4th generation 3 d bioplotter manual

envisionTEC GmbH
Instruction Manual for the
3D-Bioplotter

Instruction Manual 3D-BioplotteR
Revision Date
November 7, 2014
Software versions
Bioplotter RP: 3.0
Visualmachines: 2.8.115
Manufacturer
envisionTEC GmbH
Brüsseler Straße 51
D-45968 Gladbeck
Germany
Phone: +49 2043 9875 0
Fax: +49 2043 9875 99
E-Mail: support@envisiontec.de
Distributor in the USA
envisionTEC Inc.
15162 S. Commerce Dr.
Dearborn, MI 48120
Office: +1 (313) 436-4300
Fax: +1 (313) 436-4303
E-Mail: support@envisiontec.com

Instruction Manual 3D-BioplotteR Page 3
Introduction
This documentation forms an elementary part of the system and must be paid close attention to,
both prior to switch-on and during the operation of the machine. It is therefore advisable to keep the
hardware documentation in close proximity to the 3D-Bioplotter™, making it accessible to
the operator at all times. The documentation is aimed at individuals knowledgeable in the field of
tissue engineering and rapid prototyping, and who have also been given qualified instructions in
operating the machine.
Please read through the entire documentation and only operate the machine if you have understood
all instructions. Also pay attention to all safety instructions given in the manual, on enclosed
instructions and with delivered material packages.
Warranty
Should any material defect or errors occur, despite correct usage, envisionTEC
®
offers a one year
limited warranty period starting from when the 3D-Bioplotter™ system and the
accessories are supplied. The obligation of envisionTEC
®
is limited to repairing or replacing defective
machine parts.
No warranty can be provided for faults due to subjecting the goods to improper use or above-
average strain, nor can any warranty be provided for wearing parts. Under no circumstances will
envisionTEC
®
assume liability for the consequences or side-effects of a violation of the warranty
conditions, even if this has been agreed to or expected, and even in the case of a fault or negligence
on the part of the company.
envisionTEC
®
expressly refrains from granting any other warranty claims in this respect. Neither
representatives/dealers nor employees of the company are authorized to increase or alter the
warranty claims.
Trademarks
envisionTEC
®
and 3D-Bioplotter™ are trademarks of envisionTEC GmbH, Germany.

Table of Contents
INTRODUCTION 5
REQUIREMENTS 7
1. SAFETY RULES 8
2. DELIVERY AND UNPACKING 9
3. PLOTTING – GENERAL INFORMATION 25
4. 3D-BIOPLOTTER™ INSTALLATION 36
5. 3D-BIOPLOTTER™ CALIBRATION 37
6. VISUALMACHINES SOFTWARE TRAINING 37
7. QUICK-START 67
8. FUSE LIST 69
9. PREVENTIVE MAINTENANCE 70
10. TROUBLESHOOTING 72

Introduction
The 3D-Bioplotter™ system from envisionTEC
®
GmbH is a Rapid Prototyping tool suitable
for processing a great variety of biomaterials within the field of Computer Aided Tissue Engineering.
The 3D-Bioplotter™ system imports 3D CAD models and fabricates physical 3D scaffolds
with the outer form defined by the model’s data and a complex inner structure with a user-designed
interconnectivity porosity. For the complete process chain see Figure 1: Process chain for computer
aided tissue engineering.
Figure 1: Process chain for computer aided tissue engineering
The key point of this technique is the capability to process the widest range of different types of
materials of any singular Rapid Prototyping technology. The 3D-Bioplotter™ process can
fabricate complex scaffolds from thermoplastic melts up to 250°C, from hydrogels and two
component systems and even fabricate ceramic and metallic objects.

Figure 2: Example of materials useable on the 3D-Bioplotter™ and possible uses
Hard and soft 3D scaffolds can be fabricated through the 3D-Bioplotter™ process with a
well-defined outer form and complex inner structure. The increased surface permits a much higher
number of cells per volume when compared to commonly used block-type implants. The user
defined pore size and pore interconnectivity can be adjusted to optimize the flow of nutrient media
through the inner structure of the 3D scaffold necessary for the proliferation of cells in the interior of
the non-woven scaffold, as well as cells in the interior of soft hydrogel strands.
Figure 3: The 3D-Bioplotter™ process

Requirements
To operate, the 3D-Bioplotter has the following requirements:
Parameters Working Values
Working Surface A firm, even table, 98 x 62 x 77 cm
Temperature 18 - 30 °C (64 F – 86 F)
Humidity 10-90 %, non-condensing
Electricity 100 - 240V AC, max. 3860VA, F 50/60Hz
Air pressure Min 6 bar (87 psi), 30 L/min
To achieve optimal results, stricter requirements must be met:
Parameters Optimal Values
Working Surface A firm, even table, 98 x 62 x 77 cm
Temperature 18 - 22 °C (64 F – 71 F)
Humidity 45-60 %, non-condensing
Electricity 100 - 240V AC, max. 3860VA, F 50/60Hz
Air pressure Min 8 bar (116 psi), 30 L/min

1. Safety Rules
The 3D-Bioplotter™ should only be used by trained personnel. The handling of the 3D-
Bioplotter™ by untrained personnel, the use of the machine for other purposes than the
ones described, as well as non-compliance to this manual can lead to damages to the machine or
parts thereof, or to injuries of the user.
1.1. High pressure
Around 6-10 bar pressure is being used when the machine is operating. In spite of technical
preventive measures and regardless of how much care the operator takes, some material may still be
emitted from the machine at high pressure. Therefore, always wear eye protection when operating
the device.
1.2. High temperatures
The high-temperature head can be heated up to up to 250°C. While a protective casing around the
head greatly reduces thermal loss and isolates the head to great extent, touching some parts may
still lead to injury of the user. Manual handling of the high-temperature head (for example for
manual material cartridge change) should only occur when the head has cooled down to room
temperature or when using appropriate protective gloves and clothing.
1.3. Magnetic fields
High magnetic fields occur around the X and Y axis of the 3D-Bioplotter™. Under
exceptional conditions, this magnetic field can have a negative influence on pacemakers, hearing aids
or metal implants. People with pacemakers, hearing aids of metal implants may therefore not come
nearer than 0,5 m of the 3D-Bioplotter™.
1.4. Rapid Movement
The 3D-Bioplotter™ is a device with fast moving mechanical parts. Therefore, while the
machine is moving, no foreign objects may be placed inside of the axis’ maximum movement volume.
1.5. Sensitive electrical parts
The electrical parts of the device such as the cables to the heating unit, plugs, etc. should be handled
with care. If there is any obvious damage to electrical parts, have this repaired immediately. The
device housing may only be opened by a qualified envisionTEC
®
technician. While using liquids around
or with the 3D-Bioplotter, special care must be taken so that no liquids come in contact with
electrical parts.
1.6. Hazardous substances
If toxic, corrosive, irritating, flammable, infectious or other hazardous substances are used in the
3D-Bioplotter™, the operator must ensure that he/she is in no danger (e.g. by positioning
the device under a laboratory extractor hood). In particular, no substances may be used that could
corrode or attack pressurized parts. In addition, other users must be informed of the substances that
have been used and appropriate cleaning techniques should be applied upon completion.

2. Delivery and unpacking
The 3D-Bioplotter™ system has been packed carefully prior to shipping, in order to rule
out the possibility of damage to the machine if handled properly during transport. Should you notice
any external damage to the package upon delivery, indicate this damage to the transportation
company immediately and ask them to sign a damage report.
2.1. Unpacking the Machine
To unpack the machine, please perform the following steps in the order specified:
 Place the packaged machine on an even surface and begin by cutting the plastic bands.
 Open the top of the cardboard box and remove all boxes on the upper tray.
 Lift the cardboard box straight up and remove all loose boxes around the machine.
 Remove the platform chiller and the white foam packaging.
 Examine the machine for any damage caused during transportation, and report any damage
to the responsible forwarding agent.
 Lift the 3D-Bioplotter™ by the grey Y axis (not the white X axis!) onto a flat, stable
table.
2.2. Checking the Accessories
Various accessories are supplied for the purpose of starting up your 3D-Bioplotter™
system and carrying out the various activities. If the accessories supplied are not complete, please
contact your distributor.
 Network cable and crossover network cables
 Power cables
 Platform chiller
 High-Temp-Viscous Dispensing-Head (HTV-Dispense Head)
 Low-Temp-Viscous Dispensing-Head (LTV-Dispense Head)
 PE low-temp cartridges, metal high-temp cartridges and plotting needles
 PC with monitor, mouse and keyboard
 Software package

2.3. Setup
Setup the machine precisely following these instructions. Please remember that the quality of
production results greatly relies on correct startup. The 3D-Bioplotter™ system is largely
assembled prior to delivery. There are therefore only a few actions to be performed in order to
connect the machine:
2.3.1. Removing the transportation Lock
Remove the 2 long screws on the Y-axis
Remove the screw on the head
Replace the previous screw with this distance
spacer.
The two shorter screws fixate the end-plate on
the Y-axis.
Figure 4: The transportation lock

2.3.2. Connections
Plug in the supply cable of the 3D-Bioplotter™, the PC and the screen. Connect the 3D-
Bioplotter™ and the PC using two crossover network cables in the assigned “Machine” and
“Upper Camera” slots next to the thermo-element connectors under the left Y-axis of the machine.
Figure 5: Ethernet connectors and thermo-element connectors on the 3D-Bioplotter™
2.3.3. Air Pressure
Plug in the air supply cable to the pressure controller on the left side of the machine behind the
particle and sterile filters. Turn on the pressure on your own compressor and adjust the pressure
controller for 6-10 bar pressure, dependent of the capabilities of your compressor or compressed air
system.
Figure 6: Pressure controller, particle and sterile filters on the 3D-Bioplotter™

2.3.4. Thermo Cube
On the left side of the Thermo Cube, two adapters for cooling
liquid inlet and outlet are closed with stoppers. Remove the
stoppers by pressing the adapter down with one hand and
pulling the stopper with the other. Connect the inlet and
outlet of the Thermo Cube with the adapters of the building
platform of the 3D-Bioplotter™ (the exact order is
irrelevant). Then open the black plug on top of the Thermo
Cube and fill in cooling liquid until the swimmer inside is
completely covered. If the Thermo Cube is turned on, the
message TANK LOW will disappear.
Figure 7: The Thermo Cube
While distilled water may be sufficient for most applications, we advise all our customers to use the
supplied cooling liquid from envisionTEC
®
. This mixture will lower the freezing point of water to -15°C
(-4°F) and will provide excellent cooling/heating properties for the full temperature range of the
Thermo Cube.
2.3.5. Minichiller
On the back side of the Minichiller, two adapters for cooling
liquid inlet and outlet are closed with stoppers. Remove the
stoppers by unscrewing the covering on the adapter.
Connect the inlet and outlet of the Minichiller with the
adapters of the building platform of the 3D-
Bioplotter™ (the exact order is irrelevant). Please
take care to provide counter-torque with a second wrench
when connecting the hose to make sure not to damage the
platform connection.
Then lift the black plug on top of the Minichiller and fill in
cooling liquid until the level on the front is around half
between min and max values.
Figure 8: The Minichiller

While tap water may be sufficient for most applications, we advise all our customers to use the
supplied cooling liquid from envisionTEC
®
. This mixture will lower the freezing point of water to -15°C
(-4°F) and will provide excellent cooling/heating properties for the full temperature range of the
Minichiller.
2.3.6. Power Supply
Connect the power cable to the back left of the machine, right underneath the input and manometer
for air pressure.
Turn on the power for the 3D-Bioplotter™ by turning on the on/off switch on the left side
of the machine. A green light next to the Ethernet and thermo-couple connectors will turn on.
Figure 9: Main switch of the 3D-Bioplotter™
Make sure the emergency stop button on the left side of the front panel of the 3D-
Bioplotter™ isn’t pressed. Should it be pressed, the emergency stop button can be reset by
turning the button 20° clockwise until it clicks, snaps out a centimetre and the green band can be
seen.
Figure 10: Emergency Stop
At this point the X and Y axes of the 3D-Bioplotter™ are unlocked and can be moved easily
by hand. Make sure no foreign objects are located inside the movement volume of the 3D-
Bioplotter™ before continuing.

2.3.7. Software
Turn on the computer. Once the operating system is loaded, click on the VisualMachines icon on
the desktop. A full check-up of the machine is processed during the splash screen. Should any errors
be found, a message will be displayed and must be acknowledged to proceed.
By clicking on the on/off button in the left top of the software main screen, the software will connect
with the 3D-Biopollter™ and the machine will calibrate itself. At this point all axes will move, make
sure no foreign objects are located in the movement volume of the 3D-Bioplotter™.
Figure 11: On/Off button in VisualMachines
Once turned on, the axes will first calibrate. The sequence is first up and down, then movement left
to right and finally back to front. After calibration of the axes, the head will move to the park
position. Only now is the 3D-Bioplotter™ ready to be used.

2.4. Equipment
Figure 12: 3D-Bioplotter™ base system
The 3D-Bioplotter™ is designed to allow an optimized airflow around the plotting heads
and platform, should the system be placed into a laminar flow system for production in a sterile
environment.
Figure 13: Airflow around the platform of the 3D-Bioplotter™

2.5. Technical data
 Overall size incl. tool magazine (D/W/H): 623 x 976 x 773mm
 Weight: ~ 130 kg
 Airflow optimized system for use in commercial laminar flow hoods
 Build volume X/Y/Z: 150 x 150 x 140 mm
 Linear motors on X, Y and Z axes with a resolution of 0,001 mm
 Speed: 0,1 to 150 mm/second
 Multi exchangeable base plate fixtures
 Platform heating and cooling between -10°C and 80°C (Manufacturer Series
only)
 Automatic tool changing system (combined with SW-modifications)
 Tool magazine with park positions for 5 dispensing heads
 Use of multiple dispensing heads:
o High-Temp-Viscous Dispensing-Head (HTV-Dispense Head) with stainless steel
cartridge and a heating system up to 250°C
o Low-Temp-Viscous Dispensing-Head (LTV-Dispense Head) with PE cartridge and
temperature control between 2°C and 70°C
o UV Curing Head with a wavelength of 365 nm and built-in temperature control.
 Camera for high accuracy positioning in X and Y, as well as strand diameter control with 9 µm
resolution (Manufacturer Series only)
 Needle Z pressure sensor with 1 µm resolution
 Positioning sensor in Z for platform attachments with 1 µm resolution
The 3D-Bioplotter™ system consists of the following modules and components:
 3D-Bioplotter™ base system including
 3 axis positioning system
 Dispensing head mounted on the Z-axis with a tool changer (male)
 Base plate (including mechanical fixtures for petri dishes)
 Needle sensor
 Camera calibration plate
 Light and dark camera background plates for XY positioning plate (Manufacturer
Series only)
 Control panel
 Dispensing head magazine (with five positions)
 Industrial PC with a control card for the 3D-Bioplotter™ system and peripherals
(LCD screen, keyboard, mouse)
 Temperature control (-10°C – 80°C) for the base plate (Manufacturer Series
only)

2.6. Dispensing Heads
Three different types of dispensing heads are available:
 High-Temp-Viscous Dispensing-Head (HTV-Dispense Head)
 Low-Temp-Viscous Dispensing-Head (LTV-Dispense Head)
 UV Curing Head
2.6.1. High-Temp-Viscous Dispensing-Head (HTV-Dispense Head)
This dispensing head is designed to quickly melt thermoplastic polymers in a stainless steel cartridge
and dispense the high viscous material at a temperature just above the melt temperature to greatly
reduce thermal degradation. The whole cartridge mount is heatable from room temperature up to
250°C to bring the material to its proper processing temperature (i.e. using thermoplastic
Biopolymers like Polyactive® from ISOTIS®). The stainless steel cartridges can be removed from the
plotting head for easy cleaning and needle change.
This HTV-Dispense Head consists out of the following components:
 Dispense Head frame
 Tool changer (male)
 Heated full metal body with 2 removable heating rods and temperature sensor.
 Replaceable 10 ml stainless steel cartridge with air inlet for compressed air/gas and luer-lock
adapter
 Stainless steel luer-lock needle (changeable)
 Connector for air pressure
Figure 14: High-Temp-Viscous Dispense Head
When using the HTV-Dispense Head and requiring a full cartridge load, first fill material into the
cartridge with a small funnel up to the lower border of the inner screw thread. Heat the cartridge
with the appropriate metal needle with an open top on the HTV-Dispense Head at about 10°C above
plotting temperature. While the cartridge is still open, wait until the material is completely melted

and check the liquid level. If below half the cartridge length, fill in more material using a funnel up to
the lower border of the inner screw thread. Wait again and repeat.
Always leave at least 1 cm between the level of the liquid melt and the lower border of the inner
screw thread to avoid material in the air tube in case of foaming. Lower the temperature in the
software to the plotting temperature, close the top of the cartridge using appropriate precautions
against heat and wait 5 minutes before plotting.
2.6.2. Cleaning of High-Temp-Viscous Dispensing-Head
The HTV-Dispense Head has been redesigned for fast material refill and replacement. The stainless
steel cartridges can be opened, refilled or removed while the plotting head is still heating, using
appropriate precautions against heat. For cleaning purposes, the chemical composition of the
interior surface of the cartridges is optimized for low adhesion to most materials, which means
material remains will always be at the bottom of the cartridge.
Because most steps will be done with a heated cartridge, use proper precautions and safety
equipment (gloves, goggles, etc.) to avoid injuries.
For faster cleaning, the following order should be considered:
 Always purge material first from the cartridge until only air passes through the plotting head.
 Disconnect the pneumatic hose from the connector
 Pull the cartridge out of the plotting head
 Unscrew the top of the cartridge and place it on an heat-proof surface
 Unscrew the needle tip and place it on an heat-proof surface
 Unscrew the luer-lock connector and place it on an heat-proof surface
 If the HTV-Dispense Head is to remain heated, remove any substance residue inside the
cartridge holder carefully with a long pair of tweezers
 If the HTV-Dispense Head is to be cooled, wait until it fully cools down and clean the inside of
the cartridge holder with a paper tissue impregnated with a solvent for the material used. Do
not use liquid directly, as electrical parts inside the plotting head may be damaged
 After the cartridge and its parts have cooled down, place all metal parts with the exception
of the air pressure adapter in a closed container with the appropriate solvent for the material
used (e.g. chloroform for PLLA remains) for 24 hours
 Replace solvent as needed until no material waste adheres to the metal parts
 Finally, clean the outside of all metal parts with a cloth with clean solvent, to remove any last
transparent residue of material from these surfaces.
Should the air tube ever require replacing, always use Teflon tubes 4x3mm, as most other polymers
are not stable at higher temperatures.

Figure 15: Stainless Steel Cartridge for HTV-Head
2.6.3. Low-Temp-Viscous Dispensing-Head (LTV-Dispense Head)
The LTV-Dispense-Head is designed to take 30cc PE cartridges with Luer-Lock needles. The mount for
the cartridges is prepared for liquid-cooling/-heating within a temperature range of 0°C – 70°C. The
supplied disposable PE cartridges can be used with up to 5 bar pressure and 38 °C safely.
Figure 16: Low-Temp-Viscous Dispense Head
This LTV-Dispense Head consists out of the following components:
 Dispensing head frame
 Tool changer (male)
 Cartridge mount for 30cc PE cartridges
 Piezo elements with cooling fins and fans
 Connector for air pressure.
To attach the syringe barrel to the blue adapter, push the cartridge onto the cylindrical plug and turn
it 90° counterclockwise. The syringe should fit easily on the adapter and, while applying pressure, no
hissing between both should be hearable. If hissing occurs or the syringe can only be pushed using a
great amount of force, then the black O-ring might require lubricating or the adapter has to be
replaced.

2.6.4. UV Curing Head
The UV Curing Head is designed to project a beam of UV light at 365 nm +- 10nm. Different apertures
and filters can be added to focus the light beam and control the intensity of the light.
Figure 17: UV Curing Head

2.7. Additional components
2.7.1. Tool Changing System
All Dispensing heads are equipped with a standardized tool changing system which conducts air
pressure and the power supply for heating/cooling as well as for temperature feedback.
Figure 18: High temperature head on position 2 of the tool changing magazine
The dispensing heads parked in the tool changing magazine have to be aligned in such a way that the
female tool changer from the dispensing head mount can smoothly lock into the male connector of
the dispensing head.
While on the tool changing magazine, the heads are mechanically locked and can only be removed
automatically by the dispensing head mount or manually by first disengaging the lock over the
software (Maintenance > Tool Changer).
2.7.2. Purge and Calibration Station
At the front of the 3D-Bioplotter™ is the purge and calibration station. This station is
comprised of a field of concentric rings for camera calibration, as well as a white and a black circle for
needle tip calibration in X and Y. A pressure sensor calibrates the needle tip in Z. At the right end, the
needle tip can be cleaned by first purging material onto a Teflon basin and then passing only a few
micrometers above a thin metal wire. A metal and a plastic brush are also built-in to clean the needle
tip during the plotting process.
The Teflon basin can be removed by pulling it straight out of the block.

Figure 19: Purge and calibration station
2.7.3. Replacing the purge wire
The purge wire is stretched between two mounts. To replace the wire, first
unscrew the grub screw beneath the mount until it is visible from the outside
and push the mount to the center of the calibration station. Unscrew the
large screws holding the wire, remove the broken pieces and replace it with
a new one. Screw the new wire tightly in its place, but not yet regarding if it
is very tense. Screw the grub screws back in, which will push the mount from
the center of the calibration station, tensing the wire. Take care not to apply
too much pressure, which may break the wire.
Large screws to hold the wire
Grub screw to tense the wire
Figure 20: Purge wire

2.7.4. Platform height sensor
A pressure sensor is attached to the dispense head mount, which can be lowered
automatically by the software to calculate the height of the chosen Petri dish or
any other plotting surface. The pressure sensor will move to the center of the
platform and then lower slowly until a sufficient amount of resistance is measured.
This component requires air pressure for its operation and may be damaged if air
pressure is not connected to the 3D-Bioplotter™.
Figure 21: Platform height sensor
2.7.5. Base plate fixtures for Petri dishes
Twelve threaded holes for short screws are available on the building platform. These can be used
with the supplied fixtures to secure Petri dishes of 60 and 120 mm diameter to the platform. The
holes and supplied fixtures can also be used to secure paper sheets or plastic films. Other fixtures
(for example for well plates) are also available.
Figure 22: Building platform with Petri dish fixture

2.7.6. Sterile and particle filters
On the left side of the 3D-Bioplotter™ a particle filter (red) and a sterile filter (silver,
Manufacturer Series only) are attached between the pressure control and the
machine (see Figure 6: Pressure controller, particle and sterile filters on the 3D-
Bioplotter™). Please find with the manual filter-specific information on how to clean and
sterilize the built-in filters.
2.7.7. High definition camera (Manufacturer Series only)
A high definition CCD-camera is attached to the dispense head mount and is
controlled completely by the software. The camera is used for XY positioning of the
needle tip by taking a picture of a small droplet of material and calculating to 9 µm
the position of the center of the droplet. To use the camera and accompanying
image processing drivers, a USB dongle must be plugged in the computer at all
times.
Figure 23: High definition camera
2.7.8. Needle Calibration Station (Developer Series only)
The needle calibration station uses a non-contact process to determine the position of the needle tip
in XYZ using two sets of light sensors. This station replaces the camera calibration system used in the
Manufacturer Series to determine the position of the needle tip.
Figure 24: Needle Calibration Station

2.7.9. Additional Accessories
 Software package, includes Windows 7 Ultimate, Bioplotter RP and VisualMachines
 network cables, power cables
 Starter kit, includes different type of needles with Luer lock, PE cartridges
 Stainless steel metal cartridges and stainless steel Luer lock needles
3. Plotting – General Information
The 3D-Bioplotter™ is a special dispensing machine for fabrication of three-dimensional
objects for use in tissue engineering and medical technology. The central process involves dispensing
of a viscous material through a thin needle and the subsequent hardening of the material. This is
illustrated in Figure 25: Plotting in medium.
Figure 25: Plotting in medium
This places the following demands on the material:
 it must be possible to dispense the material
 the material must not block the nozzles
 the material must solidify quickly after dispensing

3.1. The importance of the solidification process
The material is applied in layers to form 3D objects. Because of this, two further conditions must be
met:
 the material layers must bond with each other,
 the dispensed material must not swell or shrink much during the building process.
The material can be dispensed in the presence of air or in a liquid. Dispensing in a liquid medium has
the advantage that the buoyancy effect in the liquid prevents deformation in the dispensed but not
completely hardened structure. Therefore, only quickly solidifying or highly viscous materials can be
processed in air (e.g. polymer melts).
From a material science aspect four different types of hardening processes can be considered:
 Thermally induced solidification
 Solidification induced by a chemical reaction
 Solidification induced by precipitation
 Post-process solidification through sintering
Thermally induced solidification
This includes the solidification of melts (e.g. polylactide, polycaprolactone) but also the gelling of
thermally reversible hydrogels (e.g. gelatin, agar). In addition to the above-mentioned examples for
solidification through cooling there are several examples for hardening through heating (e.g. liquid
crystalline gels from block co-polymers).
Solidification induced by a chemical reaction
In the usual case a reactive component is added to the plotting material and a second is added to the
plotting medium. When the two substances come into contact with one another after leaving the
nozzle, a chemical reaction is initiated that hardens the plotted material. This is the case when the
reactive substance in the plotting medium is much more mobile than the substance in the plotting
material. Otherwise the plotting medium would harden instead of the plotting material. Ideal in this
respect are reactions between polymeric substances (plotting material) and low-molecular
substances (plotting medium) (e.g. the reaction between polyelectrolytes and polyvalent cations).
Another particularly difficult variant to implement from a technical point of view is mixing the
reactive components directly before plotting, as usually only a short period of time is available to
dispense the viscous mixture previous to complete solidification.
Solidification induced by precipitation
In this case the chemical environment for a substance is modified in the plotting material in such a
way that it precipitates and causes the plotting material to harden. Modifications in polarity, osmotic
pressure or pH can be utilized. The important thing is that shrinkage of the plotting material is kept
low.

Post-process solidification through sintering
Ceramic powders, or even metal powders can be processed by mixing very fine powder (smaller than
50 micron) with a binder, like for example polyvinyl alcohol or methyl cellulose. The concentration of
the powder should be increased until the material is mechanically stable at room temperature. After
printing, the fragile green part must be placed into an oven or kiln and sintered at the appropriate
temperature for the particular ceramic or metal. The binder will be completely during the process.
3.2. Significance of the plotting parameters for the building process
The building process for 3D plotting is dependent on a large number of parameters. It is difficult to
calculate all of these in advance for a new material. Therefore, a series of experiments have to be
carried out to find the right settings for new materials. This section will help you find the right
settings for the process by demonstrating the influence of each individual parameter.
Needle type:
Basically there are three different types of needles:
a) conical needles (easy-run needles)
b) short straight needles
c) long straight needles
The different types are shown in Figure 26: Different needle types (cross-section).
Figure 26: Different needle types (cross-section)
In principle, conical needles and short straight needles are used for highly viscous materials. Long
thin needles, on the other hand, are used for plotting materials with low viscosity, as the increased
length provides higher friction forces to better control the plotting process. Besides the shape, the
material also plays a significant role. The dispensing needle must remain stable under the respective
dispensing conditions. Because of this, only metal needles can be used at temperatures above
approx. 40 °C. In addition, the dispensing material should not stick to the needle. Teflon needles are
very important in this respect. These are available in the long thin shape and are especially suitable
for aqueous solutions.

Needle length:
The needle length is significant for the dispensing process as it is closely connected with the viscosity
of the plotting material. Low-viscosity materials are processed with long, thin dispensing needles,
while on the other hand short or conical dispensing needle types are used for highly viscous
materials. Otherwise the material would be ejected far too quickly and the process would be almost
uncontrollable, or the material would be ejected much too slowly. For non-compressible liquids the
Hagen-Poiseuille law gives the connection between the viscosity, needle diameter and needle length
for a straight (constant diameter) needle.
V
p t
L
r
 
 



 
8
4
V is the volume of the plotting material with the dynamic viscosity η, which flows through the needle
with the diameter r and length L with a differential pressure Δp (between the tip of the needle and
the inside of the cartridge) in the time Δt. It is obvious that the material flow (dV/dt) is inversely
proportionally dependent on the needle length.
A minimum length of 2mm is recommended, a maximum length of 12.7mm (half inch) is allowed.
Needle diameter:
As described above, the needle type is also linked to the viscosity. Naturally, the needle diameter
also determines the thickness of the strand, in other words, the fineness of the object and
consequently also the building time. In the Hagen-Poiseuille law the needle diameter appears in the
fourth power, which means that very thin needles considerably prolong the building time.
Dispensing material:
A dispensing material with high viscosity, i.e. with a pasty consistency generally simplifies the
building process, as the parameters do not have to be set so accurately. Polymers or insoluble fine
fillers can be used to increase the viscosity. However, you must ensure that the filler is not so large
that it blocks the nozzle (in case of larger aggregates in the filler, sieving the material through fine
metal powder sieves after creating the paste will greatly increase production quality and reduce
blocking incidents).
Hint:
Use particles smaller than 1/4 of the needle diameter to avoid clogging the needle. Sieving the
paste after mixing the materials will greatly improve the fluidity of the mixture and further avoid
clogging.

Plotting medium:
The plotting medium must be matched with the plotting material. There are two properties of the
plotting material that especially have to be considered. a) density and b) polarity.
The density of the plotter medium should have roughly the same density as the plotting material. It
must not be much higher, as otherwise the plotting material will float to the top or the layer bonding
will be made unnecessarily difficult. In the case of polarity you must consider that when the polarities
differ too much the strand often constricts and forms drops before hardening due to the surface
tension. This can be counteracted with a different plotting medium or by adding surfactants.
However, the plotting medium must not start dissolving the plotter material or swell up, which is
often the case when the viscosities are too similar.
Figure 27: Density / polarity of different plotter media
Before beginning the test it is advisable to consider where the plotting material fits into the diagram,
so that you can find potential plotting media.
Hint:
When using the plotting media as a component in a chemical hardening process, also test the
concentration of the chemical material in the solution. A too high concentration will harden the
plotting material faster, but may greatly reduce the adhesion of later layers. If the concentration is
too low, the hardening process may be too slow and cause swelling of plotted strands.

Dispense pressure:
The dispense pressure is dependent on the material flow through the nozzle and should be adjusted
to the rate at which the material hardens. The slower a material hardens (e.g. 3-10 sec), the lower
the dispense rate has to be. A low dispense rate will allow the material to harden while still being
affected by the needle tip, resulting in thinner and rounder strands. A dispense rate too fast relative
to the hardening speed will result in wide, oval strands flattened by the material’s own weight during
the hardening period. The faster a material hardens (e.g. in 1-2 sec), the higher the dispense rate
should be, so that the adhesiveness of the plotter material is still high enough to bond the layers
when it reaches the previous layer.
Further, the dispense rate must be adjusted to the XY movement speed of the 3D-
Bioplotter™. Figure 28 illustrates various situations of dispense rate vs movement speed.
With a dispense rate too high relative to the XY movement speed, too much material is dispensed
and the strand starts to swell or are pushed to the sides (a). In a case such as this, the simplest
solution is to reduce the dispensing pressure slightly. The middle case illustrates the optimum
situation: The material leaves the nozzle and is immediately pressed against and bonded with the
previous layer. The strand is only slightly deformed. In the right hand case (c) the XY movement
speed is too fast relative to the dispense rate. The strand is stretched after it has been dispensed and
it touches the previous layer much later, often resulting in droplet formation instead of tubular
strands. In a case such as this the simplest solution is to increase the dispensing pressure slightly.
a) b) c)
Figure 28: Various relationships between dispense rate and XY movement speed
A wrong relation between dispense pressure and XY movement speed will be visible in the corners of
large objects. Illustrated in Figure 29, a speed value too high will result in rounded corners (a), while
a speed value set too low will result in large amounts of material being dispensed on the corners of
the object, making the sides of the object much higher than the center (c). Small, sharp corners will
create perfect objects (b).

a) b) c)
Figure 29: Various corner delays and the effect on the pore structure of the built body, side view (top row) and
view from above (bottom row).
Hint:
Objects should be frequently observed under a microscope to verify the strand diameter obtained,
which may differ from the strand diameter calculated due to too high XY speeds as well as incorrect
pressure or feeding rates. Because the first layer is usually slightly flattened on the building
platform, only the second or third layer should be used for strand diameter control.
Layer thickness:
The layer thickness is directly linked to the way the layers bond, see Figure 30: Cross-sections of
strands to illustrate various relationships between layer thickness and strand diameter.
If the layer thickness is set too high, the layers will barely touch, making bonding inadequate and the
object brittle. Therefore, the layer thickness must be set slightly lower than the strand thickness. If a
lower thickness is chosen, the strands are very deformed in the overlapping area and the
interconnecting porosity drops considerably. In addition to this, in some cases it is not just the
directly neighboring layers that bond but also the subsequent ones. This has a negative effect on the
desired pore structure. Generally 80% is the optimum value.
a) b) c)
Figure 30: Cross-sections of strands to illustrate various relationships between layer thickness and strand
diameter

Hint:
Incorrect layer thickness won’t be observable in the first layers, but will be easily noticed the higher
the dispenser head moves. Too low layer thickness will make the dispenser head collide with
previously dispensed layers. A layer thickness value set too high will make the dispenser head plot
too high above the previous layers, making dispensed strands fall onto the previous layers.
Pre-flow delay:
When the dispensing impulse is set, pressure builds up in the cartridge and the material begins to
flow. However, it takes some time before the plotter material actually comes out of the nozzle.
Because of this, a pre-flow delay is set. For low-viscosity materials this is almost zero, or is
unimportant. For extremely high viscous materials it can be as much as 2 seconds. Generally 0.2 sec
is a good value if the error is observed.
Figure 31: Examples of the influence of pre-flow delay
Post-flow delay:
The pre-flow delay is used to bond the strand firmly with the previous layer before the dispensing
process is completed. To do this, the nozzle stops briefly for the set amount of time while pressure is
still applied. Generally 0.1 sec is a good default value. A negative value can be used to stop the
applied pressure before the nozzle movement stops to avoid large droplet formation at the end of
each layer or stretched vertical filaments of highly viscous plotting materials.
Figure 32: Examples of the influence of post-flow delay

Pattern:
Different patterns can be defined on the 3D-Bioplotter™. In any one layer strands are
always arranged in a parallel design. The direction of the next layer can be changed by any value
between 0,1° and 179,9°, creating a complex grid with well-defined inner porosity. When dispensing,
it is important to ensure that the ejected strand occasionally comes into contact with the strands of
the previous layer, thus stabilizing the object.
The XY orientation of the strands takes place in a coordinate system that is superordinate to the
object. The strand distance, shift in XY and alignment (angle) in the XY level for the section lines of
each layer can be specified. Additionally, it can be specified if corners should be built or if the
machine should stop at the end of each parallel strand. An outer contour function can also be
activated, which encloses the surface of the component.
With the current 3D-Bioplotter™ hardware and software configuration, automatic tool
changing is possible, which means that the material and the dispensing pattern can be changed
automatically during the building process to fabricate multi-layered 3D-scaffolds (see Figure 33).
Hint:
The layer thickness of all used materials must be equal in multi-layered 3D scaffolds to avoid empty
spaces.
a) b) c)
Figure 33: (a) Single material object, (b) multi-material object with layer-wise change, (c) multi-material object
with material changes inside each layer.
Strand distance:
The minimum strand distance is approx. 80% of the strand diameter, which will create full material,
closed layers. Gaps larger than three times the strand diameter, i.e. a strand distance of four times
the strand diameter, are difficult to build, especially when using materials with slow hardening
properties. Generally, a distance between strands twice the diameter of the strand, i.e. pores as wide
as the strands themselves, will result in very well defined object patterns. The strand distance has a
considerable effect on the porosity of the object.
Hint:
Low viscous, slow hardening materials will flow together at the corners, especially if the distance
between strands is very narrow.

Shift in XY:
To prevent the cross-points of the strands to be on top of each other on the z axis, it is possible to
allocate an offset for the strands in X and/or Y relative to the coordinate system. A step-like three
dimensional lattice structure will be fabricated, where the pores are not in a straight line in X or Y but
are still interconnected.
a) b)
Figure 34: vertical cut through an object with (a) no offset; (b) an offset of 33%
Outer contour:
The outer contour is decisive as to whether the sides of the object are open or closed. The gap
between the outer contour and the object should not exceed the diameter of the strand or else the
outer contour will not be connected to the inner pattern.
a) b) c)
Figure 35: a) non continuous strands with no contour; b) continuous strands with no contour; c) continuous
strands with contour.

Platform Temperature:
The temperature of the platform can be precisely controlled for different applications:
 When working with cells, the temperature of the building platform and any Petri dishes on
top of the platform can be risen to cell compatible levels.
 When working with thermoplasts, the temperature of the building platform can be risen to
increase the solidification duration of the material. This will allow the material to better
adhere to the building platform and reduce curling.
 When working with pastes, the temperature can be lowered to increase the viscosity of the
material once printed, or can be raised to increase the evaporation of the liquid phase of the
binder.
The temperature measurement of the Chiller occurs after the liquid intake valve. This provides a very
accurate measurement of the temperature around room temperature, but may display some
deviation at the lowest and highest limits of the Chiller. For a more accurate temperature control,
use thermo-elements in the thermo-element connectors of the 3D-Bioplotter to visualize the
temperature of the measurement point at all times.
Figure 36: Differences between set and measured temperatures on the Chiller, the building platform and a Petri
dish with distilled water. Room temperature was 30°C during measurement. Values may vary depending on the
Petri dish used.
0
10
20
30
40
50
60
0 10 20 30 40 50 60
MeasuredTemperature
Set Temperature
ThermoCube
Platform
Petri dish

4. 3D-Bioplotter™ Installation
Please make sure that the 3D-Bioplotter to be installed is positioned at the final production place.
Head positions and building platform are calibrated to a micrometer; any further movement of the
machine might shift the positions saved in the software. Prepare the 3D-Bioplotter™ and
the Chiller by connecting all power cables and tubes. Install Windows 7 and VisualMachines on the
PC and connect the PC with the 3D-Bioplotter™. The 3D-Bioplotter™ should be
ready for use.
Important Notice:
Please use at least 6 bar and a maximum of 10 bar, 7-8 bar air pressure are recommended to work
with the 3D-Bioplotter. Filtered, water- and oil-free pressure air is recommended. Please make sure
that the surrounding atmosphere is constant in temperature and humidity.
4.1. Axes
The axes achieve a positioning accuracy of 1 µm in all three dimensions. The guides are self-
lubricated and should be kept clean of foreign materials and fingerprints at all times. To avoid
damaging the axes, you should always use the transport lock displayed in Figure 4 when the device is
being moved.
4.2. Heads
The parking positions are locked when the machine is delivered. To unlock the positions, go to
“Maintenance > Tool Changer” and press the grey circle marked “Open” next to each parking
position. Place the head firmly into the parking position and press the now yellow circle once more to
lock the position once more.
Make sure to keep on pressing the heads onto the parking positions before locking the positions, to
ensure there is no gap between the heads and the positions, which may damage the locking
mechanism.
Also, make sure not to touch the electrical connections on the top of the head, as this may cause a
short circuit.

5. 3D-Bioplotter™ Calibration
Turn on the PC and start the VisualMachines software. Make sure that no foreign objects are inside
the movement volume of the dispense head mount. Click on the On/Off button at the top left of the
screen to connect the software with the 3D-Bioplotter™ (see Figure 11: On/Off button in
VisualMachines). The 3D-Bioplotter™ will automatically calibrate itself by moving all axes
to the pre-defined positions. At the end of the calibration the dispense head mount will move to the
far left corner and the machine is ready to be used.
In case of emergency press the red button in the left side of the front panel of the 3D-Bioplotter.
After restarting the system press the On/Off button in software to recalibrate the machine.
5.1. Needle calibration
Needle calibration is required after each needle change or material refill and should be done starting
the machine. First pick the material to be used in “Configuration > Dispense Tool Manager”. Pick the
appropriate head in “Maintenance > Tool Changer” using the “Change Mounted Tool” box. If
necessary, the needle tip can be filled by going to “Maintenance > Robot Head” and pressing and
holding the “Purge” button. Finally, go to the screen “Calibration > Camera and Needle” and press
“Calibrate” in the “Needle” box.
5.2. Platform calibration
Platform calibration can be conducted at the beginning of each building job by setting a mark on
“Platform height control” under “Execution Control > Project Editor”. The dispense head mount will
move to the center of the platform engage the pressure sensor, and then it will lower slowly until a
sufficient amount of resistance is measured.
6. VisualMachines Software Training
6.1. Software Overview
The software for the import of STL data and for control of the 3D-Bioplotter™ comprises of
two individual modules.
1. The 3D-Bioplotter software to import STL data and for layer creation
2. The VisualMachines software for material parameters and machine control

Figure 37: Data flow when working with the 3D-Bioplotter™
6.2. The 3D-Bioplotter software
The 3D-Bioplotter software reads STL and BPL files and allows the user some minor editing and
positioning functions. When the software starts, the RP software will open an empty screen. Go to
File -> Open and choose an STL or BPL file from an appropriate folder. Choose if the opened STL file
should be processed as a 3D-Modell or a Support Structure and if the part should be placed based
on the coordinates saved in the CAD data file (As is) or if it can be placed at the point of origin
(starting from the center of the platform).

Figure 38: The choice of object type and positioning when loading a part
On the next screen the building platform size can be picked (e.g. 60 mm petri dishes) as well as the
material to be used.

Figure 39: The choice of platform size and layer thickness when loading a part
Additional parts can be loaded under File > Open and Add. Alternatively, existing parts can be copy
pasted under Edit > Copy and Paste, or using CTRL+C and CTRL+V.
The part will be displayed on the platform, which can be moved by clicking and dragging with the left
mouse button. If several parts are loaded, they can be chosen by clicking on them with the right
mouse button.

Figure 40: A loaded part on the 3D-Bioplotter software
The dimensions of the parts are displayed on the left corner based on the bounding box.
Figure 41: Part properties of the loaded files
If a part is chosen, then some minor editing can be processed by clicking on Geometrical Operations.
A new work surface with a series of tabs will open.

Figure 42: Geometrical operations: inch to mm conversion
On the first tab the dimensions of the part can be corrected by clicking on the inch -> mm or the mm
-> inch buttons. This process is reversible by clicking on the other button.
Figure 43: Freehand operations on the 3D-Bioplotter software
Freehand operations allows to user to move the part by clicking on the arrows on top of the part and
placing it on the platform. XY-Alignment allows the movement of the part only in the X and Y
dimension, while 3D-Transformation allows the user to move the part in all dimensions and rotate
the part in all three dimensions as well. It is also possible to rescale the part by hand in
3D-Transformation.
Hint
Rescaling a part in Z will increase the size of the part centered on the middle of the object. The part
may then be positioned below the building platform and may need to be repositioned in Z.

Figure 44: Translate operation on the 3D-Bioplotter software
On the Translate tab the part can be moved in any dimension to exact coordinates by writing the
step size in the appropriate field and clicking the left button (to move in negative direction) and the
right button (to move in positive direction). The step size can be lower than 1 (e.g. 0.01), the part can
be moved in several directions at the same time.
Figure 45: Rotate operation on the 3D-Bioplotter software
The parts can also be rotated in all three dimensions precisely using the Rotate tab. The angle of
rotation must be inserted in the text field and the button for the appropriate axis pressed. The
direction of the rotation is defined by the button the user presses, either negative (left button) or
positive (right button). Parts can only be rotated in one direction at a time.
Figure 46: Scale operation on the 3D-Bioplotter software

Parts can be scaled in all dimensions individually or in all dimensions at the same time. Insert the
scaling factor (1.1 will scale by 10%, 2 will double/halve the size) in the Rescale tab and press the
button of the axis the scaling should take place.
After re-scaling the part, the parts can be renamed to be correctly displayed in Visualmachines.
Right-click and hold over the part to be renamed, a new pop-up will appear.
Figure 47: Renaming option and material change option
Figure 48: Renaming screen
If parts are not aligned to the platform, Bioplotter RP allows some simple re-alignment of the parts.
Click the Re-align button on the top tab , the part will be displayed in triangles. Click on one of
the triangles belonging to the new bottom surface. This triangle will be marked green.

Figure 49: Re-alignment of parts on the 3D-Bioplotter software - before
Click the Standard display mode button on the top tab to finalize part rotation. The part will be
rotated so, that the marked triangle will be flat against the platform.
Figure 50: Re-alignment of parts on the 3D-Bioplotter software - after

After all modifications to the part and placement in X and Y, the part should be placed exactly at
0mm in Z. The easiest way is in Filter, option Automatic Placement.
Figure 51: Automatic part placement on the 3D-Bioplotter software
After editing and positioning the parts on the building platform, they must be sliced with the
corresponding layer thickness (usually 80% of the inner diameter of the needle tip used).

Figure 52: Slicing operation on the 3D-Bioplotter software

Figure 53: The file after slicing
Lastly, the objects must be saved as BPL files for the VisualMachines software. In File > Save as the
parts can be saved as BPL files.
Hint
Saving the part in the folder C:VisualMachinesBPL Inbox will automatically load the file in
VisualMachines as a new project. The BPL file will also be automatically deleted, as it isn’t needed
anymore.

Figure 54: Save Parts as BPL in the 3D-Bioplotter Software
Hint
If the placement of a part isn’t exactly as planned, it isn’t required to position the part from the STL
file from the start. Load the BPL part in the 3D-Bioplotter software and translate the part only as
much as needed based on the results of the 3D-Bioplotter.
Preparing multi material projects
When preparing multi-material projects, simply load several files at once into the 3D-Bioplotter
software and place them accordingly. Make sure to select all files before slicing.
After slicing, in the save menu choose “save selection merged”. One file with all project parts will be
saved, which can be loaded in the VisualMachines software.
Lastly, the Bioplotter RP software is copy protected by a license key. Each PC generates a unique
computer ID, for which a license key can be generated by envisionTEC
®
. When opening Bioplotter RP
for the first time, the following screen will be displayed:

Figure 55: Bioplotter RP licensing window
Customers must copy the computer ID to an email (or attach the saved Computer ID file) with the
3D-Bioplotter™ serial number and send this to support@envisiontec.de. A license file will
be returned, which can be loaded in the same window. By pressing OK, the file will be activated by
the software.
The license information can be verified at any time in Tools, option License.
Figure 56: Bioplotter RP license information

6.3. The VisualMachines software
The VisualMachines software is located on the drive C: of the PC in the folder C:VisualMachines.
The software can’t be operated without a connection to the 3D-Bioplotter™, so first always
connect the 3D-Bioplotter™ to the PC and turn on the machine before starting the
software. When clicking on the VisualMachines icon, a splash screen will appear, where a full check-
up of the machine and the required drivers will be displayed.
Figure 57: The build control tab of the VisualMachines software
When VisualMachines starts, the program will open the Build Control tab under Execution Control.
On this screen, prepared jobs can be loaded and started and the dispense head mount can be moved
to pre-defined positions. Move to Safe Height rises the dispense head mount in the Z axis to top
height. Move to Park (large blue symbol next to the on/off switch) moves the dispense head mount
first to top height in Z, then to the back left corner of the movement volume.
With Select a prepared job can be selected to run once Start is pressed, as default in Auto Mode. By
switching to Step Mode the user must press Start at each step, which is only useful for problem
detection. With an activated Dry Run button the job will be processed but no material will be
dispensed.
Pressing Stop Cycle during a job will allow the 3D-Bioplotter™ to build the current layer or
contour to the end, then stop and return the head to the parking position. The user can then press
Start to continue to job from the next layer. Pressing Abort will immediately stop the machine, the
job can’t be continued.
The values showed during a build job on this tab are only for display and can’t be changed. As an
exception, the user can change from Material Definition to Live Adjustment in the field Material

Parameter Tuning and adjust speed and pressure to more appropriate values. Values will only be
adjusted once Set has been pressed. To save the new values as the default material parameters,
press Save Values as Material Default.
Further, any error messages in the software will be displayed in this screen.
G-code will be generated automatically live in the background during the building process. The
generated G-code is dependent on material properties, project parameters, inner structure definition
and the 3D data in the BPL file. Each time the project is started these values are re-read, a new G-
code will be generated and the object built correspondently.
Figure 58: The project editor tab of the VisualMachines software
In the tab Project Editor new building jobs can be added and old jobs can be edited. By pressing New
a window will open, in which you can pick the BPL file you wish to use. A name can be defined under
Project Name, the values in Number of Parts and Number of Layers are only for display.
A mark can be set in Platform Height Control to make the 3D-Bioplotter™ verify the height
of the platform or any Petri dishes on top of it before starting the job. The height at the center of the
platform will be measured. Clean needle before start ensures that the needle tip is perfectly clean at
the beginning of a job. Calibrate needle before start will run the needle calibration process before
the job starts. Clean after tool change ensures that needle tips are not clogged and clean after each
tool change. If a multi-part project is loaded, the option to build the parts Concurrently or
Sequentially will be available.
Transfer Height defines the height the needle tip should raise after stopping the deposition at the
end of each layer or strand before moving to the next position. Needle offset defines the spacing

between the needle tip and the platform. Values between 50% and 100% of the inner diameter of
the needle tip will be correct, dependent on the materials and platform substrate. Image Taking
Interval (Manufacturer Series only) will let the camera take a picture of the center of
the part every x layers. Use a value of 0 to turn off this option. The images will be saved under
c:visualmachineslogimages[Project name].
All parts of the current job are displayed under Parts. For each part a material can be assigned by
clicking on the part and corresponding material and pressing Assign. Likewise, UV Programs can be
assigned for each part. An Inner Structure Definition should also be assigned for each part. Lastly, for
each part the inner structure and the contour can be turned on or off by placing/removing marks
next to Build Inner Structure and Build Contours.
Hint
When loading a multi material BPL file, several parts will be displayed in the Parts window. Each
part requires material and pattern assignment. In a core-shell type of project, only the shell part
will require contours to be build, if at all.
Figure 59: The dot pattern project editor tab of the VisualMachines software
A new feature of VisualMachines is 2D dot pattern printing using Low Temperature Materials. A
rectangular field centered on the middle of the platform is created using the set Number of Points X
and Number of Points Y. The Distance between Points can be varied in X and Y as long as the size of
the rectangle is smaller than the platform size. Transfer Height defines the height the needle tip
should raise after depositing each dot. A mark can be set in Platform Height Control to make the
3D-Bioplotter™ verify the height of the platform or any Petri dishes on top of it before
starting the job. The height at the center of the platform will be measured.

Figure 60: The material parameter tuning tab of the VisualMachines software
The key feature of the 3D-Bioplotter is the flexibility in the choice of materials. To expedite the
discovery of the processing parameters, the Material Parameter Tuning procedure has been
developed. A mark can be set in Platform Height Control to make the 3D-Bioplotter™
verify the height of the platform before starting the test. Needle offset defines the spacing between
the needle tip and the platform. Values between 50% and 100% of the inner diameter of the needle
tip will be correct, dependent on the materials and platform substrate. The Background Color should
be chosen accordingly.
Under Pressure Tuning Parameter a fixed Speed can be selected, as well as the minimum and
maximum pressure. Click Confirm Clean Platform first once the platform has been correctly
prepared, then Run Pressure Tuning. 5 strands will be printed on the back half of a 100x100 mm
surface.
On the Manufacturer Series only, finally the user can press Check Strand Widths to
automatically use the camera to measure the printed strand diameters.
Analog, the Speed Tuning Parameter can be used at a fixed Pressure with Min and Max Speed
values. The 5 strands will be printed in the front half of the 100x100 mm surface.
Hint
Medium speed will be considered around 10 to 20 mm/sec. Choose the fixed value for the speed in
Pressure Tuning Parameter accordingly. Always test for pressure before testing for speed.

Hint
To optimize the measured results, run the Check Strand Widths with Vision Training on.
Figure 61: Tool Changer tab of the VisualMachines software
Under Maintenance > Tool Changer materials can be assigned to different tools. Choose the material
and a tool number on the left of the material panel and press Assign. When removing the material,
choose the dispense tool and press Remove.
Hint
The tool number is not the parking position. Each head is hardware coded and has a fixed ID
number. The ID number of each individual head is displayed on a small label on each head.
Hint
Once a material has been assigned to a dispense head, heating or cooling set in the material
parameters will start immediately.

Hint
Every time the software starts, the assignment of materials will be reset to avoid unneeded heating
of the heads. It is therefore not required to un-assign the materials on the heads before shutting
down the software
All functions of the parking positions can be accessed from the Tool Changer tab. A circle under each
position will unlock/lock the corresponding position once clicked, underneath which the current
temperature of the dispense head is displayed. After pressing Scan Current Configuration the
dispense head mount will verify each filled park position and reset the numbering of the heads
according to position number.
Hint
When locking a head into position, make sure to first unlock the position, carefully place the head
in the new position and keep on pressing downwards on the head while clicking on the lock button.
Otherwise, the springs in the connector may push the head upwards, misaligning the locking
system.
Hint
Every time a parking position is manually opened, the head assignment for that parking position is
reset. When changing the positions of the printing heads, it will be necessary to Scan Current
Configuration. DON’T open the parking position of the head currently attached to the Z-axis!
In the Change Mounted Tool field a dispense head can be picked up by selecting a certain dispense
head or put back into the parking position by selecting Remove Current Tool. The current mounted
tool, its temperature and filled material are displayed in the field Current Mounted Tool.
Hint
The software will always wait until the temperature of the material is within 1°C of the set
temperature in the software. This may result in some waiting time, but will also ensure optimal
printing results.

Figure 62: The robot head tab of the VisualMachines software
The tab Robot Head allows the user to directly influence the dispense head mount or any dispense
head attached to it. While the X and Y axes can be moved when the machine is off or the software
switch is turned to Off, the Z axis remains locked at all times. The axis can be unlocked on this screen
when the software switch is turned to Off be pressing the Brake Off switch. Press the Brake On
switch to lock the Z axis again.
Hint
When moving the Z axis manually, move it slowly, as it may damage internal components of the
machine.
By pressing Needle Cleaning the procedures set in Figure 68 regarding cleaning of the needle for this
material will be executed. Move to Purge Station will move the dispense head immediately above
the purge station. Purge will dispense material at the displayed pressure, which can be updated live
by inserting a new value in Purge Pressure or clicking on the grey/green bar. Should the Dry Run
option be in use in the Execution Control tab, it can be disabled here by clicking the yellow circle next
to Dry Run.
A fixed Purge Time can also be set and, by pressing Purge (Time Controlled), the 3D-Bioplotter will
dispense at the set pressure for the set amount of time. This function can be used to initially test
material properties at different pressure levels.

Figure 63: The thermocouple tab of the VisualMachines software
The Thermocouple tab displays the current temperature measured by the four thermocouple
positions. These values are also displayed in the Build Control tab (see Figure 57: The build control
tab of the VisualMachines software). The names of the thermocouples can be changed to unique
names, for example the measured position. The names are reset every time the software is turned
off, the values displayed have no effect on the operation of the machine.

Figure 64: The Platform Temperature Control tab of the VisualMachines software (using the Thermo Cube)
Figure 65: The Platform Temperature Control tab of the VisualMachines software (using the Minichiller)

The Platform Temperature Control tab displays any error messages from the Thermo Cube or
Minichiller in State Message. When no message is displayed, the connection to the Chiller is on, at
which point the user can see the current temperature of the Chiller under Current Temperature. By
selecting a value in Platform Temperature and pressing the Set Temperature Manually, the Chiller
can be manually set to a specific temperature (useful immediately after starting the Thermo Cube). If
the values saved in the material definition should be used, the circle next to Set Temperatures
Automatically can be pressed (yellow = on).
In the material definition (Figure 68), the user can select the option of only starting a job when the
necessary platform temperature has been reached, in which case the start of the job would be
delayed until the Thermo Cube heats/cools down to the selected temperature. The maximum
temperature deviation in this particular case can be set in Temp. Check Tolerance.
Figure 66: The camera and needle calibration tab of the VisualMachines Software
Both the camera and the needle can be calibrated in the Camera and Needle calibration tab. Press
Calibrate in the Camera field to calibrate the camera. This process is fully automated; the camera will
take several pictures of the concentric rings on the purge station and use these to calibrate itself. By
pressing Calibrate in the Needle field the needle will first touch the pressure sensor for Z positioning,
clean the needle according to the values set in the Material Editor tab, and finally deposit a small dot
on one of the round calibration plates in the purge station. Lastly, a picture of the small dot will be
taken with the high definition camera to calibrate the needle tip in X and Y.

The values displayed in Current Mounted Tool, Calibration Settings and Needle Offset are only for
visualization and can’t be changed.
Should the results from the calibration process be so wrong, that the z sensor will not be pressed or
the dot be outside of the camera field, then the values can be reset with the appropriate Reset
buttons.
Figure 67: The vision result tab of the VisualMachines software
The Vision Result tab displays the last image taken by the high definition camera of the 3D-
Bioplotter™ for the needle calibration. The image recognition software should encircle the
printed dot with a green line. The center of the dot will be defined as the needle tip position in XY.

Hint
If the dot isn’t encircled, then the contrast between dot and background might be too low. Choose
the other background in the Material Editor tab (see Figure 68: The material editor tab of the
VisualMachines software). The dot might also be too small for the software to correctly recognize,
increase either the pressure or the time of the dot printing values in the Material Editor tab, or
increase the Z offset value.
Hint
For transparent materials, the gray field provides the best results.
Hint
If materials create vertical threads, which are then visible on the image, then careful removal of
the thread may be required for the Vision software to recognize the dot.
Figure 68: The material editor tab of the VisualMachines software
On the Material Editor tab an overview of all saved low and high temperature materials is displayed.
Each material can be selected and the corresponding parameters changed. Under Material Name an

appropriate name of the material can be chosen and a short description of the material (e.g. lot
number, color, etc) can be saved. Under Basic Parameters the values for temperature (2°C – 70°C for
low temperature; 30°C – 250°C for high temperature), Pressure and Speed in X and Y can be set. A
unique description of the needle type or size should be saved for better documentation. The Pre-
Flow Delay defines a short period of time at the beginning of each layer/contour during which the
pressure starts but the needle doesn’t move yet. The Post-Flow Delay defines the short period of
time at the end of each layer/contour after the needle movement has ended but during which
pressure is still being applied. Both values are often required by high viscous materials (see page 32).
Wait time between layers defines a pause between two layers or contours. This pause is often
required by materials with slow hardening processes to allow the material some stability before
adding new material on top of it. The Minimal length value defines the shortest length of one strand
that can be plotted with this material. Any strand shorter than this value will be ignored during the
building process.
When marking the checkbox next to Temperature, the user is able to define Heating Curves. From
one to a maximum of 5 temperatures can be defined, with Waiting Time for each temperature step.
The speed at which the temperature should be reached can’t be set, the 3D-Bioplotter will always try
to reach it at maximum efficiency. The job will only start once the heating curve program has run to
completion.
Platform temperature defines the temperature of the platform as will be controlled by Chiller. If the
job is started before the temperature of the platform is correct, a delay in starting the job can be
automatically set up by placing a mark in wait on platform temperature.
Under Cleaning a number of different procedures can be chosen for needle tip cleaning (used both in
Maintenance > Robot Head and in Calibration > Camera and Needle, as well as in the automated
cleaning procedures during the build). By marking Do Purge the needle will first purge some material
into the purge station at the pressure set under dot printing; the duration can be set under Purge
Time. Marking Thread Strip will let the needle tip pass just a few micrometers above the taut wire to
clean purged material on the needle tip. Additionally, the needle tip can be driven through a Plastic
Brush (for plastic needles) or through a Metal Brush (for metal needles) to remove material remains
on the needle tip. An automated cleaning procedure can also be defined by selecting after how many
layers automated cleaning should occur under Automatic Cleaning Interval.
Hint
Always select Thread Strip if Purge is selected!
Hint
An Automatic Cleaning Interval of 0 means no cleaning procedures should occur. For pastes a value
between 3 and 10 layers should be picked, for polymer melts a value between 5 and 20 layers
should be sufficient. Only use automated cleaning with hydrogels if sterility is not an issue. Never
use automated cleaning with cell laden materials, as sterility of the brushes can’t be assured.

In Dot Printing the Pressure and Dispense Time for Dot Printing Projects can be set. A small
correction of the distance of the needle tip to the base plate can be defined in Needle Z Offset for
improved results. The speed of the movement in Z can be set in Needle Z Speed.
Under Calibration the dark or light Calibration Station can be selected to maximize the contrast
between the material’s color and the platform’s color. A calibration of the needle tip can be
automatically executed after each material change by marking Calibrate after Tool Change. The
Pressure and Dispense Time for the calibration process can be set here as well, as well as the Needle
Z Offset.
Figure 69: The inner structure pattern editor tab of the Visual Machines software
In the Inner Structure Pattern Editor patterns can be loaded, edited and saved. For each layer an
absolute Angle relative to the X axis and a distance between strands relative to the center of the
strands can be defined. A shift in X and Y relative to the superordinate coordinate system can be set
in Strand Shift X and Strand Shift Y. On simple 0/90° inner patterns this will create a complex stair-
like system. Each layer can then be saved by pressing Add New Layer Set. Once two or more layers
are saved, they can be moved up or down the layer set.
The saved inner structure patterns repeat as saved. Two layer sets will create A-B-A-B-A-B…
structures; three layer sets will create A-B-C-A-B-C-A-B-C… structures; four layer sets will create A-B-
C-D-A-B-C-D-A-B-C-D… etc.

Figure 70: The UV Programs tab of the VisualMachines software
In UV Programs patterns can be loaded, edited and saved. For each layer an absolute Angle relative
to the X axis and a distance between strands relative to the center of the strands can be defined. A
shift in X and Y relative to the superordinate coordinate system can be set in Strand Shift X and
Strand Shift Y. On simple 0/90° inner patterns this will create a complex stair-like system. Each layer
can then be saved by pressing Add New Layer Set. Once two or more layers are saved, they can be
moved up or down the layer set.
Figure 71: The support programs tab of the VisualMachines software

From the Support Programs tab the 3D-Bioplotter application and the Magics application (if
installed) can be started.
Figure 72: The tools tab of the VisualMachines software
From the Tools tab User Management can be accessed (for service purposes only).
Additionally, an automated Backup can be set up, either on the hard drive, an USB stick or on the
server to which the PC might be connected. The time interval for the backup can be defined, and a
manual request can be sent by pressing the Create Backup Now button.

7. Quick-Start
7.1. Quick-Start with known material and existing project
1. Turn on the 3D-Bioplotter™ and the VisualMachines software
2. Turn on the Thermo Cube (if required) and verify that enough cooling fluid is filled.
3. Press the On/Off switch in VisualMachines
4. Go to Execution Control > Project Editor and open the correct project
5. Assign the material to the part
6. Assign the pattern to the part
7. Press Save to save the project!
8. Place the cartridge with needle tip in the appropriate printing head.
9. Go to Configuration > Dispense Tool Manager and assign the material to the appropriate
printing head
10. Go to Maintenance > Robot Head
11. Go to the purge station and press purge, until the needle tip is full.
12. Go to Calibration and calibrate the needle
13. Back to Execution Control, press Start
7.2. Quick-Start with known material and new STL file
1. Start the Bioplotter RP software
2. In File > Open choose the appropriate STL file
3. Choose 3D model and keep the arrangement As Is
4. Pick the correct building area and material you wish to use
5. Click on the middle mouse button, then drag with the left mouse button pressed the part
onto the middle of the displayed virtual platform.
6. Click on the middle mouse button again to end the repositioning in XY of the part
7. In Filters > Automatic Placement choose the appropriate z offset (~70% of the needle inner
diameter) and press ok to reposition the part in Z.
8. Choose Pre-Processing in Filters > Slicing
9. Choose Uniform Slicing in Filters > Slicing, with the appropriate layer thickness (~80% of the
needle inner diameter)
10. Save the file as BPL in File > Save As, picking Save Selection Separately
14. Go to Execution Control > Project Editor and press New
15. Choose the BPL file just saved
16. Assign the material to the part
17. Assign the pattern to the part
18. Press Save to save the project!

printing head
22. Go to the purge station and press purge, until the needle tip is full.
24. Back to Execution Control, press Start
7.3. Quick-Start in testing new materials
4. In the tab Programming > Material Editor press New and add a new material
5. Add descriptions for the material, as well as for the needle tip
6. Add a value for temperature, if known
printing head
9. If necessary, wait for the material temperature to increase/decrease
11. Go to the purge station and press purge at a value of 1 bar for 10 seconds or until some
material is dispensed
12. If nothing is dispensed, try for other values in pressure or different needle tips if necessary
13. In the tab Programming > Material Editor, add the final pressure value to Pressure in Basic
Parameters and Calibration / Dot Printing.
15. Go to Safe Height, clean the needle tip manually and press Purge for 3 seconds. Measure the
length of the strand of material that came out of the needle tip.
16. In the tab Programming > Material Editor, add the length of the dispensed material divided
by 2 (people usually count too fast) to Speed in mm
18. If necessary, change dispense time or z-offset in Calibration / Dot Printing of the
Programming > Material Editor tab.
19. Go to Execution Control > Project Editor and open the correct project
20. Assign the material to the a small cube (at least 15x15x5mm)
21. Assign a simple pattern to the project (90° change, 3x needle inner diameter as distance
between strands).
22. Go to Execution Control, press Start
23. Stop Cycle after 3 layers or abort before, if necessary
24. In the tab Programming > Material Editor, change pressure and speed as required to obtain
better results. Repeat from Step 22 until the full part can be built with no defects.

8. Fuse list
Mounted on the back panel of the 3D-Bioplotter™ are the fuses to
the complete electrical components of the system, which can be easily accessed
from the front of the machine. Each is labeled for service.
Do not change fuses without consulting envisionTEC
®
first.
Figure 73: Fuses
ID Component Fuse type
F41.1 Main Fuse 16 A slow-blow (5 mm x 20 mm)
F41.2 Main Fuse 16 A slow-blow (5 mm x 20 mm)
F43 Power Supply Fuse 24 VDC 10 A slow-blow (5 mm x 20 mm)
F44 Power Supply Fuse 48 VDC 6.3 A slow-blow (5 mm x 20 mm)
F45 Power Supply Fuse 48 VDC 6.3 A slow-blow (5 mm x 20 mm)
F51 Fuse for Cooling on Position 1 4 A slow-blow (5 mm x 20 mm)
F51.1 Fuse for Cooling on Position 2 4 A slow-blow (5 mm x 20 mm)
F52.1 Fuse for Cooling on Position 4 4 A slow-blow (5 mm x 20 mm)
F53.1 Fuse for Cooling on Z-Axis 4 A slow-blow (5 mm x 20 mm)
F61 Fuse for Heating on Position 1 6.3 A slow-blow (5 mm x 20 mm)
F61.1 Fuse for Heating on Position 2 6.3 A slow-blow (5 mm x 20 mm)
F62.1 Fuse for Heating on Position 4 6.3 A slow-blow (5 mm x 20 mm)
F63.1 Fuse for Heating on Z-Axis 6.3 A slow-blow (5 mm x 20 mm)

9. Preventive Maintenance
Preventive Maintenance needs to be done regularly to ensure optimal performance of the 3D-
Bioplotter™. Warranty can only be guaranteed if preventive maintenance has been
performed according to plan.
Notice
The time intervals displayed below relate to an 8 hour per day, 5 days per week usage. For more
extensive usage, the time intervals need to be shortened accordingly.
Module Maintenance Action Materials Time Interval
Working Area
The work area must be cleaned
and all foreign objects removed.
Vacuum cleaner;
a dry, lint-less dust cloth
Once per
day
Backup
User files and machine settings
must be backup, preferably to a
server or external medium.
Auto-Backup can be set in
Tools > Tools > Backup
Once per
3 days
Machine Frame
Cleaning of the machine frame,
as well as covers. Assure that
no dispensing residues are on
platform, wires or brushes.
Dry, lint-less dust cloth
Once per
week
Camera
recognition
Calibrate the camera position.
Run the automated
calibration process in
Calibration > Camera
Once per
week
Pneumatic Unit
Release of impurities and liquids
from primary filters, make sure
input pressure is over 6 bar.
See filter manuals for
correct procedure
Once per
week
Camera
recognition
Control of functionality of all
LEDs on the ring around
camera.
Visual control, open tab
Service > Camera
Once per
month
Needle Z
calibration
Rotate the plate of the needle Z
sensor carefully clockwise to
make sure it is locked.
Once per
month
X and Y axes
Manually move the axes from
one end to the next. Make sure
the movement is frictionless.
Once per
month
X and Y linear
measuring strips *
Careful cleaning of the linear
measuring strips
Optical cleaner, ethanol or
iso-propanol; soft, dry,
lint-less, friction free cloth
Once every
3 months
X and Y linear
guide rail *
guide rails. Minimal oiling of the
rails
Petroleum Ether; lint-less,
friction free dust cloth;
B04-XYACHSEN-OEL
Once every
3 months
Z Axis Spindle
guide rails. Minimal greasing of
the spindle
Petroleum Ether; lint-less,
friction free dust cloth;
B04-ZACHSEN-FETT
Once every
3 months
Primary Filter
Element
Once per
year
Sterile Filter
Element
Once per
year

Recommendation
As a dry, lint-free dust cloth use envisionTEC
®
article number B04-ABWISCHTUCH.
As the optical cleaner use envisionTEC
®
article number B04-OPTIC-REINIGER.
* Notice
When cleaning the components of the linear motors (guide rails, measuring strips), only friction
free cleaning supplies can be used. The most important factor is that any dirt or staining is
loosened or dissolved and can be wiped away free of streaks with a soft, lint-free cloth without
applying any pressure.
NO FRICTION IS ALLOWED!
In case of hard-to-remove residues or damage to either rails or measuring strips, contact
envisionTEC
®
before trying more aggressive cleaning agents.
Warning
After any preventive maintenance, always make sure that the working area of the machine, as well
as the axes are free of any foreign object before restarting the system.

10.Troubleshooting
10.1. When working with ceramics
Problem: Frequent clogging of the needle
Solutions:
The ceramic paste must be sieved through a metal sieve previous to insertion in the syringe.
Needle inner diameter should be at least twice the particle size
Plotting speed may be too low, allowing material in the needle tip to dry
Plotting speed may be too low, allowing materials in the needle tip to solidify (if melted).
10.2. When working with polymer melts
Problem: When working with polymer melts with a melting temperature less than 100 °C above room
temperature, the speed of solidification may be too low during object construction, so that previous
layers will still be liquid when starting the next one. The end result is an object with no porosity and
no design accuracy, or outer walls much higher than object interior. This is a common problem when
working with polycaprolactone.
Solution: Increase the Wait Time between layers to allow previous layers to solidify before
continuing the building process.
Problem: Frequent clogging of the needle
Solution: Either the material is still too viscous or the temperature on the needle tip is just below the
melting temperature. Either way, increasing the temperature should resolve the issue.
Problem: Material is being dispensed in droplets instead of strands
Solution: The temperature of the material is too high. This might be only a few degrees. Decrease the
temperature in 5°C steps, wait for 15 minutes and try again. Repeat until the material solidifies or
strands are dispensed.
10.3. When working with hydrogels
Problem: Hydrogel layers do not stick to the surface, especially when printing in a petri dish.
Solution: Use a piece of paper or flat filter on the bottom of the petri dish. Decrease the z-offset in
Bioplotter RP if necessary to improve adhesion.

Problem: Hydrogel layers do not stick to the previous layer, especially when printing in a liquid.
Solution: The solidification process of the individual layers is too fast. Decrease the speed of the
solidification process.
10.4. General troubleshooting
Problem: The dot is visible in the camera calibration, but is not automatically recognized.
Solution: The dot is too small. Increase the pressure or dispense time, or if no change is visible, the z-
offset in calibration/dot-printing.
Problem: The strands of the top layer are wavy, instead of being straight.
Solution: Too much material is being dispensed and is being pushed to the sides. Decrease pressure
or increase speed for that particular material.
Problem: The strands of the top layer are straight, but the previous layers are wavy.
Solution: Too much material is being dispensed and the material is pushing the previous layers.
Decrease pressure or increase speed for that particular material.
Problem: On large objects, the corners are visibly higher than the center of the object.
Solution: Either the material is shrinking, or too little material is being dispensed. Slightly increase the
pressure or decrease the speed for that particular material.
Problem: The object requires more material than can be filled in one single cartridge.
Solution: During the job, before the cartridge runs out, press Stop Cycle. Refill the cartridge, wait for
the material to melt if necessary, purge material from the needle tip and do a new needle
calibration. Press Start and answer Yes when asked if you wish to continue the previous job.
The better the calibration on each step, the smoother the surface will be on the finished object.
Problem: No material is being dispensed in the first layer.
Solution: The Z-offset used in Bioplotter RP is too small, the needle is scratching the surface. Increase
the Z-offset.

Problem: The first layer is completely closed, while following layers have vertical porosity.
Solution: The Z-offset used in Bioplotter RP is too small, the material is being spread across the
surface. Increase the Z-offset.
Problem: Material is being deposited in the first layers correctly, but as a series of dots in later layers.
Solution: Not enough material is being dispensed to create a strand. Instead, a droplet is being
accumulated on the needle tip, until it touches previously deposited material. Increase the pressure
or decrease the speed for this particular material.
Problem: The z-axis will take a long time to pick up a head.
Solution: The z-axis will only pick-up a head when the temperature of the head is within a margin of
1°C from the set temperature for the assigned material. In tool changer will be displayed which
temperature is set and the current head’s temperature. By changing the set temperature to the
current temperature in Programming, the head will be picked up almost immediately after.
10.1. VisualMachines Error Messages
Reason: Calibration or cleaning can’t be done if no material has been assigned to the tool on the Z-
axis.
Solution: Assign a material to the tool in the Configuration -> Dispense tool manager tab.

Reason: The needle tip is too short during the calibration process.
Solution: Either use a longer needle tip or the white Luer Lock Adapter as an extension to the existing
needle (needs to be screwed in from the outside).
Reason: VisualMachines is expecting the Thermocube to reach the correct temperature, but it is
currently not on.
Solution: Either turn the Thermocube on, check for error messages or disable the Thermocube
connection to VisualMachines in the Configuration -> Thermo Cube tab, option Set Temperature
Automatically (Material Definition)
Reason: The material defined in the project is not assigned to a tool.
Solution: Choose the correct material either in Execution Control -> Project Manager or in the
Configuration -> Dispense tool manager tab.

Patterns (top view)
Pattern Angle Mechanical Stability Porosity
0° Low High
90° Medium Medium
45° High Low

10.2. Layer thickness (vertical cut of several layers)
Observed Description
Layer thickness is set too high; the layers are only connected at
small spots. The objects have very low mechanical stability
Layer thickness is set too low, later layer press onto the
previous ones, causing elliptical strand formation and may also
cause movement of strands on the previous layers. Porosity is
lowered due to smaller spaces between strands
Layer thickness is set right, strands overlap around 10 % on
connection points to create strong bonds between layers
The smaller the object, the less impact a wrong layer thickness will have. The error is linear, which
means it will be clearer on larger objects. For example with a 10 % error at 10 and 20 layers:

10.3. Adhesion to the building platform (vertical cut of the first layer)
Observed Description Solution
Low contact of the first layer with the
bottom, material will not stick and
strands will move while plotting the
second layer
Increase pressure
Decrease XY speed
Increase platform
adhesiveness
Very broad strands, high contact with
the surface, very low porosity of the
first layer
Decrease pressure
Increase XY speed
Increase material viscosity
Strands only slightly larger than on
further layers, good adhesiveness to
the surface, height is around 80%
strand diameter
-

10.4. Corners (top view)
Very rounded corners, side movement
pulls the previous strand slightly
sideways, high side porosity, decreased
mechanical stability
Increase pressure
Decrease speed
Thick fuzzy corners, large drops of
materials on the sides, no side porosity,
exterior wall is higher than the interior of
the scaffold
Decrease pressure
Increase speed
Sharp corners, no sideways pull, low side
porosity, good mechanical stability,
interior and exterior are equal in height
-
10.5. Distance between strands (vertical cut of two layers)
Upper strand drops between strands
of the previous layer
Decrease distance between
strands
Decrease speed
Increase material solidification
speed
Upper strands do not drop, but are
unequal in height regarding the
position over the previous layer
Increase layer thickness
Increase material solidification
speed
Strands are always straight and
equal in height, disregarding
position over the previous layer
-

10.6. Easily visually observable pattern defects
Relationship between pore size and
strand diameter does not fit the
programmed pattern.
Example: 400 µm needle and
0.8mm distance between strands
should result in equally sized
strands and pores.
Increase or decrease speed
as required.
Strand diameter is clearly larger
over holes of the previous layer, a
typical sign of too much material
being deposited.
Decrease speed
Increase speed.
Strand diameter is clearly smaller
over holes of the previous layer, a
typical sign of too little material
being deposited and then stretched
Increase pressure
Decrease speed

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