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Z406 System User Manual Z Corporation
www.zcorp-users.com 57
6.3 POLYESTER RESIN
Many types of transportation equipment require the use of
geometrically complex ducting for heating, ventilation and
air conditioning (HVAC) of the interior space. Prototype
ducting produced on the Z Corporation 3D Printer can be
used for form and fit testing, as well as air-flow testing
across a range of temperatures and humidity. The parts
can be prepared to have sufficient toughness and
resiliency to survive bench testing and functional testing
in an automobile.
The basic parts are produced in zp15e starch powder. It
is recommended to print a sample part first to practice all the process steps if you are a new user.
This step is worthwhile, especially when dealing with large parts because it will help to minimize
waste and to increase efficiency.
Infiltration Details
This application requires use of a marine-grade, thixotropic, low viscosity polyester resin. This resin
is widely available at hardware stores and industrial supply centers. Some common manufacturers
are Evercoat, Fibre Glast, and/or FiberLay.
Materials Required
• Polyester resin and catalyst
• Plastic container for resin
• Disposable brushes
• Fiberglass mat (optional) Kevlar, E-, S-glass mat
• CA or equivalent glue for joining assemblies
• Personal Protective Equipment (Gloves, Eye protection, Apron)
Application Time
Highly dependent on part 5-30 minutes
Application Technique
Applied by brush
Working Life
15 Minutes
Set Time
4 hours (minimum)
Environmental Setting
Please read the Material Safety Data sheets for these products carefully. This operation should be
conducted in a well ventilated area with protective eyewear.
Instructions:
1. Depowder and air dry parts for a minimum of four hours.
2. Apply the resin by brush to individual parts per the material’s directions and allow them to
cure.
3. Sand as needed and check any critical dimensions. Finally, use cyanoacylate (resin) to
construct any multi-part assemblies as required.
4. Apply polyurethane resin.
- Z406 System User Manual 1
- September 2004 1
- Z Corporation 1
- Table of Contents: 2
- APPENDIX I 5
- Table of Figures 6
- 1 YOUR Z406 SYSTEM 8
- 1.4 Z406 SYSTEM COMPONENTS 14
- 1.6 USEFUL TIPS 15
- 2.1 HARDWARE CONTROLS 18
- Technical Tip 19
- Wash Fluid Binder Solution 26
- Color Binder 26
- Solution 26
- Waste Fluid 26
- 3 USING ZPRINT SOFTWARE 29
- 3.2 ORIENTING THE PART 30
- 3.4 PRINTING THE BUILD 33
- 4 POST PROCESSING THE PART 34
- 4.2 DEPOWDERING THE PART 35
- 1. Turn on air compressor 36
- 2. Turn external vacuum on 37
- Press down on 38
- ON/OFF Switch 40
- Suction Control 40
- Air Pressure 40
- 4.3 DRYING THE PART 45
- 5 INFILTRATING THE PART 49
- 6 APPLICATIONS 54
- 6.2 PAINTING PARTS 56
- 6.3 POLYESTER RESIN 57
- 6.4 ELECTROPLATING 58
- 6.5 WATER TRANSFER PRINTING 59
- 6.6 INVESTMENT CASTING 62
- 6.7 FLEXIBLE PARTS 64
- 6.8 THERMOFORMING 65
- 6.9 RTV MOLDING 67
- 7 MAINTENANCE 73
- All targets are 80
- 7.3 COLOR ALIGNMENT 82
- 7.4 FLUSHING THE BINDER 84
- 7.5 GREASING THE FAST AXIS 84
- 7.6 GREASING THE SLOW AXIS 85
- 7.7 OILING THE SNOWPLOWS 86
- 7.8 CLEAN UNDER THE GANTRY 86
- 9 CHANGING MATERIAL SYSTEM 92
- Change Powder Type 94
- Recommended Saturation 95
- 9.1 USING ZCAST POWDER 97
- 9.2 USING ZP250 POWDER 100
- Use a paper 104
- 10 TROUBLESHOOTING 106
- 11 Z406 SYSTEM DETAILS 110
- 12 SYMBOLS USED 111
- 12.1 SYSTEM SPECIFICATIONS 112
- 12.3 ERROR CODES 113
- 13 INDEX 117
- 501 Direct 119
- Metal Casting 119
- 1 Introduction 122
- 2 General Safety 123
- 2.1 Safety Precautions 123
- 2.2 Safety Symbols 123
- 2.3 Safety Instructions 124
- PREPARING AND BAKING MOLDS 126
- POURING MOLTEN METAL 126
- FINISHING 127
- 3 ZCast Advantages 128
- 3.1 The Material 128
- 3.2 Design Freedom 128
- 4 Locating a Foundry 130
- 4.1 Foundry Trial Parts 130
- Direct Pour 132
- Shell Method 132
- Combination Method 133
- 5.3.1 Direct Pour Method 134
- 5.3.2 Shell Method 135
- 5.4 Printing Your Model 136
- 5.5 Conclusion 136
- 6.1 Direct Gating 137
- 6.3 Shelling your Mold 137
- 6.4 Stiffening Ribs 138
- 6.5 Venting 138
- 6.5.1 Venting Cores 139
- 6.5.2 Venting the Mold 140
- 6.6 Parting Lines 143
- 6.8 Mating Surfaces 144
- Rubber Hose 144
- 6.9 Geometry Guidelines 145
- 6.12 Chills 146
- 6.13 Printing 146
- 6.13.1 Machine Settings 147
- 7 Mold Preparation 149
- 8 Pouring Metal 151
- 9 Material Handling 152
- 9.1 Storage 152
- 9.2 Disposal 152
- 9.3 Powder Recycling 152
- 10 Finishing 153
- 10.1 De-molding 153
- 10.2 Secondary Operations 153
- 10.3 Ovens 153
- 11 Foundry Consumables 154
- 11.1 Sand Casting Glossary 155
- 11.1.4 Pouring Cup 156
- 11.1.5 Sprue 156
- 11.1.6 Well 156
- 11.1.7 Runners 156
- 12 Conclusion 157
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