Implementation of the EvoDent DLP E-120 3D Dental Print Solution

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1 The EvoDent DLP E-120 3D Dental Print Solution provides dental offices and laboratories an easy to use and accurate solution for printing various types of 3D models inhouse. To insure a successful implementation and continual operation, please review the following to insure all the component required for your implementation and daily operations are in place and you understand the workflow. If you have any questions after reading this document or during the usage of your EvoDent solution, feel free to call EvoDent s Customer Care Department at The EvoDent DLP E-120 3D Dental Print Solution consist of the following: 1. EvoDent DLP E-120 3D Printer and accessories 2. EvoDent UltraSonic Cleaner, with 3 glass beakers and caps 3. UnionTech Post Print Curing Unit 4. UnionTech s PolyDev Nesting Software Window 10 compatible Additional items required for implementation and continual operation 1. A standard CAD-CAM Workstation operating MS-Windows 7 or higher, or like workstation, where the Polydev Software can be installed and utilized. This software should have access to the EvoDent DLP E120 printer via the network. It does not need to be in the same room, just the same network. 2. An Ethernet network providing WIFI or cable access to the Workstation and 3D Printer (cable preferred) a. Internet connectivity required for software updates 3. Alcohol used to clean excessive resin from model after printing. Recommend 96 Proof or higher. (Ethyl Alcohol is recommended for a better clean, but Isopropyl Alcohol may be used) 4. Paper towels to set build platform on after print and clean resin. 5. Latex Gloves provided with E Microfiber or soft towels to set Resin Tank on whereby protecting the bottom glass of the tank. 7. A solid counter or table to support the EvoDent DLP E-120 3D printer, as well as the Curing Unit. 8. Disposable Super Fine Paint Funnels used to filter resin when pouring back into bottle or cleaning tank. 9. Medium Size Plastic Funnel used so disposable funnels maybe inserted into when pouring. 10. Resin Model, Casting, Surgical Guide, Ortho, etc. Whatever resin you want to print 11. Access to Compressed Air to clean model after wash and before curing 12. CAD-CAM solution capable of producing SLT files of 3D dental objects (inlab 18, 3Shape, Exocad, etc) The EvoDent DLP E-120 3D Dental Print Solution is designed to be a self-installable. The printer is easy to setup and the software is easy to install and use. The software is shipped with the printer on a USB Drive. Understanding the Standard Workflow of the EvoDent DLP E-120 3D Dental Print Solution 1. Create STL File - The EvoDent DLP E-120 3D Dental Print Solution is integrate into your current digital workflow. After a case is designed and exported/saved to a 3D STL file, the PolyDev software is used to load the STL file and virtually position the object(s), or model(s), on the printer s build platform, ready to be printed. 2. Using PolyDevs Software to create Job file - Once the object(s), or model(s), are position virtually on the build platform, they are saved in a.utk file on the local drive or USB drive or sent directly to the printer. When sending to the printer, the user selects the printer to be used and clicks the paper airplane icon on the screen. During this process, as well as the Save to Disk processes, the PolyDev software slices the objects into various layers, creates a.utk job file and stores the job on the selected printer, ready to be printed. Copyright EvoDent Page 1 of 9

2 3. Inspect Printer and Print Job - Inspect the printer to insure the build platform, resin tank and resin are in place and ready to print, the job is started at the printer by selecting the job by name and pressing the print icon. Depending on the type of job being printed, it may take anywhere from 20 minutes to over an hour to completely. 4. Remove Job from Build Plate - Once the job is printed, the build platform is removed from the printer and the object(s), or model(s), are carefully removed from the build platform using a provided small chisel tool. Caution should be used so not to injure the user when removing. 5. Clean Models - Upon removal, the models are then place into a glass beaker, which it filled with clean alcohol, and inserted into the ultrasonic cleaner for 60 seconds. This is referred to the first wash. After the first wash, the models are placed in a second beaker, which is filled with clean alcohol, and once again inserted into the ultrasonic cleaner for 60 second again. This is referred to as the second wash. Upon completion, an air tool is used to dry the models. The models are inspected to insure all excess resin is remove. 6. Curing the Models - Once the models are cleaned, they are placed in the third beaker which is filled with clean water. The beaker is places inside the Curing Unit where the model(s) will be further cured under UV lighting for a specific amount of time; which is dependent on the type of resin used. (Please note, not all models require being cured in water. Consult your User Guide to insure the resin you are using requires water during the curing process.) Once cured, the models are removed and dried using a soft towel. Any excessive water can be removed from the models using compressed air to blow it dry. The models are now completed and ready to use. Installing the Printer and Components 1. Strong Counter a. Locate a sturdy table, counter or desk which can support the EvoDent DLP E-120 3D Printer and place the printer on the platform. The platform should be low enough to allow a user to easily open and closed the door and access the both resin tank and build platform. 2. Curing Unit and Ultrasonic Cleaner a. The Curing Unit and Ultrasonic Cleaner should be set in an appropriate location based on your workflow. Be careful when unboxing the Ultrasonic Clearer as it includes three glass beakers. 3. Included items packaged with the Printer include: a. Power Cord - Plug the cord into back of the printer and the other end in a standard 120 outlet b. Ethernet Cable - Plug in one side of an Ethernet cable to the network port on the back of the printer and the other side to a wall port, or switch, on the same network segment as the computer with the PolyDev software. c. WIFI Antenna - Attach the WIFI antenna if you plan on using WIFI, otherwise, simply discard it. d. USB Drive includes PolyCom Software e. Removal and Resin Tools. 4. Build Platform a. The printer includes a perforated build platform inside the printer s work area. b. The build platform can be easily removed and inserted. Make sure the build platform is in place before printing by turning the round gold handle at the top. 5. Resin Tank a. The printer also includes a Resin Tank, found in a separate box. The tank is rectangle in shape and has a thick plate of glass as its foundation. Remove the Resin Tank from the box and slide it into Copyright EvoDent Page 2 of 9

3 place inside the printer s work area. Be careful not to place your fingers directly under the glass, leaving smudges or inside the glass, which may damage the inside of the resin tank. Each resin tank has a thin film on the inside of the glass to insure the resin does not stick to the glass during normal operation. (if you ordered more than one resin tank, they will be packaged in separate boxes.) b. You will notice one of the inside corners of the Resin Tank is slightly modified with a small pour spout to allow pouring the resin from the tank back into the bottle when changing resins. You will also notice markings on the opposite side, listing the levels of the resin inside the tank. c. Insert the resin tank, with the pour spout to the back left, by sliding it in at the bottom of the work area. (You may need to turn the sleeve handles, on the right and left, to loosen the guides in order to allow the tank to slide in.) Once the tank is inserted all the way back, lock the sleeve handles down so the tank cannot move. 6. Turn on your Printer a. With the power cord and the Ethernet Cable attached at the back of the printer (or WIFI antenna attached), press the silver button on the front of the printer to turn on the printer. The screen on the front of the printer will light up and you will see the DSCON software. You will note the screen is a touch screen and menu options and selections can be made using your finger. Once the DSCON application is on the screen, the printer is ready to use. 7. The DSCON Software a. The DSCON Software is used to start all print jobs and to perform various maintenance processes. Once a job is submitted to the printer, the file name will be displayed in a list on the screen. You can also submit a job to the printer by saving the job to a file and then using a USB drive to load the.utk job file to the printer. There are two tabs on the main screen. One tab refers to the printer s internal drive and list the jobs stored on the drive. The other tab refers the printer s USB port and list the jobs stored on a connected USB drive. 8. Setup Network Connection and Test the build platform to insure it moves correctly a. Before starting a job on the printer, you will want to run a simple test to insure the build platform moves up and down. b. VERY IMPORTANT Please note each resin tank has a protected coding on the inside glass, which should always be protected from scratches. To protect the coding when testing the positioning of the build platform, fold a sheet of copy paper in half and place the folded sheet in the empty resin tank. c. Once the paper is in place, using the printer s touch screen menu console and select the Option button. Here you will find four options on the left of the screen, Control, Settings, Info and About Us. i. Press the Settings option to insure your network setting are configured. (If you elect to use WIFI, then press the icon to the left of the WIFI IP Address (Blank) to setup your WIFI.) d. Once the Network settings are confirmed, press the Control option to move to the Motion Control and Function Screen. Then press the Home Pos icon, which will move the build platform down onto the glass in the home position. Again, during this test insure that you have a folded piece of 8.5x11 sheet of paper sitting inside the resin tank so the build platform does not rest directly on the glass. Keep in mind, every job starts with the Build Platform at the home position in a tank of resin. e. When the build platform stops moving and rest on top of the paper inside the resin tank, you will see it is at the Home Position. If you desire, you can use the provided feeler gauges to insure the Copyright EvoDent Page 3 of 9

4 spacing between the paper and build platform are tight. After inspection, press the Move Up icon on the screen to move the build platform all the way up to the Rest or UP position. f. If the build platform moved down to the Home Position when you pressed the Home Icon and then moved up to the top when the Top icon was pressed, then it passed your initial test and you are ready to add resin and print your first model. You can now remove the paper from the resin tank. Press the icon arrow at the top left of the screen to move back to the main menu where all the print jobs will be displayed. 9. Adding Resin a. As resin is a polymer, it is recommended to shake, or stir, the resin for a certain amount of time prior to using. The amount of time is dependent on the type of resin itself, so take a moment to review the manufactures recommendation or quick guide booklet. For example, UnionTech s recommend shaking its EvoDent Model Resin for at least five minutes prior to using. Once the resin is shaken, or stirred, pour the resin directly into the Resin Tank. You can find marking inside the resin tank on the back-right side. Pour the resin in the tank up between the 10 and 15 marks. Now your printer is ready to print. Installing and Using the PolyDev Software 1. The PolyDev Software Application can be located on the USB drive which is included with the printer. Copy the install folder from the USB drive to the selected workstation and install the PolyDev software. The software can be loaded on a separate PC or on your current CAD-CAM workstation, running Windows 7 or greater, or a similar workstation. 2. When you open the PolyDev application for the first time, it will require a registration process. You cannot move forward until the software is registered and your PC will require a internet connection to register. You will find your license number on the USB drive in a separate file named, License Key. Copy and paste the license key information into the field and type in the additional requested information. Once completed, press Register and the registration process will be completed. A new splash screen with be displayed. 3. The splash screen requires a printer and material type be selected prior to moving forward. As all resins are tested and certified by UnionTech, all the resins settings are preset and listed. Insure the E-120 Printer is selected as the printer and using the dropdown menu, select the appropriate resin material. Press the Save button. If there is a software update available, you will be prompted to update your PolyDev application at the time. You can update or wait till a later time. (Please note, resin materials are constantly being tested and certified and will be provided automatically via updates.) If, you elect to update the software, you will need to restart the PolyDevs software afterwards. Copyright EvoDent Page 4 of 9

5 4. The PolyDev Application menu consist of four major areas a. Top level Main Menu ribbon pretty much identical to the left side vertical menu b. Left side vertical Main Operational Menu load files, move models, orientate models, add supports, and print the models on the platform c. Top right Magnification and Platform View options changes views of the platform d. File Browser Menu Box - Listing all the file currently in the work area 5. To load one or more models, select the Folder icon located at the top of the Vertical Main Menu a. The model, or models, will appear. 6. With the loaded model selected and highlighted, select the second option Layout on the side Vertical Main Menu and select Automatic Layout. If the bases of the models are easily identified by the application, the model(s) will be placed flat on the build platform and ready to be printed. If the base is not identifiable, press the fourth menu option Orientation, click on the open box to insert an check mark next to the Move to Platform option, select the button Select Base Mode and move your cursor to the bottom of the model and click the bottom of the model. This will move the base flush with the platform. (This example is for models with flat bases, such as full arches or quadrants. Other types of models, such as surgical guides, denture bases, C&B require supports and will not be automatically placed on the build platform. To prepare these types of models, you will want to use the auto-support option under Support option 5.) 7. If you desire to adjust the placement of the model by moving or rotating it, simply select the model and using standard CAD-CAM controls, using your mouse to move the model, or models, on the virtual build platform. 8. Once you have your model positioned on the Virtual Build Platform the way you desire, you are ready to submit your job to the printer. (We recommend using one model initially and using the Automatic Layout until you become more comfortable with the workflows. Again, use option five to print models with structures.) Copyright EvoDent Page 5 of 9

6 Sending the Job to the EvoDent DLP 3D Printer with PolyDev 1. To submit a job to the printer, click the Printer Icon, the sixth option on the Vertical Main Menu. A box will pop up in the center of the screen requesting a name for the job which is to be saved or printed. Enter a name for the job to be printed. The name you assign the job will appear on the screen of the printer after it is sent to the printer. 2. Once the job is named, you will have the option to Local Save or Sent to Printer. Both options creates a.utk job file; which contains all the images to be printed. Saving the job locally, allows you to save the.utk job file to a local or USB drive so it can be loaded on the printer in case there is not a network connection. Otherwise, always select Send to Printer. (If you desire to save the work file, because you need to exit the program and will come back later to complete the work and send the job to the printer, then you should use the Save or Save As options from the top ribbon menu under File. This will create an.evodent work file.) 3. When you elected to send the job to the printer, a Print box appears where you will need to: a. Select the printer which you will be sending the job to print. (If you have multiple printers, all will show up on the screen. Printers which are online will have a green dot next to them) b. Select the Paper Airplane option on the top right section of the printer. i. A new Progress Bar appears at the top center of the application as a.utk job file is being created and sent to the print. Once the job is created, a message with state the job has been sent to the printer. You can now go to the printer and you will see the name of the job on the Printer s touch screen ready to be printed. Selecting and Printing a Job from the Printer 1. Once the job is visible on the printer s screen, touch the job you want to print and press the icon on the bottom right of the screen which indicates, move forward. 2. A new screen will appear, providing information on the job to be printer. Double check the information and when you are satisfied, press the icon to start the job. 3. The build platform will begin to move from the top position in the work area to the home position. Once at the home position, the job will begin and the build platform with move up and down, 50 or 100 microns at a time dependent on the job s settings, until the job is complete. Copyright EvoDent Page 6 of 9

7 Post Print Cleaning 1. Job Completed - When the job is complete, the build platform will move to the top position inside the work area with the printed jobs attached to the build platform. At this point, it is safe to remove the build platform from the printer and remove the models from the build platform. 2. Remove Platform - To remove the platform, simply loosen the build platform by turning the round knob at the top of the platform and slide the build platform forward. 3. Remove Models - As the build platform is wet with resin, and may tend to drip resin, set the build platform down on a paper towel, to reduce the possible of excessive spills, on a sturdy platform from which you can remove the model(s). Then using the provided chisel tool, loosen the model from the platform by gently prying at each corner ever-so-slightly and patiently lifting each area slightly until it falls from the platform. (The effort and patience required to move the model from the platform is dependent on the type of job. As the models are not totally cured, it is important to be patient and lift gently when removing a model from the build platform. It may take a few weeks to get the hang of it, but users are typically motivated to slow down after breaking a few and having to reprint!) Once the model is slightly lifted, it will pop right off the platform. When using supports, the models can be removed from the supports by hand or using a sharp tool to cut the supports. 4. First Clean - Once the models are off the platform, place the models in the first glass beaker which is filled with enough clean alcohol to cover the models. Insure the base of the ultrasonic cleaner, where the glass beaker will sit inside, is appropriately filled with water. Turn the ultrasonic cleaner on for 60 seconds. The excess resin, the resin which was not cured by the 3D printer s projector s UV light, will be washed away. 5. Second Clean it is the same process as the first clean, except the models will be extracted from the first beaker and placed in a second beaker with clean alcohol. The second beaker is place in the water of the Ultrasonic cleaner, again for 60 seconds. 6. Air Dry after the second wash, the models can be place in a paper towel, which absorbs the alcohol and then using compressed air, the models are blown to remove all the alcohol. Afterwards the models are inspected for any excessive resin which didn t get wash. Excessive resin is easily identified as it is shiny. If the alcohol is clean, and of a significant grade (96 proof), the two washes will remove all excess resin. If not, any remaining excess resin will need to be removed manually using a soft cloth or tooth brush. Slightly excessive resin in areas which do not matter is fine, but must be clean in areas where slight distortions can make a difference. (for example, excessive or shiny spot on the inside of a hollow model do not matter, but inside an implant cavity it can affect the fit.) Post Print Curing 1. Now that the models are washed and dried, they can be place in the third beaker, which is filled with enough clean water to cover the models. 2. The beaker is placed in the Curing Unit and the timer is set based on the type of resin used. 3. After the time is reached, the beaker is taken out of the tank and the models are removed, dried and completed. Changing Resins and Cleaning the Tank and Platform When changing resins and having only one resin tank, it is important to drain the existing resin from the tank back into the bottle using a super fine paper paint filter to strain the resin during the pour. The paper paint filter is generally set inside of a plastic funnel to provide support. Filtering the resin will insure any cured particles which could have fallen from a printer model do not find their way into the resin bottle and contaminate the new resin. Copyright EvoDent Page 7 of 9

8 Once the existing resin is removed, the resin tank and build platform must be clean using alcohol. You must be careful when cleaning the resin tank not to scratch the glass. Once clean, the tank can be air dried. The build platform must also be clean with alcohol and dried using compressed air. If there is any residue of resin or alcohol in the tank or on the build platform, if could contaminate the next resin and cause the jobs to fail. Therefore, insure the tank and build platform are clean and dry prior to starting a new job. Caution: Printing Models Flat Against the build platform All model bases which sit flat on the build platform should be designed with ample height to provide strength when being removed from the build platform. If the model is too thin, it becomes difficult to remove from the build platform without breaking. Thin models will need to be printed with supports, printed as a solid model or printed with a solid base, to reduce the possibility of breaking when being removed. In the examples below, one model is too thin and tends to break with removed, while the other model is set to an acceptable height. The average can vary, but a good guideline is generally between 18MM to 22MM on an upper arch from the top of the front tooth to the base. Many of the commercial grade dental CAD-CAM tools (3Shape, inlab 18, ExoCad, etc) automatically create models with appropriate base heights. Yet when using generic non-specific dental applications, such as Meshmixer and others, there is a tendency to slice the base too thin after extruding. So just doubt check to insure your application provide enough height prior to saving or exporting to an.stl file. This will help to insure your model does not break when removing. Additionally, if you are printing a hollow model you will want to insure the thickness of the edges around the bottom of the model are between 2.5MM and 3.0MM. This will insure the model has enough surface to hold the model during printing. Again, most commercial dental CAD-CAM applications do a good job in insuring their hollow feature provide considerably enough width on the edges to insure adhesion to the platform. Most application will allow you to set and modify the width. Lastly, printing dies. Dies can be challenging for all 3D printers, as the bases tend to be small in comparison to the size and weight of the die. Depending on the applications, some dies may require supports and bases to support them. When placing supports on dies, insure the positioning of the supports do not interfere with the fit of the dies. Copyright EvoDent Page 8 of 9

9 Adding Supports Many models will not be able to be placed flat on the build platform to be printed, as their surfaces are not smooth or cannot be distorted by laying on the platform. Such models require Supports. The PolyDevs software allows you to easily add supports to a job manually or automatically. Option Five, Supports, allow you the options to add Bar Supports or Only Baseboard and Edit and Delete Supports. Baseboard are when we want to add a thin layer to the bottom of a flat object. All supports automatically add a flat baseboard to the build platform from which the supports are supported. Printing Dies You can create an.stl model with dies within your CAD-CAM software to be printed on the EvoDent DLP E120. Yet the fit of the die, into the model, will vary depending on the settings within your CAD-CAM software. The space between the model cavity and the die can be set to allow a tight or lose fit of the die within the model. The fit is completely dependent on the user s preference. The image to the left display the recommended settings for the parameters in 3Shape s CAD-CAM Software. You will notice the settings for Die to Model Spacing, circled in red, which should be set to As well as various optional setting such as friction bars, etc., in the red square, which should be set to After printing your model with die, if the model is too tight for your personal preference, then increase the size of the spacing to If too loose, then tighten the die by decreasing the spacing to Again, settings are depending on the software you are using and your personal preference. To the left, is an image from Sirona s inlab CAD-CAM software. Here you will notice the Gap to Model is set to This is the recommended setting. Again, if you find the setting to be too loose or too tight for your preference, adjust accordingly. Copyright EvoDent Page 9 of 9