2 Z Corp Service (781)852-5050/(877)88-ZCORP

Figure 1. The Printing Process............................................................................................................... 6

Figure 2: The Z402C System Shelling and Infrastructure Features....................................................... 7

Figure 3: Illustration of Z402C System Print Orientations ..................................................................... 8

Figure 4: The Main System Software Window ..................................................................................... 11

Figure 5: Carwash Detail ..................................................................................................................... 27

4 Z Corp Service (781)852-5050/(877)88-ZCORP

1 YOUR Z402C SYSTEM

8. Troubleshooting. This section offers some troubleshooting tips.

1.1.2 HOW IT WORKS

Step 4: As the gantry traverses Step 5: The feed piston moves up

Figure 1. The Printing Process

6 Z Corp Service (781)852-5050/(877)88-ZCORP

Other interior areas

Exterior walls printed at

Figure 2: The Z402C System Shelling and Infrastructure Features

z-axis Less Strong

8 Z Corp Service (781)852-5050/(877)88-ZCORP

1.2 PRINTING A PART OVERVIEW

1.2.1 STEP 1: IMPORTING THE FILE

1.2.2 STEP 2: PREPARING THE 3D PRINTER

1.2.3 STEP 3: PRINTING THE PART

2 THE ZCORP SYSTEM SOFTWARE

2.1 RECOMMENDED SYSTEM

• Microsoft Windows* NT 4.0 or Windows 2000 Professional operating system

• 256 MB of RAM or more

• True Color Graphics

• 1024 X 768 pixels (or better)

• Graphics card accelerated for OpenGL

2.2 INSTALLING THE ZCORP SYSTEM SOFTWARE

3. Read the licensing agreement carefully.

*Microsoft Windows is a registered trademark of Microsoft Corporation.

10 Z Corp Service (781)852-5050/(877)88-ZCORP

2.3 MAIN WINDOW

Layer Count Height from

Figure 4: The Main System Software Window

Save Mirror Ten Layers Up

New 3D Print Copy Rotate One Layer Up Selection List

Open 3D Print Setup Translate Justify Ten Layers Down

Import Scale One Layer Down About

2.5 OPENING A FILE

Open. When you initially open the System