01.1 - Operating Manual - M2 Gen3 - A1117 - EN

M2 cusing
Single-Laser / Dual-Laser
Operating Manual
Version: 1.1.17
M2 cusing Operating Manual
Other applicable documents
The following documents which also apply together with this operating manual are enclosed in the
annex to this operating manual:
 M2 cusing installation manual

 CL WRX software manual
 Operating manual for the fiber laser system
 Operating manual for the scan head
 Operating manuals for machine PC
 Electrical plan
 Pneumatics plan (compressed air, inert gas)
 Safety data sheets for metal powders
 Process guidelines
Concept Laser GmbH

An der Zeil 8 96215 Lichtenfels
Tel.: +49 (0) 9571 / 1679-444
Fax: +49 (0) 9571 / 1679-499
Email: info@concept-laser.de
Internet: www.concept-laser.de
Version: 1.1.17
© Concept Laser GmbH 2017
Version 1.1.17
Table of contents
Table of contents
1 General information................................................................................................1
1.1 Purpose of the operating manual................................................................................................... 1
1.2 Storage of the operating manual.................................................................................................... 1
1.3 Conventions of presentation and explanation of symbols ................................................. 1
1.4 Indication of liability ............................................................................................................................. 3
1.5 Copyright protection............................................................................................................................ 3
1.6 Figures and drawings........................................................................................................................... 3
2 General safety instructions ...................................................................................4

2.1 Designated use ....................................................................................................................................... 4
2.2 Improper use ........................................................................................................................................... 4
2.3 Basic safety instructions .................................................................................................................... 5
2.3.1 Dangers posed by electrical energy ........................................................................................ 5
2.3.2 Dangers posed by pneumatic equipment and inert gas supply ................................. 6
2.3.3 Dangers posed by explosion and fire ..................................................................................... 6
2.3.4 Danger posed by laser radiation .............................................................................................. 7
2.3.5 Dangers posed by mechanisms................................................................................................ 8
2.3.6 Dangers posed by harmful, chemical substances ............................................................ 8
2.3.7 Dangers posed by high temperatures ................................................................................... 9
2.3.8 Gerneral dangers at the workspace ....................................................................................... 9
2.4 Responsibility oft he operator ...................................................................................................... 10
2.5 Qualification oft he personnel ...................................................................................................... 11
2.6 Handling reactive metal powders ............................................................................................... 12
2.6.1 What are reactive materials? ................................................................................................. 12
2.6.2 Rules of behaviour when handling reactive materials................................................. 13
2.6.3 Appropriate storage ................................................................................................................... 14
2.7 Personal protective equipment ................................................................................................... 15
2.7.1 Classification of the personal protective equipment ................................................... 16
2.7.2 Use of the required personal protective equipment .................................................... 17
2.8 Safety and emergency stop devices........................................................................................... 18
2.8.1 Emergency stop switch ............................................................................................................. 18
2.8.2 Main switch with emergency stop function ..................................................................... 20
2.8.3 Separating protective devices and protective doors ................................................... 21
2.9 Securing against reactivation ....................................................................................................... 21
2.10 Danger areas ........................................................................................................................................ 21
2.11 Safety notices on the device ......................................................................................................... 22
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Table of contents
3 Technical data ....................................................................................................... 26

3.1 General specifications...................................................................................................................... 26
3.2 Build module......................................................................................................................................... 26
3.3 Connected loads ................................................................................................................................. 26
3.4 Performance data .............................................................................................................................. 27
3.5 Laser system ........................................................................................................................................ 27
3.6 Ambient conditions ........................................................................................................................... 27
3.7 Approved metal powders (classification) ................................................................................ 28
3.7.1 Non-reactive metal powders .................................................................................................. 28
3.7.2 Reactive metal powders ........................................................................................................... 28
3.7.3 Hydrogen-forming metal powders....................................................................................... 28
3.8 Emissions ............................................................................................................................................... 29
3.9 Type plate .............................................................................................................................................. 29
4 Structure and function ........................................................................................ 30

4.1 Theoretical principles of the LaserCUSING® process ....................................................... 30
4.1.1 Laser radiation – theoretical principles ............................................................................. 31
4.2 Performance specification ............................................................................................................. 32
4.3 Overview of the M2 LaserCUSING® machine ........................................................................ 33
4.3.1 Process station ............................................................................................................................. 35
4.3.2 Handling station ........................................................................................................................... 38
4.3.3 Build module .................................................................................................................................. 40
4.3.4 Accessories and additional equipment .............................................................................. 42
4.4 Laser system ........................................................................................................................................ 43
4.5 Filter module and ventilator .......................................................................................................... 44
4.6 Connections.......................................................................................................................................... 45
4.6.1 Inert gas supply and pneumatic system ............................................................................ 45
4.6.2 Electrical equipment and machine PC................................................................................ 46
4.7 Displayes and operating elements ............................................................................................. 47
4.7.1 Displays ............................................................................................................................................ 47
4.7.2 Control panel ................................................................................................................................. 48
4.8 Software ................................................................................................................................................. 50
4.8.1 CL WRX machine software ...................................................................................................... 50
4.8.2 QM coating software .................................................................................................................. 50
4.9 QM modules ......................................................................................................................................... 51
4.9.1 QM meltpool .................................................................................................................................. 51
4.9.2 QM laser........................................................................................................................................... 51
4.9.3 QM atmosphere ........................................................................................................................... 51
4.9.4 QM documentation ..................................................................................................................... 51
4.9.5 QM coating ..................................................................................................................................... 51
4.9.6 QM liveview .................................................................................................................................... 51
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Table of contents
5 Transport, installation and initial commissioning .......................................... 52
6 Operation .............................................................................................................. 53
6.1 Safety instructions for operationg .............................................................................................. 53
6.2 Qualification of the personnel ...................................................................................................... 56
6.3 Personal protective equipment ................................................................................................... 57
6.3.1 Classification of the personal protective equipment ................................................... 58
6.3.2 Use of the required protective equipment ....................................................................... 59
6.4 Shutdown in an emergency ........................................................................................................... 60
6.4.1 Switching on machine after emergency stop .................................................................. 61
6.5 Before switching on........................................................................................................................... 62
6.6 Switching on ......................................................................................................................................... 63
6.7 Carrying out a reference run ......................................................................................................... 65
6.8 Preparing the build process ........................................................................................................... 67
6.8.1 Preparing the build plate .......................................................................................................... 67
6.8.2 Preparing the handling station .............................................................................................. 68
6.8.3 Inertising the glovebox .............................................................................................................. 70
6.9 Pouring in powder .............................................................................................................................. 72
6.9.1 Filling with powder bottles ...................................................................................................... 73
6.9.2 Filling with powder containers .............................................................................................. 75
6.10 Opening the inertised glove box .................................................................................................. 82
6.11 Inserting the powder container into the machine ............................................................... 85
6.12 Fitting the build plate ....................................................................................................................... 88
6.12.1 Cleaning the build chamber platform ................................................................................. 88
6.12.2 Fitting the standard build plate ............................................................................................. 90
6.12.3 Fitting the build plate with clamping system .................................................................. 91
6.12.4 Final tasks ....................................................................................................................................... 92
6.13 Defining the zero position of the build plate (scraping) ..................................................... 93
6.13.1 Using the coater blade made of steel ................................................................................. 95
6.13.2 Using the coater blade made of plastic or elastomer .................................................. 96
6.14 Starting the build process .............................................................................................................. 99
6.14.1 Creating the build job................................................................................................................. 99
6.14.2 Moving the build module into the process station...................................................... 102
6.14.3 Inertising the process chamber........................................................................................... 104
6.14.4 Carrying out individual layer exposure ............................................................................. 106
6.14.5 Starting the automatic build process ............................................................................... 108
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Table of contents
6.15 Observing the build process ........................................................................................................ 109

6.15.1 Observing the movement path of the coater ................................................................ 109
6.15.2 Observing the powder application and the applied layer of powder .................. 109
6.15.3 Observing the melting process ............................................................................................ 111
6.15.4 Observing the part .................................................................................................................... 111
6.15.5 Observing the extraction / inertisation ............................................................................ 112
6.16 Interrupting and continuing the build process .................................................................... 113
6.16.1 Interrupting and continuing the build process ............................................................. 113
6.16.2 Continuing the build process ................................................................................................ 113
6.17 Completing the build process ..................................................................................................... 116
6.17.1 Moving the build module into the handling station .................................................... 116
6.17.2 Cleaning metal powder off the part................................................................................... 117
6.17.3 Disassembling the build plate .............................................................................................. 121
6.18 Removing the part ........................................................................................................................... 124
6.19 Removing the powder container from the machine ......................................................... 128
6.20 Changing powder ............................................................................................................................. 130
6.21 Switching off ....................................................................................................................................... 131
6.21.1 Standby mode ............................................................................................................................. 132
7 Faults .................................................................................................................... 133

7.1 Safety instructions for troubleshooting ................................................................................. 133
7.2 Qualification of the personnel .................................................................................................... 135
7.3 Troubleshooting tasks.................................................................................................................... 136
7.3.1 What to do in the event of a fault....................................................................................... 136
7.3.2 Measures prior to operation following faults ................................................................ 136
7.4 General handling of error messages ........................................................................................ 137
7.5 Error messages ................................................................................................................................. 138
8 Maintenance........................................................................................................ 152
8.1 Safety instructions for maintenance ....................................................................................... 152
8.3 Maintenance schedule ................................................................................................................... 157
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Table of contents
8.4 Cleaning the LaserCUSING® machine ..................................................................................... 159

8.4.1 Powder removal ......................................................................................................................... 160
8.4.2 Transferring the metal powder into powder bottles.................................................. 163
8.4.3 Cleaning the machine surface (outside) .......................................................................... 170
8.4.4 Cleaning of the handling station ......................................................................................... 171
8.4.5 Cleaning the guide rails and drive belt of the coater ................................................. 173
8.4.6 Cleaning the coater blade ...................................................................................................... 174
8.4.7 Cleaning emptying openings of the build and powder chamber shafts ............ 175
8.4.8 Cleaning of the process chamber ....................................................................................... 178
8.4.9 Cleaning the protective glass of the scan head lens .................................................. 179
8.5 Cleaning the filter module ............................................................................................................ 181
8.5.1 Separating and flooding the filter module ...................................................................... 182
8.5.2 Changing the filter cartridge ................................................................................................. 185
8.5.3 Storage and disposal of the filter cartridge .................................................................... 188
8.5.4 Connecting the filter module to the machine ............................................................... 189
8.6 Cleaning the powder container (master container) .......................................................... 191
8.7 Inspection and maintenance work ........................................................................................... 194
8.7.1 Visual inspection for any damage or wear...................................................................... 194
8.7.2 Checking / setting the pressure of the gas connections ........................................... 196
8.7.3 Checking / setting the pressure of the expansion seal ............................................. 197
8.7.4 Replacing glove box gloves .................................................................................................... 198
8.7.5 Checking / emptying the condensate container on the maintenance unit ...... 199
8.7.6 Rotating or replacing the coater blade ............................................................................. 200
8.7.7 Replacing the excess pressure filter of the process chamber................................ 207
8.7.8 Checking the level of contamination of the build and powder chamber shafts
........................................................................................................................................................... 209
9 Dismantling, storage and disposal .................................................................. 212

9.1 Safety instructions for dismantling .......................................................................................... 212
9.3 Dismantling the product ............................................................................................................... 214
9.4 Storage.................................................................................................................................................. 214
9.5 Disposal of the Product ................................................................................................................. 215
10 Accessories, wearing and spare parts ............................................................. 216
11 Support and Customer Service ........................................................................ 217
12 Table of figures ................................................................................................... 218
13 Maintenance record ........................................................................................... 219
Version 1.1.17 v
1 General information
Read the operating manual!
To ensure that the machine is used safely and correctly, the operating manual and all other documents
accompanying the product should be read carefully.
1.1 Purpose of the operating manual

This operating manual provides information about safety, transport and storage, installation, initial
comissioning and decomissioning, structure and function, operation and maintenance of the M2 cusing
LaserCUSING® machine.
This operating manual is intended for the operator and user of the machine and must be read before it
is first put into operation.
It can also be used as a basis for training of the corresponding personnel.
It is urgently recommended for the machine operator to get confirmation from the user in writing that
they have taken a note of and are aware of the safety instructions which are listed.
If this operating manual is lost, the operator or the user of the machine is requested to ensure that it is
replaced.
1.2 Storage of the operating manual

This operating manual (inclusive the other applicable documents) is an integral part of the M2 cusing
machine and should always be kept readily available near to it.
The user of the LaserCUSING® machine must be able to access the operating manual at any time.
1.3 Conventions of presentation and explanation of symbols

Signal words in safety instructions and their meaning
This operating manual contains warnings and notices which are needed for safe handling of the
machine.
Signal word Meaning
Danger Immediate hazard with a high risk.

DANGER indicates a dangerous situation which leads to death or serious injuries
if instructions are not heeded.
Warning Possible hazard with a medium risk.
WARNING indicates a dangerous situation which can lead to death or heavy
injuries if instructions are not heeded.
Caution Hazard with a low risk.
CAUTION indicates a dangerous situation which may lead to slight to heavy
injuries if instructions are not heeded.
Table 1-1: Signal words and their meaning
Version 1.1.17 1
Structure of the safety instuctions

The safety instructions contain information about the danger, the possible consequences and the
emergency response measures.
Nature and source of the danger.
Possible consequences if the danger is disregarded.
 Measures to avert the danger.
Signal word
List of warning symbols used

The following safety symbols are used in this operating manual.
Warning about a danger spot Warning about the risk of squeezing
Warning about dangerous electrical Warning about potentially explosive

voltage substances
Warning about laser radiation Warning about the risk of slipping
Warning about hot surfaces Warning about the risk of tripping over
Warning about harmful and irritant Warning about flammable substances

substances
Warning about hand injury
Information notices
Note
Note indicates information and useful tips.
Order
Order indicates a situation in which personal protective equipment is required.
Typographical conventions
The following typographical conventions are used in this operating manual:
 Prompt to perform an action
1.
Prompt to perform a sequence of actions in a specific order
2.
 Indicates the consequence of an action
–,,▪ Bullet point

italic Indication of cross-references
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1.4 Indication of liability

All information and notes provided in this operating manual were compiled with consideration of the
applicable standards and regulations, the state of the art and our many years of knowledge and
experience.
In the following cases the manufacturer cannot accept any liability or provide any guarantee for
damage:
– In the event of failure to follow this operating manual
– In the event of non-designated use of the machine
– In the event of employment of non-trained and unauthorized personnel
– In the event of unauthorized technical modifications
– In the event of technical changes
– In the event of use of non-recommended spare parts or accessories
– In the event of unsatisfactory monitoring of parts which are subject to wear and tear.
– In the event of inappropriate implementation of repair and maintenance work
– In the event of operation of the machine with defective safety and protection devices.
The obligations agreed in the delivery contract, the general terms and conditions as well as the delivery
terms and conditions of the manufacturer and the statuary regulations valid at the time of the
conclusion of this contract apply.
1.5 Copyright protection

© Copyright 2017 CONCEPT Laser GmbH
All rights reserved.
This documentation contains information which is protected by copyright.
This documentation may not be photocopied, multiplied, translated or digitally stored either completely
or in extracts without agreement of the CONCEPT Laser GmbH.
Changes to this documentation or the product described which involve technical advancement are
reserved. This documentation describes the condition of the product at the time of publication and may
not necessarily match future versions of the product.
1.6 Figures and drawings

Figures and drawings serve a general illustrative purpose.
Possible functions and representations may differ from the machine supplied. The specified dimensions
are non-binding.
Version 1.1.17 3
2 General safety instructions

This section provides an overview of all the important aspects of safety for protecting people and
ensuring safe and trouble-free operation. Further task-specific safety instructions are contained in the
sections on the individual stages.
2.1 Designated use

The M2 cusing LaserCUSING® machine is designed to be used exclusively for the purpose of
manufacturing components from metal powder using laser radiation (LaserCUSING® process).
Designated use includes in particular:
– installation and operation of the machine in a well-ventilated room.
– reading this operating manual and complying with all of the instructions contained in it, in particular
the safety instructions.
– complying with the local accident prevention regulations and the national provisions on
occupational health and safety.
– complying without exception with the specifications provided in the chapter General safety
instructions on the page 4 and using exclusively the materials which are described in the material
data sheets.
– carrying out all inspection and maintenance work at the prescribed time intervals.
Any use which extends beyond the designated use or any other type of use is deemed to be improper
use.
2.2 Improper use

Danger posed by improper use!
If the LaserCUSING® machine is not used in the designated way, this may lead to dangerous situations.
 Use the M2 cusing LaserCUSING® machine only for assignments which correspond to the
DANGER designated use.
The following processes must not be carried out using the M2 cusing LaserCUSING® machine under any
circumstances and are deemed to be improper use:
– Laser marking
– Laser material erosion
– Manufacturing of parts from metal powders other than those which are specified in this operating
manual or in the enclosed material sheets.
Claims of any type on account of damage caused by non-designated use are excluded.
Version 1.1.17 4
2.3 Basic safety instructions

The following section lists residual risks which can be presented by the machine even if it is used in the
designated way.
To reduce the risks of personal injury and material damage and to avoid dangerous situations, the safety
instructions which are listed here and the safety instructions in the subsequent sections of this manual
must be followed.
2.3.1 Dangers posed by electrical energy

Danger posed by dangerous electrical voltage!
If you touch live parts, there is an immediate danger to life posed by electric shock. Any damage to the
insulation or individual parts may be life-threatening.
DANGER  Never touch live parts of the machine.
 The electrical cabinet, protective doors and components must be kept closed at all times. Access
is permitted only to authorised personnel with a key or tool.
 Have any electrical work which is not described in this operating manual carried out only by a
qualified electrician. Unqualified personnel must be forbidden from carrying out work on electrical
components!
 Regularly check the electrical cables for any signs of damage. If there is any damage, switch off the
voltage supply immediately and arrange for a repair to be carried out.
 Before any work is carried out on the electrical equipment, the LaserCUSING® machine must be
disconnected from the mains power supply via the main switch. The machine must be secured with
a padlock to prevent it being switched on again unintentionally.
 After work has been done on the electrical equipment, all safety-relevant circuits and assemblies
must be checked to ensure that they work properly. Any loose connections must be tightened again
and damaged lines and cables must be replaced.
Danger posed by stored charges!

Electronic components may have stored electric charges which are retained even after the component
has been switched off and disconnected from the power supply.
DANGER After all main switches have been switched off, life-threatening voltages may still exist on the following
components:
– Mains cables
– Power units
– Drive amplifier
– Laser supply
 Before working on the specified components, in particular the mains cables, disconnect them
completely from the power supply. Allow 10 minutes to pass in order to ensure that the internal
capacitors have fully discharged.
Version 1.1.17 5
2.3.2 Dangers posed by pneumatic equipment and inert gas supply

Danger of suffocation from toxic gases or inert gas!
Escaping inert gas, such as the colourless and odourless protective gases nitrogen and argon, can cause
a lack of oxygen.
DANGER  Do not damage or disassemble inert gas lines.
 Always check the inert gas connections to make sure they are solid and tight.
 Check the inert gas supply and connections for any leaks.
 Always make sure there is sufficient ventilation when working on the machine.
 If a gas leak is discovered, the room must be vacated immediately and you may only reenter it
wearing suitable breathing equipment.
 It is imperative that you follow the safety data sheet for the inert gases used, as well as the
operator's operating instructions.
Danger posed by compressed air!

Warning about injuries caused by hoses spinning around, swirled-up dust and movement of pneumatic
drives.
DANGER
 Do not damage or disassemble lines carrying compressed air.
 Always check the compressed air connection to make sure it is solid and tight.
 Check the compressed air lines and connections for any leaks.
 The lines and hoses carrying compressed air may only be replaced by Concept Laser GmbH.
2.3.3 Dangers posed by explosion and fire

Danger of explosion from reactive metal-air mixtures!
Swirling up of the approved light-metal alloys as well as their process-related soot and filter residues in
an atmosphere containing oxygen may produce an explosive atmosphere.
DANGER  Mark the danger area around the machine as a potentially explosive area (EX area).
 Avoid the use of any effective ignition sources within the potentially explosive area.
 There is a complete ban on smoking in the EX area.
 Wear antistatic protective equipment in order to prevent electrostatic discharge.
 Avoid swirling up metal powder or metal dust, soot deposits and filter residues.
 Never extract reactive metal powder using a conventional vacuum cleaner or industrial vacuum
cleaner; always use an approved wet separator.
 Only extract very small residual amounts of metal powder.
 Never extract metal powder from small, enclosed volumes
 Always wipe off soot residues or filter residues using a cloth slightly damped with water.
 Only start the extraction when sufficient inertisation of the process chamber with a residual oxygen
content of max. 2% has been achieved.
 Never open the process chamber door during an ongoing build process or when the ventilator is
turned on.
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Danger of explosion from formation of oxyhydrogen!

Different metals react to different extents with water to form hydrogen. Flooding of the filter module
with water will result in the formation of small amounts of hydrogen. When these metal powders are
DANGER extracted with the wet separator using water as the separating medium, this also results in the
formation of hydrogen in the wet separator. If hydrogen accumulates and mixes with air containing
oxygen, an explosive hydrogen-air mixture known as oxyhydroen is produced.
 Ensure that there is sufficient ventilation in endangered areas.
 Only ever store water / metal mixtures and moist metal residues in open containers outdoors or in
containers which can be vented.
 Check the water level in the wet separator before and regularly during operation.
 Empty and clean the wet separator and the accessories used as required, but at least once a day at
the end of the working day.
Danger of fire from highly flammable substances!

Reactive metal powders, soot deposits and filter residues can catch fire and cause serious to fatal
injuries.
DANGER  Smoking is prohibited within the danger area and the immediate surroundings. Do not use any
naked flames or ignition sources.
 A suitable fire extinguisher must be placed in the area of the M2 cusing LaserCUSING® machine.
 To extinguish the fire, only use metal fire-extinguishing powder fire class D.
 Never attempt to put out the fire using water.
 In the event of a fire, stop work immediately. Vacate the danger area until the all-clear is given.
2.3.4 Danger posed by laser radiation

Danger of injury from laser radiation!
Laser radiation is very dangerous to the eye and can destroy the retina.
Laser radiation is dangerous to the skin and causes burns.
DANGER
Laser radiation can cause fires and explosions.
 Never carry out any work with the laser system switched on.
 The safety devices, in particular the housing cover, the protective doors and the cover hood, must
not be opened.
 Never look directly at the laser beam or the scatter beam.
 Always use suitable laser protection goggles in the danger range of the laser. (Laser protection class
4, wavelength 1070 nm)
 Never place body parts in the path of the laser beam. This also applies to parts of the body covered
with clothing.
Version 1.1.17 7
2.3.5 Dangers posed by mechanisms

Danger of injury from squashing on the doors!
If body parts are situated between the door and the machine when doors are being opened and closed,
this can result in serious injuries.
WARNING  No body parts should be located between the door and the machine when the doors are being
opened and closed.
Danger of injury from squashing on the build module!

If body parts are situated in the movement path of the build module, this can lead to squashing.
 During the movement of the build module, there are must be no people, body parts or objects in the
WARNING movement path.
Hand injury caused by squashing on the coater!

When the coater is moved, this can cause hand injuries.
 The M2 cusing LaserCUSING® machine must not be opened during the build process.
CAUTION
 When the coater is operating, you must not reach into the glove box.
Hand injury caused by cutting on the coater blade!

Sharp edges and pointed corners can cause abrasions and cuts to the skin.
 Be careful when working close to sharp edges and pointed corners.
CAUTION
2.3.6 Dangers posed by harmful, chemical substances

For details about safety measures, the recommended safety equipment and about first-aid measures,
please consult the safety data sheets for the individual metal powders!
Danger of damage to health when handling metal powders and filter dusts!
When handling metal powders and filter dusts, there is the danger of damage to the respiratory tract
and lungs.
WARNING If the metal powder or its dusts get into the eyes, there is the danger of damage to the eyes.
Metal powders and filter dusts are suspected of having a carcinogenic effect.
 Wear a suitable breathing mask when handling metal powders and filter dusts. We recommend a
breathing mask with a P3 particle filter.
 Wear suitable, close-fitting protective goggles.
 Particular care must be taken when working on the build chamber and removing the filter cartridge
of the filter module. Swirling up of powder should be avoided.
 Follow the relevant safety data sheets for the individual metal powders which are attached to this
operating manual. The specifications contained in them must be complied with at all times.
 The recommended protective equipment must always be worn.
 Eating and drinking and storing foodstuffs is prohibited in areas in which powder or soot deposits
are to be expected.
 Maintain general workplace hygiene.
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Danger of damage to the skin from contact with metal powders!

The metal powders CL 20ES, CL 50WS, CL 91RW, CL92PH, CL 100NB (Inconel 718) and CL 101NB
(Inconel 625) contain the element nickel. Nickel is a toxic element which causes irreversible damage to
WARNING the skin. Nickel is suspected of being allergenic and carcinogenic.
 You should wear suitable protective gloves when handling these metal powders and their filter
dusts.
 Particular care must be taken when working on the build chamber and removing the filter cartridge
of the filter module. Swirling up of powder should be avoided.
operating manual.
2.3.7 Dangers posed by high temperatures

Danger of injury posed by hot surfaces!
The parts are machined using a laser beam. The surfaces of the parts may be hot.
 Before working in the area of the build plate and with parts or hybrid parts, wait until they have
CAUTION cooled down to below 40°C.
 When removing the filters and claning the chambers, heat protection gloves must be worn.
2.3.8 Gerneral dangers at the workspace

Danger of injury from falling or tripping over supply lines of the machine!
The electrical cables of the machine, as well as ventilator, cooling water, inert gas and compressed air
lines, present a trip hazard. A fall may cause serious injuries.
CAUTION  The lines must be secured in place with appropriate covers so that people cannot trip over them or
get their foot caught in them.
 Mark the trip hazards with marker tape.
 Remove any objects which are no longer needed from the working area and in particular from the
area close to the floor.
Danger of injury from slipping on metal dusts!

Metal dusts present a slip hazard. A fall may cause serious injuries.
 Keep the working area clean and dry at all times.
CAUTION
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2.4 Responsibility oft he operator

Definition of operator
The operator is the person who operates the machine himself for commercial or economic purposes or
hands it over to a third party for use / application and during operation bears legal product responsibility
for the protection of the user, the personnel or third parties.
Operator's duties
The M2 cusing LaserCUSING® machine is state of the art and guarantees a high level of safety. When
operating the machine in practice, this safety can only be achieved if all of the necessary measures are
taken.
It is the operator’s duty of care to plan these measures and to check that they are carried out.
In addition to the safety instructions in this manual, the safety, accident prevention and environmental
protection regulations which apply to the area in which the machine is used must be complied with.
The following applies here in particular:
 The M2 cusing LaserCUSING® machine and its components may only be used in the designated way.
(See section 2.1 Designated use)
 The M2 cusing LaserCUSING® machine and its components may only be operated when they are in
perfect working condition. If any damage or destruction is found on the M2 cusing LaserCUSING®
machine and / or its components, the machine must be taken out of operation immediately and
Concept Laser GmbH's customer service team must be notified. (See chapter 11 Support and
Customer Service)
 All safety devices must be checked at regular intervals to make sure they are in good working
condition and complete.
 The repair and maintenance schedule contained in this operating manual must be implemented.
 The operator must clearly lay down and stipulate the responsibilities for installation, operation,
troubleshooting, maintenance and cleaning.
 Only qualified and authorised personnel may operate, maintain and repair the machine.
 The personnel must receive instruction at lease once a year on occupational safety and protection
of the environment.
 The operator must ensure that all people who come into contact with the machine have read and
understood this manual.
 The operator must provide the personnel with the necessary protective equipment and issue a
binding instruction that the necessary protective equipment must be worn.
 All safety notices and warning signs which are attached to the M2 cusing LaserCUSING® machine
must be clearly legible at all times and must not be concealed or removed.
Instruction
The operator must provide instruction to the personnel on a regular basis. To make this easier to track,
an instruction record should be prepared with the following minimum content:
– Date of the instruction
– Name of the person receiving instruction
– Contents of the instruction
– Name of the person giving instruction
– Signatures of the person receiving and person giving instruction
Version 1.1.17 10
2.5 Qualification oft he personnel

The different tasks described in this manual present different requirements in relation to the level of
qualification of the people who are entrusted with these tasks.
Danger if the personnel are insufficiently qualified!
Insufficiently qualified people are not able to assess the risks when working with the machine and place
themselves and others at risk of serious or fatal injuries.
DANGER  Make sure that all work is only carried out by people who are qualified to do it.
 Keep insufficiently qualified people away from the working area.
All work may only ever be carried out by people who can be expected to execute this work reliably.
People whose ability to react is influenced, e.g. by drugs, alcohol or medicine, are not allowed to carry
out any work.
User
The operating personnel must be at least 18 years old and have good knowledge of the operating
language.
Only people who have read and understood this manual may carry out work on the machine. The
operator is urged to get users to confirm in writing that they are aware of the content of this operating
manual.
The user has received instruction in an instruction briefing by the operator on use, safety devices and
possible hazards in the event of incorrect behaviour. The user may only carry out tasks which go beyond
normal operational use if this is specified in the manual and the operator has explicitly given the user
this task. The operator is urged to get users to confirm in writing that they have received the instruction
briefing.
Maintenance personnel
The maintenance personnel is authorised to carry out tasks which go beyond normal operational use.
These include special maintenance work.
Only people who have received an operator training session and an additional instruction briefing by the
manufacturer are permitted to carry out special maintenance work. The operator is urged to get the
maintenance personnel to confirm in writing that they have received the instruction briefing.
Manufacturer
Certain pieces of work may only be carried out by specialist personnel from the manufacturer.
Other personnel are not authorised to carry out this work. To arrange for the required work to be carried
out, contact our customer service department. (See chapter 11 Support and Customer Service)
Version 1.1.17 11
2.6 Handling reactive metal powders

2.6.1 What are reactive materials?
The metal powders which are approved for the LaserCUSING® process include metal powders of
aluminium and titanium. These powders and the process-related soot residues from all approved metal
powders are reactive.
This means that they react very quickly with other substances such as oxygen from the atmosphere.
Reactive metal powders
Reactive metal powders are the metal powders whose chemical properties mean that they react
spontaneously with oxygen and nitrogen (titanium) in the presence of these elements.
The reactive metal powders include the light-metal powders aluminium and titanium and all alloys of
these metals.
The reaction is dependent here on the particle size and the distribution or swirling up in the air.
Soot residues
Soot residues are the particulate substances which are produced during the LaserCUSING® process as a
result of the fusing and partial vaporisation of the metal powders. The composition of the soot residues
is dependent on the metal powder used. What all soot residues have in common is the very low particle
size and the high reactivity associated with this.
All soot residues are among the reactive materials. Soot residues therefore pose a risk of fire and
explosion. The ignition energy of the soot residues of reactive metal powders is in fact so low that they
are capable of spontaneous ignition.
Soot residues can be identified by their black colouring and occur mainly in the process chamber, the
pipe system and the filter module of the machine.
Flammable metal dusts
A substance is deemed to be flammable if it continues to burn after catching fire even if the ignition
source is removed. Deposits of soot, filter residues and reactive metal powders generally tend to burn,
glow or smoulder after igniting.
Dust explosion
Swirled-up dust of reactive metal powders and soot residues can react in the form of an explosion.
A dust explosion can occur if flammable, swirled-up dust is present in a suitable concentration in a
mixture with a gaseous oxidiser (usually oxygen in the air, "dust-air mixture") and the ignition energy is
exceeded. The ignition energy for soot explosions is so low here that they are capable of spontaneous
ignition if there is turbulence.
Hydrogen evolution
Different metal powders react to different extents with water to form hydrogen. If metal powders are
passivated in water, hydrogen is formed. If the hydrogen accumulates and mixes with air containing
oxygen, an explosive hydrogen-air mixture known as oxyhydrogen is produced.
Version 1.1.17 12
2.6.2 Rules of behaviour when handling reactive materials

The following basic measures for avoiding dust explosions or fires must always be adopted when
handling reactive materials:
1. Avoid the release of dust or swirling up; restrict the dust concentration to below the explosion
limits.
– Only the exact quantity of reactive metal powder that is actually required for the current
LaserCUSING® process should be stored in the danger areas of the LaserCUSING® machine.
– Store larger quantities of reactive metal powders in a fire-resistant cabinet, in a well-ventilated
place.
– Avoid swirling up of metal powders, soot residues and filter residues in an atmosphere
containing oxygen and thus creating a potentially explosive atmosphere.
– Never extract fairly large quantities of metal powder with the wet separator.
– Extract metal powder from small, enclosed volumes.
– Visible powder deposits are to be picked up with a cloth slightly dampened with water.
2. Replace oxygen as a reactant with gaseous inert substances provided that an explosion or fire is no
longer possible when the value is below the oxygen limit concentration (inertisation).
– Always ensure that there is sufficient inertisation and avoid any contact between reactive
metal powders and an atmosphere containing oxygen.
– Store reactive metal powders only in the containers in which they were supplied by Concept
Laser GmbH and ensure that there is sufficient inertisation in the containers.
– Make sure that the correct inert gas is used!
For titanium alloy powders, only argon is used as the inert gas.
For aluminium alloy powders, nitrogen is used as the inert gas.
– Do not open the powder containers or powder bottles in an atmosphere containing oxygen, but
only within the glovebox with sufficient inertisation.
3. Avoid effective ignition sources.
– When doing any work within the danger areas, wear your antistatic protective equipment.
– Make sure that all of the systems which are used on the machine are earthed.
– All of the devices used (e.g. wet separator, lifting device) must to be earthed before they are
used.
– Use only the accessories which are recommended by Concept Laser GmbH.
4. Avoid any accumulation of hydrogen and formation of oxyhydrogen.
– Always ensure that there is good ventilation in dangerous areas.
– Only ever store water / metal powder mixtures and moist metal powder residues in open
containers outdoors or in containers which can be vented.
– Adhere to the prescribed times when cleaning the tools which are used, e.g. the wet separator.
Version 1.1.17 13
5. When handling reactive materials, always wear the required personal protective equipment,
consisting of:
– Heat protection gloves
– Full breathing mask with particle filter P3
– ESD kit
– Heat protection clothing (heat protection overall with a hood or heat protection suit and
balaclava)
– Full breathing mask or breathing half-mask and protective shield
Please also note Section 2.7 Personal protective equipment.
6. If possible, work in pairs when handling reactive materials. People working on their own must be
sufficiently monitored, e.g. by providing suitable emergency call facilities.
7. Make sure that a second person is always in attendance when any work is done on the filter
module.
8. Metal fire extinguishers must be placed in the danger area of the LaserCUSING® machine and
within reach of the place where the reactive materials are stored.
If you have any questions regarding the fire-extinguishing systems, please contact your local trade
association.
2.6.3 Appropriate storage

1. The powder may only be stored in the vessels in which it is delivered or in the master and standard
powder containers from Concept Laser GmbH.
2. The powder must be stored under an inert atmosphere. Make sure that the correct inert gas is
chosen:
For titanium alloy powders, only argon is used as the inert gas.
For aluminium alloy powders, nitrogen is used as the inert gas.
3. Never store metal powders in the machine over a prolonged period of time.
4. A fairly large powder stockpile must be stored in a fire-resistant cabinet in a well-ventilated place.
5. Do not open the powder bottles or the powder container in an atmosphere containing oxygen, e.g.
in the ambient air.
6. Only open the powder bottles or the powder container when there is sufficient inertisation (oxygen
limit concentration ≥ 2.0%).
Note!
Storage of the powder outside of the building is ideal.
7. Note the special regulations governing the removal and storage of contaminated cartridge filters
from the extraction and filter device. (See section 8.5.3 Storage and disposal of the filter cartridge)
Version 1.1.17 14
2.7 Personal protective equipment

The required personal protective equipment (PPE) is dictated by the metal powders used and the
activities performed on your LaserCUSING® machine.
The personal protective equipment must always be worn when the operator is working with metal
powders and their process-related soots in an atmosphere containing oxygen.
Two groups of metal powders can be processed: reactive and non-reactive metal powders. (See section
3.7 Approved metal powders (classification)) Depending on which group the metal powders used are
assigned to, different requirements result for the personal protective equipment to be worn.
When working with reactive materials (reactive metal powders and soot residues), the extended PPE
must always be worn. You will find an overview of the protective equipment required in each case in the
section Classification of the personal protective equipment.
Description of the personal protective equipment
Protective work clothing

Protective work clothing is close-fitting and dirt-repellent work clothing with tight sleeves and without
any protruding parts.
Chemical-resistant protective gloves

Protective gloves are used to protect the hands from aggressive chemicals.
Breathing mask (P3)

The particle-filtering half-mask prevents the user breathing in harmful dusts, mists and fumes.
Protective goggles (tight-fitting)

The protective goggles are used to protect the eyes from any powder dust, parts flying around and any
liquid splashing.
Full breathing mask (P3 )

The particle-filtering full mask prevents the user breathing in harmful dusts, mists and fumes. The
integrated face protector protects the entire facial area from a sudden flash fire with a jet of flame.
Heat protection gloves

Heat protection gloves are used to protect the hands from thermal risks such as heat and fire.
Antistatic protective equipment (ESD kit; ESD mat; antistatic protective clothing)
Antistatic protective equipment is used to prevent electrostatic charges.
The protective equipment consists of an ESD wristband with an earthing cable and a press stud.
In addition ESD protective mats or ESD floors can be put down in the danger zones.
Version 1.1.17 15
Flame-resistant clothing for limited flame propagation

Protective clothing is used to provide protection from thermal risks, in particular from a sudden flash fire
with a jet of flame. The flame-resistant clothing is must chosen so that the specified protection aim is
achieved. (Head and neck protection, body and face protection)
2.7.1 Classification of the personal protective equipment

Standard PPE
Protective gloves
Breathing half-mask P3
Protective goggles, tight-fitting
Extended PPE
Heat protection clothing (heat protection overall with a
hood or heat protection suit and balaclava)
Full breathing mask P3
ESD wristband
Version 1.1.17 16
2.7.2 Use of the required personal protective equipment

Overview of the protective equipment required depending on the metal powders used and the activities
to be carried out.
Note
All activities are performed in an atmosphere containing oxygen.
Metal powder used
Activity non-reactive reactive
Brushing, scooping, wiping metal powders Standard-PPE Extended-PPE
Extracting metal powder Standard-PPE Extended-PPE
Wiping soot residues deposits Extended-PPE Extended-PPE
Cleaning the process chamber Extended-PPE Extended-PPE
Cleaning the filter module Extended-PPE Extended-PPE
Changing the filter in the process gas circuit

Extended-PPE Extended-PPE
(Filter moduel / pressure relief valve)
Exhausting the build and powder chamber
Extended-PPE Extended-PPE
shafts
Protective work
Protective work
clothing, protective
Working in the closed and inertised glovebox clothing and protective
gloves and ESD
gloves
wristband
Protective work
Protective work
Transport in powder bottles or powder clothing, protective
clothing and protective
containers (closed) gloves and ESD
gloves
wristband
Version 1.1.17 17
2.8 Safety and emergency stop devices

Danger to life from defective safety devices!
If safety devices do not work properly or have been rendered inoperative, there is the risk of serious or
even fatal injuries.
DANGER  Before starting work, check whether all safety devices are in good working condition and have been
installed correctly.
 Never override or bypass safety devices.
 Ensure that all safety devices are accessible at all times.
2.8.1 Emergency stop switch

In the event of any danger to people or the risk of damage to the machine, the emergency stop switch
must be pressed immediately.
When the emergency stop switch is pressed, the machine comes to a safe standstill.
In a safe standstill:
– the current build process is interrupted immediately,
– all drives are shut down,
– the laser is switched off immediately,
– the inert gas supply is interrupted and
– all pending control commands are reset.
 The signal strip flashes red.
 The illuminated button "Emergency stop reset" flashes red.
Danger to life from uncontrolled restart!
An uncontrolled restart of the machine may result in serious or even fatal injuries.
 Make sure before restarting the machine that the cause of the emergency stop has been rectified
DANGER and that all safety devices are in place and in good working order.
 Only unlock the emergency stop switch when there is no longer any danger.
Note
The electrical connections are NOT disconnected from the mains.
The machine PC and the controller remain active.
The EMERGENCY STOP switches should only be used in a dangerous situation. To perform a normal
switch-off of the LaserCUSING® machine, please follow the instructions on how to handle it in the
section 6.21 Switching off.
Version 1.1.17 18
Location of the emergency stop switch

The M2 cusing CUSING® machine is equipped with one emergency stop switch.
The emergency stop switch is installed on the control panel.
Emergency stop
switch
Figure 2-1: Location oft he emergency stop switch
1 Emergency stop switch
Note on the emergency stop switch of the laser system

The emergency stop switch on the laser system on the rear side of the machine is also designed as a
machine emergency stop switch.
Version 1.1.17 19
2.8.2 Main switch with emergency stop function

The main switch is at the same time also designed as an emergency stop switch. By turning the main
switch to the "0" position, the machine is shut down by immediately switching off the power supply and
an emergency stop is thus triggered.
Location of the main switch
Main switch
Figure 2-2: Location of the main switch
Note on the laser system key switch

The laser system key switch is designed exclusively to choose operating states of the laser system.
Version 1.1.17 20
2.8.3 Separating protective devices and protective doors

The M2 cusing LaserCUSING® machine is enclosed by separating protective devices (casing). The casing
is designed to protect users from:
– metal powders or parts which may be emitted or ejected
– unintentional intervention in the build process
– contact with operating media during the build process
– contact with laser radiation.
2.9 Securing against reactivation

DANGER and that all safety devices are in place and in good working condition.
 Only turn the main switch back to the "I" position when there is no longer any danger and all
maintenance or repair measures have been completed.
Main switch 1. Turn the main switch to the "0" position.

 The power supply is switched off.
2. Secure the main switch with a padlock.
3. Remove the key.
4. Give the key for the padlock to a responsible employee for safekeeping.
5. Attach an appropriate warning sign to the machine to notify other employees.
2.10 Danger areas

All areas in which there are residues of reactive metal powders or process-related soot deposits are
classified as danger areas.
These include the following areas in particular:
– Working area around the LaserCUSING® machine in which metal powder is being processed.
– The danger area includes the LaserCUSING® machine and all areas in which powder and soot
residues may be formed.
– Filter module
– Storage location of the reactive metal powders and the filter residues.
These danger areas must also be marked by the operator as potentially explosive areas.
Version 1.1.17 21
2.11 Safety notices on the device

The following symbols and notification signs can be found on the M2 cusing LaserCUSING® machine.
Danger posed by illegible safety notices!
Over the course of time, stickers and signs may get dirty or become indecipherable in some other way
so that dangers cannot be identified and necessary operating instructions cannot be followed.
WARNING This leads to a risk of injury.
 Maintain all safety notices, warnings and operating instructions so that they are easy to read at all
times.
 Replace any damaged signs or stickers immediately.
Overview of the safety notices on the machine (front view)
Figure 2-3: Safety notices on the machine (front view)
Version 1.1.17 22
Overview of the safety notices on the machine (rear views)
Figure 2-4: Safety notice on the machine (detailed view of the filter module)
Figure 2-5: Safety notice on the machine (rear view closed)
Version 1.1.17 23
Meaning of the mandatory signs
Use breathing protection

It is imperative that you wear a breathing mask when working in this area.
If you breathe in metal powders and filter dust, there is the danger of damage
to the respiratory tract and lungs.
Use protective gloves
It is imperative that you wear protective gloves when working in this area.
The toxic nickel contained in the metal powders and filter dust can cause
irreversible damage to the skin or sensitisation through skin contact (allergic
reaction).
Use eye protection
It is imperative that you wear tight-fitting protective goggles when working in
this area.
If metal powder and filter dusts come into contact with the eyes, there is the
risk of damage to the eyes.
Meaning of the warning signs
Electrical voltage
The working area which is marked with this sign may only be opened if the
machine has been disconnected from the mains power supply.
Disconnect the machine from the mains power supply via the main switches
and by pulling out the mains plug.
Unauthorised persons may not access the marked workplaces and may not
open the marked cabinet.
Laser beam
In an area marked with this sign, there is a risk of coming into contact with
invisible laser radiation.
Do not look or reach into the path of the laser beam.
Work in this area may only be carried out when the machine is switched off.
LASER class 1
The laser radiation is assigned to the laser class 1 in accordance with DIN EN
60825-1. This means, the accessible laser radiation is safe under reasonable
predictable conditions.
LASER class 2 M
The laser radiation is assigned to the laser class 2M in accordance with DIN EN
60825-1. This means, the laser radiation lies only within the visible spectral
range and without the use of optical instuments within the maximum period of
0,25 s is harmless to the eyes. If any optical equipment is used, the laser beam
can become dangerous.
Do not look at the laser beam in this range and do not observe it with any
optical equipment.
Outlet opening for laser radiation

Outlet opening for visible and invisible laser radiation Avoid exposure visible
and invisible laser radiation is emitted from this aperture.
Version 1.1.17 24
Warning sign on the process chamber door

Do not open the process chamber door during the build process or when the
ventilator is switched on.
Fire Hazard
do not vacuum the filter
Hot surface
LaserCUSING® components are machined using a laser beam.
The surfaces of the components may become hot; this is not always obvious.
The build chamber platform is equipped with a heating system.
When the build plate is heated, it reaches a temperature of up to 200 °C. If you
come into contact with the surface, there is a danger of burns.
Do not touch components without wearing protective gloves.
Explosive atmosphere
Areas which are marked with this sign are potentially explosive areas. A
dangerous explosive atmosphere may be formed here.
Please follow all the necessary safety measures that apply in such an area.
Hand injuries
Do not reach into an area marked with this sign while the machine is in
operation.
In these areas, there is the risk of hand injuries when the components are
moved.
Risk of squashing
No people or body parts must be located in the area marked with this sign
while the machine is in operation.
In these areas, there is a risk of squashing when the build module is being
moved.
Version 1.1.17 25
3 Technical data
3 Technical data
Follow the relevant operating manual for the components used which are attached to this manual.
The specifications contained in them must be compiled with at all times.
3.1 General specifications

Machine part Weight in kg
Basic machine approx. 2 200
Filter module empty approx. 100
Filter module flooded approx. 460
Dimensions L x B x H in mm
Basic machine 2542 x 1818 x 1999,5
Filter module 1050 x 525 x 1490
General specifications
Control cabinet protection class IP54

In accordance with
Safety of the controller
EN ISO 12849-1
CE marking
3.2 Build module

Build chamber Powder chamber
Dimensions (L x B x H) in mm 250 x 250 x 280 250 x 250 x 280

3
Volume in dm approx. 18 approx. 18
Design height in mm
max. 280
(minus build plate thickness)
Exposure field in mm 245 x 245
3.3 Connected loads

Electrical connections
Power connections 3P/N/PE AC 230/400 V ± 10 %

Power consumption max. 6,8 kW
Ethernet 100 MB/s
Network connection
Machine connection: RJ45-socket
Version 1.1.17 26
3 Technical data
Compressed air connection

Gas pressure 6 – 10 bar, unoiled
Quality DIN ISO 8573-1 Class 1.6.1
Volume flow, max. 100 l/min
Inert gas connection Nitrogen Argon
Gas pressure 5 bar 5 bar

Quality ≥ 2.5 ≥ 2.5
3.4 Performance data

Performance data
Manufacturing speed 2 – 35 cm3/h

(depending on material / laser power)
Scan speed 7 m/s, 4,5 m/s with variable focus adjustment
LaserCUSING® layer thicknesses® 20 – 80 µm
Protective gas consumption < 1 m3/h
3.5 Laser system

Laser system
Single-Mode,
Laser
CW modulated Ytterbium fiber laser
Protection class Laser protection class 4
200 W, 400 W,
Power (depending on wquipment)
2 x 200 W, 2 x 400 W
Wavelength 1070 nm
Laser beam diameter 50 µm
3.6 Ambient conditions

Temperature
Operation 15 – 35°C
max. temperature change 2 °C/h
Storage at the installation site 0 40°C
Atmospheric humidity
max. atmospheric humidity 80 %

Storage at the installation site 80 %
Version 1.1.17 27
3 Technical data
General ambient conditions

Installation height above sea level max. 2000 m
electromagnetic radiation Do not operate any devices which emit high-frequency
radiation in the immediate vicinity of the machine.
3.7 Approved metal powders (classification)

The use of others metallic powders than those listed below is only permitted following prior explicit
approval by Concept Laser GmbH.
3.7.1 Non-reactive metal powders

Non-reactive metal powders are the metal powders which do not react or react only to small extent
with oxygen of the atmosphere.
Alloy type Name
Stainless steel CL 20ES (1.4404)
Hot-work steel CL 50WS (1.2709)
CL 91RW
CL 92 PH
Nickel CL 100NB (Inconel 718)
CL 101NB (Inconel 625)
CoCrW remanium® star CL
3.7.2 Reactive metal powders

Reactive metal powders are the metal powders which react strongly to very strongly with oxygen of the
atmosphere.
Alloy type Name
Aluminium CL 30AL
CL 31AL
Titan CL 41TI ELI
CL 42 TI
rematitan® CL*
3.7.3 Hydrogen-forming metal powders

Hydrogen-forming metal powders are the metal powders which form the reactive gas hydrogen if they
come into contact with water.
Alloy type Name
Aluminium CL 30AL
CL 31AL
Version 1.1.17 28
3 Technical data
3.8 Emissions
Emissions
Sound pressure level at distance of 1 < 70 dB (A)

m
3.9 Type plate
Figure 3-1: Front view with closed handling and process stations
The type plate is located on the right-hand side of the machine, below the wall-mounted cooler and
contains the following information:
– Manufacturer and manufacturer's address
– Type/version
– Year of construction
– Supply voltage
– Compressed air supply
– Inert gas supply
– Ethernet conncetion
The type plates of the other components of the LaserCUSING® machine are explained in the operating
manuals for the respective component (see other applicable documents).
Version 1.1.17 29
4 Structure and function

4.1 Theoretical principles of the LaserCUSING ® process
The generative production process known as LaserCUSING® allows the tool-less production of complex
parts which can be subjected to mechanical and thermal loading directly from their 3D CAD data.
The word "CUSING" is a combination of the C of CONCEPT Laser and the word FUSING. The
LaserCUSING® process can be employed, for example, in tool manufacturing, model making, diecasting
or in production.
During the LaserCUSING® process fine metal powder is applied layer by layer and fused locally with a
fibre laser. Following cooling, the material solidifies immediately. The parts are therefore given their final
properties in the production process directly.
The contour of the part is produced by directing the laser beam using a mirror deflecting unit (scan
head). The part is built up layer by layer by lowering the bottom of the build chamber, applying more
powder and fusing again.
The special feature of the LaserCUSING® machines is the stochastic exposure strategy based on the
"island principle". The segments of each individual layer – so-called "islands" – are worked through in
succession. The patented process ensures a significant reduction in stresses within the part, which
allows solid and large-volume parts to be generated with low warping.
The LaserCUSING® parts can be designed as solid bodies or with cavities and – with suitable design and
fabrication – they are 100% liquid-tight and gas-tight. The part can also be produced as a hybrid part on
the basis of a pre-milled base body which is clamped onto the build platform.
After the LaserCUSING® process (build process), the part merely has to be detached from the build plate
and any supporting structure that may be in place and undergo a surface treatment if necessary.
Figure 4-1: Example part 1 Figure 4-2: Example part 2 Figure 4-3: Example part 3
Figure 4-4: Example part 4 Figure 4-5: Example part 5
Version 1.1.17 30
4.1.1 Laser radiation – theoretical principles

The word LASER is an acronym and is made up of the initial letters of: "Light amplification by stimulated
emission of radiation".
Figure 4-6 to 4-8 illustrates the difference between spontaneous emission and stimulated emission, on
which the phenomenon of laser radiation is based.
Absorption:
An incident photon (light quantum) raises an electron from a lower
energy level to a higher energy level. This causes the photon to be
h absorbed, it thus "disappears".
Figure 4-6: Absorption
Spontaneous emission:
An electron which for a certain time was in a higher energy state
spontaneously transfers to a lower energy state and in doing so gives off
h energy by emitting a photon (light quantum). This emission of light quanta
happens spontaneously, e.g. in a light bulb.
Figure 4-7: Spontaneous emission
Stimulated emission:
A photon or a light quantum meets an electron which is in a higher or
h
stimulated energy state. This results in the photon inducing the electron
h to transfer to a lower energy level and in the process release energy in
h the form of a second photon. The incident light is therefore amplified. The
light emitted by a laser is monochromatic and coherent, i.e. the light
waves have only one wavelength and have a fixed phase relationship with
respect to one another.
Figure 4-8: Stimulated emission
Laser light is therefore produced when energy-rich particles are forced by incident light quanta to
release their energy in the form of light with a defined wavelength (stimulated emission) and in doing so
to drop back to a lower energy level.
This causes amplification of the incident light because in the transition to the lower energy level two
light quanta are emitted (light amplification). What is characteristic here is that the phase position,
direction and polarisation of the emitted light quanta are identical.
In lasers, light which is emitted spontaneously is amplified by induced emission. So that the induced
emission processes predominate and the special characteristics of laser radiation are produced, it must
be ensured that the laser photons pass through the amplifying material, the laseractive medium, several
times. This results in the characteristic laser arrangement comprising laser- active material and mirrors
shown below.
Version 1.1.17 31
Figure 4-9: Characteristic structure of laser active medium, mirrors and pump source
The stimulating light quanta are radiated into the laser-active medium from what is termed a pump
source, e.g. a flash bulb or a laser diode. Here they induce the stimulated emission. The photons which
are emitted are reflected on the mirrors and pass through the laser-active medium several times before
they emerge as laser radiation at the right-hand mirror which has low partial transparency. The end
mirror (left) and the partially transparent output mirror (right) combine with the pump chamber (pump
sources and laser-active medium) to form the resonator.
The laser-active medium consists of doped glasses. They can also be stretched to form thin glass fibres.
The glass fibres can then be pumped through the end surface which is coated in an appropriate way
with light quanta from laser diodes. Because of the large surface area of the fibres in relation to their
volume, a good dissipation of heat from the laser-active medium takes place. This reduces losses in the
quality of the beam resulting from thermal effects. The geometry of the active medium in the form of a
glass fibre results in the emission of diffraction-limited basic mode radiation. The result of these positive
effects is that fibre lasers emit a very good quality of beam compared to “conventional” solid-state
lasers with high power stability.
The M2 cusing LaserCUSING® machine is equipped with an Ytterbium fibre laser system which operates
in a continuous mode. The emitted laser light has a wavelength of 1070 nm.
4.2 Performance specification

The M2 cusing LaserCUSING® machine can be used to manufacture parts from different series materials
without moulds using powder and a laser.
The LaserCUSING® machine guarantees safe and reliable processing of reactive materials under an inert
atmosphere.
Version 1.1.17 32
4.3 Overview of the M2 LaserCUSING ® machine

Front view
The structure of the LaserCUSING® machine can be divided up into two sections.
On the left-hand side of the machine you will find the handling station and on the right-hand side the
process station. Both sections are secured against unauthorised intervention with protective doors.
The build module is moved within the machine between the two sections - the handling station and the
process station.
1 2 3 4 5
Figure 4-10: Front view with the handling and process stations closed
1 Handling station, closed

2 Viewing window
3 Process station, closed with control panel
4 Right-hand side of the machine
5 Cooler of the electrical cabinet
Version 1.1.17 33
Rear view
The electrical cabinet, the laser unit and the access to the filter module are situated on the back of the
The electrical cabinet behind the process station includes the electrical equipment and its connections
to the machine. The main switch of the LaserCUSING® machine is located on the electrical cabinet.
The filter module is located behind the left-hand protective door.
1 2 3 4 5 6 7
Figure 4-11: Rear view (model displayed: dual laser)
1 Electrical cabinet for electrical equipment and machine PC

2 Main switch
3 Service door, access to the pressure relief valve of the process gas circuit
4 Laser system
5 Service door, access to the filter module
6 Upper protective door, access to the pneumatic equipment and inert gas supply
7 Lower protective door, access to the powder container / powder bottle of the powder overflow
Version 1.1.17 34
4.3.1 Process station

The process station is where the LaserCUSING® component is fabricated. To do this, the build module is
moved into the process chamber of the process station. In the process chamber there is switchable
lighting.
The LaserCUSING® process takes place under an inert atmosphere (inertisation). Before the build
process, an inflatable seal (expansion seal) between the process chamber and the build module seals off
the working space so that it is almost gas-tight and the process chamber is flooded with inert gas.
To keep the amount of inert gas consumed during the build process as low as possible, the inert gas is
moved around in a closed circuit after the process chamber has been flooded. The extracted inert gas is
cleaned via the filter module which can be flooded with water and returned back to the build process. If
the build module is not coupled to the process chamber, the pipes of the process gas circuit are
automatically closed via butterfly valves.
The inert gas management of the process chamber controls and regulates the residual oxygen content
and the inert gas throughflow as standard.
The control panel of the LaserCUSING® machine is integrated on the process station door.
Near the control panel there is a viewing window which is fitted in the process station door. Through
this viewing window it is convenient to observe the ongoing build process without interrupting the laser
protection circuit.
Version 1.1.17 35
1 2 3 4 5 6
Figure 4-12: Overview of the process station
1 Process station door (open) with viewing window and control panel
2 Process chamber lock
3 Process chamber door with laser protection glass
4 Process station
5 Cover of laser rail
6 Connections for earthing of operator and wet separator
Version 1.1.17 36
Process chamber
The process chamber is the actual working chamber for the LaserCUSING® process. The process
chamber is designed for the high requirements that are needed when using a laser system.
The laser rail is located above the process chamber, behind the cover. The Scan head and the resonator-
external optics are fitted on the laser rail. The laser beam is transfered into the process chamber via a
fibre-optic cable of the beam generator via the components of the laser rail.
Easy access to the process chamber is enabled via the process chamber door. During an ongoing build
process, the process chamber door is closed and secured via the process chamber lock and a safety
sensor.
1 2 3 4 5 6 7 8 9 10 11
Figure 4-13: Overview of the process chamber

1 Safety sensor
2 Lock of the process chamber door
3 Oxygen sensor
4 Process chamber lighting
5 Viewing window of the scan head lens
6 QM coating camera system
7 QM coating flashlight
8 Connectors cover for laser power meter
9 QM liveview camera
10 Temperature sensor
11 Process chamber door
The process chamber can, in addition to the QM modules QM atmosphere and QM Laser, optionally also
be equipped with the QM modules QM meltpool, QM coating and QM liveview. These quality modules
monitor the LaserCUSING® process and allow precise assessment and control of the process. Note the
other relevant documentation in relation to the individual QM modules.
Version 1.1.17 37
4.3.2 Handling station

In the handling station, the build module is mounted or removed and the metal powder for the
LaserCUSING® process is introduced into the powder chamber.
For working under a protective atmosphere, the build module is sealed so that it is gas-tight with the
glove box. Assignments within the glove box are then carried out through the glove box gloves.
The handling station is equipped with earthing connections for the user and the wet separator. For the
build process, the build module is moved from the handling station to the process station.
3
4
5 6 7 8 9
Figure 4-14: Overview of the handling station
1 Door of the handling station (open)

2 Switch for clamping system (optional)
3 Earthing connection for wet separator
4 Connection for ESD wriststrap
5 Service door to the build module
6 Glove box glove
7 Glove box flap
8 Butterfly valve of the powder inlet
9 Safety sensor
Version 1.1.17 38
Glove box
The actual working area of the handling station is the glove box. This is where the build module for the
LaserCUSING® process is armed or disarmed. When it is closed, the glove box provides a physically
isolated working area for contactless handling of metal powder by the user. The glove box flap is
equipped with a large glass front panel to provide an optimum view into the glove box. If the build
module is coupled to the glove box and the glove box flap is closed, it can additionally be inertised for
the purpose of using reactive metal powders. Safe intervention is then guaranteed via the glove box
gloves. The inertisation is monitored by an oxygen sensor. An excess pressure in the glove box is
prevented by an integrated pressure-compensation filter.
A light barrier monitors the front of the glove box and protects against any unauthorised intervention in
the glove box. If the light barrier is broken, ongoing axis movements are stopped immediately to prevent
any hazard being posed to the user.
On the glove box there is a powder inlet butterfly valve.
1 2 3 4 5 6 7 8 9 10 11 12
Figure 4-15: Overview Glove box
1 Switch for clamping system (optional)

2 Earthing connection for wet separator
3 Connection for ESD wriststarp
4 Light barrier
5 Pressure equalisation opening with filter
6 Lighting
7 Glove box flap
8 Powder inlet hose
9 Inert gas supply
10 Connections for automatic shaking sieve (optional)
11 Powder chamber cover in the wall mounting
12 Safety sensor
Version 1.1.17 39
4.3.3 Build module

The build module is the actual working area of the M2 cusing LaserCUSING® machine and can be divided
up into three areas.
The powder chamber is filled with metal powder before the build process and is designed to provide
metal powder continuously during the build process. The height of the powder platform and thus the
capacity of the powder chamber can be regulated via the machine software.
The build chamber is where the part is fabricated. To do this, the build plate is placed on the build
chamber platform. Depending on what equipment your machine has, the build plate can be fixed in
place via a clamping system or it is screwed onto the build chamber platform. A build plate heating
system is optionally integrated in the build chamber platform.
During the LaserCUSING® process, the metal powder is transferred from the powder chamber by means
of the coater blade to the build chamber. The metal layer transferred in this way is then, at the areas
which are defined by the software, fused with the laser beam.
On the left-hand side of the build module you will find the powder overflow. Excess metal powder is
skimmed off when the coater blade is moved into the powder overflow and thus into the powder
container below the build module. The powder container can be extracted by means of the lifting device
via the bottom left-hand side door.
The build module is moved between the handling and the process stations for different process phases.
Figure 4-16: Overview of the build module (working surface)
1 Build module surface

2 Powder overflow
3 Build chamber platform
4 Clamping system (optional)
5 Powder chamber platform
6 Coater with blade replacement system
7 Cover of the guide rail (rear)
8 Cover of the guide rail (front)
Version 1.1.17 40
A powder container is coupled to the machine below the powder overflow. Metal powder that is
conveyed into the powder overflow is trapped and collected in the powder container. If the build module
is in the handling station, the powder container beneath the powder overflow can be accessed via the
bottom side door of the handling station.
The powder container is removed with the lifting device from the LaserCUSING® machine.
The emptying openings of the build and powder chamber shafts can be accessed via the front service
door of the handling station.
1 2 3 4 5 6 7 8 9 10 11
Figure 4-17: Overview of the build module (bottom)
1 Bottom side door of the handling station

2 Powder container below the powder overflow
3 Powder outlet valvel on the powder container
4 Retaining plug for connecting hose
5 Connecting hose between powder container and powder overflow
6 Clamping fastener on the powder container
7 Emptying openings of the build chamber shaft
8 Build chamber shaft
9 Emptying openings of the powder chamber shaft
10 Powder chamber shaft
11 Service door of the handling station
Version 1.1.17 41
4.3.4 Accessories and additional equipment

The M2 cusing LaserCUSING® machine can be delivered with the following accessories and additional
equipment.
Reduced-size build chamber
The use of the reduced-size build chamber reduces the volume of the build chamber and powder
chamber of the M2 cusing LaserCUSING® machine. This is achieved primarily by mechanical reduction in
the size of the basic area of the build chamber and the powder chamber.
The reduced-size build chamber is used for manufacturing small parts from costly metal powders as the
smaller volume means that less metal powder needs to be provided for the build process.
Powder chamber extension
The powder chamber extension enlarges the volume and thus the maximum capacity of the powder
chamber.
This allows a larger quantity of metal powder to be stockpiled for a build process.
Clamping system
To allow simple fixing of the build plate on the build chamber platform, it can be equipped with a
clamping system. The clamping system is operated via two buttons and a lever on the handling station.
If the machine is equipped with a clamping system, the build chamber platform cannot additionally be
operated with a build plate heating system.
Build plate heating system
The build plate heating system is located on the build chamber platform and is controlled via the
machine software. The build plate or parts and hybrid parts can be heated up via the build plate heating
system.
Heating up the build plate reduces negative thermal processes for the build process, increases the bond
between part and build plate or hybrid part and reduces stresses in the part.
The build plate heating system is incompatible with the clamping system.
Automatic shaking sieve
The metal powder needs to be sieved prior to each use to ensure its quality. For smaller quantities of
powder, the automatic shaking sieve offers an optimum solution. It is placed on the powder chamber
and connected to the existing pneumatic connections in the glove box. It is operated on the control
panel via the machine software.
Version 1.1.17 42
4.4 Laser system

Note
For a detailed description of your laser system, please consult the operating manual for the fibre laser,
which is enclosed as another relevant document to this operating manual.
Depending on the model, the M2 cusing LaserCUSING® machine is equipped with one or several Yb: YAG
solid-state lasers, known as a fibre lasers.
The diode-pumped Yb: YAG fibre laser generates the laser beam for the LaserCUSING® process.
The laser beam is fed to the process station via a fibre-optic cable (transport fibre). The glass fibre core
of this optical fibre is very liable to fracture, and the fibre must therefore not be laid by untrained
personnel!
The laser systems are located on the back of the LaserCUSING® machine above the service door to the
filter module.
Figure 4-18: Overview of the laser system (model displayed: single laser)
Laser safety
During normal operation with the protective doors closed, the M2 cusing machine is classified as
belonging to the non-dangerous laser protection class 1.
The escape of laser radiation from the beam generator or the M2 cusing machine is not possible in
handling mode and in the LaserCUSING® process because the laser can only be switched on if the build
module is situated in the process station and the working space is closed and secured (locked). The
protective devices (protective doors, automatic switch-off) prevent any escape of laser radiation when
the machine is used as prescribed.
When the laser system is open, the machine is classified as belonging to laser protection class 4.
Version 1.1.17 43
4.5 Filter module and ventilator

The filter module and the ventilator are located on the rear side of the LaserCUSING® machine behind
the handling station. The filter module is connected to the process chamber via solid piping.
During the LaserCUSING® process, the inert gas is extracted from the process chamber by the
extraction system, cleaned via the filter module and returned back to the process chamber.
There are two cartridge filters inserted in the filter module which filter soot and metal powder particles
out of the inert gas. The filter cartridges are cleaned by means of highly effective pulses of compressed
air (filter cleaning), even during operation.
The ventilator is suitable for extracting the fumes from build processes involving reactive metal powders
and it has the appropriate explosion protection.
The purified inert gas is then returned back to the process chamber.
1 2 3 4 5 6 7 8 9 10
Figure 4-19: Overview of the filter module with solid piping of the process gas circuit
1 Service door, access to the pressure relief valve of the process gas circuit
2 Pressure relief valve of the process gas circuit
3 Return process gas solid piping
4 Service door, access to the filter module
5 Filter module
6 Connection for the filter cleaning
7 Fill level indicator
8 Solid piping of the process gas feed
9 Cover of the filter module
10 Service door, filter module
Version 1.1.17 44
4.6 Connections
4.6.1 Inert gas supply and pneumatic system
All of the connections for the compressed air supply (pneumatic connections) and the inert gas supply
are located on the pneumatic plate behind the right protective door of the handling station.
1 2 3 4 5
Figure 4-20: Overview of the pneumatic plate
1 Maintenance unit for compressed air

2 Maintenance unit for inert gas argon
3 Compressed air regulator for expansion seal
4 Maintenance unit for inert gas nitrogen
5 Flow meter for inert gas
Inert gas supply
In order to prevent oxidation on the surface of the part and to avoid hazards which may result from the
high reactivity of the metal powders with atmospheric oxygen, the processing of the metal powders
(both the powder handling and the LaserCUSING® process) is carried out under an inert gas
atmosphere. In order to keep consumption levels as low as possible, the inert gas is transported in a
closed circuit. The proportion of residual oxygen in the process or handling station is measured during
the build process and during the powder handling and the inertisation is adjusted to reflect the residual
oxygen values specified in the software.
Version 1.1.17 45
Pneumatic system
The following components are pneumatically driven:
– Expansion seal for closing of the build module and process station
– Bolts for locking the build module to the process chamber
– Drives for moving the build module (W direction)
– Valve island for the compressed air and inert gas supply.
Details on the pneumatic system can be found in the pneumatic circuit diagram in the other relevant
documents.
4.6.2 Electrical equipment and machine PC

The electrical equipment, the machine PC and the PC QM Meltpool are located on the back of the
LaserCUSING® machine in the left-hand electrical cabinet behind the process station.
The main switch of the LaserCUSING® machine is located on the electrical cabinet. If the machine is
switched on, the electrical cabinet doors are locked.
They can be opened only after the machine has been switched off.
In terms of its electrical equipment, the LaserCUSING® machine is supplied as a standard model and as
a UL model.
The electrical equipment of the standard model is designed and built in accordance with IEC standards.
The UL model of the LaserCUSING® machine is designed and built specifically for the US-American
market applying NFPA 79 and UL 508A.
The electrical cabinet contains the following components:
– programmable logic controller (PLC)
– control and back-up elements
– 24 V power supply units
– servo amplifiers for the drives including transformer and power supply unit
– measurement cards for the oxygen measurement cells
The electrical cabinet is cooled by the cooler attached to the wall on the side of the machine.
The machine PC for the CL WRX software is fitted on the right-hand door of the electrical cabinet.
The QM Meltpool PC is located on the left-hand door of the electrical cabinet.
Version 1.1.17 46
4.7 Displayes and operating elements

4.7.1 Displays
Signal strip
The signal strip is a LED strip which displays machine states with visual singnals. They are easy to spot
even from the distance.
The signals can be distinguished by their colour and lighting time and make it possible to easily identify
the machine state.
The signal strip of the LaserCUSING® machine is located above the handling and the process stations.
These machine states are indicated by the following signals:
Signal Operating status
Build process has been interrupted because of a
Red continuous light
fault
Yellow continuous light Build process is being prepared, the process
chamber is being inertised
Green flashing light Build process completed
Green continuous light Build process is ongoing
Laser status display

The laser status display is a visual indicator of the operational readiness of the laser system. The LED
strip is located directly on the laser system.
Signal Operating status
Orange continuous light The laser is ready to operate.
The laser can be started.
The laser is in operation.
Signal off The laser is not ready to operate.
Version 1.1.17 47
4.7.2 Control panel

The control panel of the LaserCUSING® machine is located on the protective door of the process station.
It is divided up into a monitor, control keys and input aids.
1 2 3 4 5 6 7 8
Figure 4-21: Overview of the control panel
1 Keyboard
2 Monitor
3 USB port
4 Emergency stop switch
5 „Emergency stop reset“ button
6 „Error reset“ button
7 Controller OFF button
8 Controller ON button
Machine software
The monitor displays the user interface for the machine or laser PC.
For description of the machine software please consult the related documents.
Version 1.1.17 48
Control keys
The emergency stop switch is located on the left-hand side of the button panel.
Button Function Display
Switch on the controller lights up green if the controller is active
Switch off the controller flashes red if the controller is not active
flashes red when there is an error

Reset error messages
message
Reset the emergency status

flashes red if the emergency switch has
(if the emergency stop button has been
been activated
unlocked before)
Version 1.1.17 49
4.8 Software
For details about the machine software, see the CL WRX software manual.
For details about the QM coating software, see the "QM coating Setup" software manual.
4.8.1 CL WRX machine software

CL WRX machine software controls the M2 cusing LaserCUSING® machine.
The following processes can be controlled using the machine software:
– machine and process operation,
– monitoring of the machine and process control,
– selection, copying and positioning of the parts,
– parameter selection and assignment and the corresponding build time calculation,
– status report checks and logging (part report, PLC messages).
4.8.2 QM coating software

The QM coating software analyses and assesses the images which are taken of the layer application.
The QM coating software only works in conjunction with the machine software of the M2 cusing
If the QM coating software identifies a defective layer application, this is communicated to the machine
software and the build process is automatically adjusted on the basis of the recorded data.
The QM coating software is only installed in conjunction with the QM module of the same name.
Please note the equipment of your machine.
Version 1.1.17 50
4.9 QM modules
The QM modules which have been developed for the M2 cusing LaserCUSING® machine are designed to
allow continuous monitoring of the LaserCUSING® process. Use of the QM modules allows a quality-
controlled manufacturing process which monitors and documents the part quality.
All of the available QM modules are listed and explained in brief below. A detailed description of the
individual process monitoring systems can be gleaned from the separate documents for the individual
modules.
4.9.1 QM meltpool
The QM meltpool module allows monitoring of the meltpool in real time. To do this, the radiation
emitted by the meltpool is recorded and evaluated by an analysis unit. The build process is monitored
here directly as events actually happen at the microscopic level with several thousand scans a second.
The data is documented and visualised by the machine software.
4.9.2 QM laser
Laser energy is the central tool used in the metal laser fusing process. The prerequisite for good part
quality is therefore compliance with the specified laser power. The QM laser module continuously
documents the power emitted by the laser system during the build process.
4.9.3 QM atmosphere
The QM atmosphere module guarantees continuous monitoring and regulation of the oxygen
concentration in the process chamber. The data is recorded and documented by the machine software.
4.9.4 QM documentation
The QM documentation module is implemented in the machine software and creates a clear report for
all of the data of the QM modules: QM meltpool, QM laser and QM atmosphere.
The documented data can be exported in clear graphs or as a straight text file.
4.9.5 QM coating
The QM coating module monitors and analyses the powder layer applied during a build process.
To do this, for each powder layer an image is taken before and after the layer application and evaluated
by the associated analysis software.
If a defective layer application is detected, the QM coating module can trigger renewed layer application
or an increase in the powder supply.
4.9.6 QM liveview
For continuous real-time monitoring of the process chamber, the QM liveview module is offered.
For this purpose, the process chamber is monitored by a camera and the images taken can be viewed
directly via a web interface.
Version 1.1.17 51
5 Transport, installation and initial commissioning
5 Transport, installation and initial commissioning

Danger to life from unauthorized transport, installation and initial commissioning!
There is a danger to life if the LaserCUSING® machine is incorrectly transported, installed and initially
commissioned.
DANGER  These activities may only be performed by the manufacturer, Concept Laser GmbH.
 To arrange for the required work to be carried out, contact our customer service department.
(See chapter 11 Support and Customer Service).
Following initial commissioning (including the fabrication of a part for official acceptance) by the
manufacturer, the declaration of acceptance must be completed, stamped with the company stamp by
the operator's authorised representative and signed.
Version 1.1.17 52
6 Operation
6 Operation
The user of the M2 cusing LaserCUSING® machine will come into contact with reactive metal powders
and their process products when working on the LaserCUSING® machine.
Note for your safety!

Always note the general safety instructions in chapter 2 General safety instructions.
Please also note the safety data sheets for the metal powders used.
6.1 Safety instructions for operationg

Danger of injury from improper use!
Improper use can lead to serious injuries and considerable material damage.
 Carry out all operating steps in accordance with the specifications and instructions in this manual.
DANGER
 Never override or bypass safety devices during operation.
Danger of electric voltage!

DANGER  Never touch live parts of the machine.
 The electrical cabinet, protective doors and components must be kept closed at all times.
Access is permitted only to authorised personnel with a key or a tool.
 Have any electrical work which is not described in this operating manual carried out only by a
qualified electrician. Unqualified personnel must be forbidden from carrying out work on electrical
components!
 Regularly check the electrical cables for any signs of damage. If there is any damage, switch off the
voltage supply immediately and arrange for a repair to be carried out.
 Before any work is carried out on the electrical equipment, the LaserCUSING® machine must be
Version 1.1.17 53
6 Operation

components:
– Mains cables
– Power units
– Drive amplifiers
– Laser supply
capacitors fully discharge.

Swirling up of the approved reactive light-metal alloys, as well as their process-related soot and filter
residues in an atmosphere containing oxygen may produce an explosive atmosphere.
DANGER  Avoid the use of any effective ignition sources within the potentially explosive area.
 Wear antistatic protective equipment in order to prevent electrostatic discharge!
 Avoid swirling up metal powder or metal dust, soot residues and filter residues.
 Never extract metal powder from small, enclosed volumes.
 Always wipe off soot residues or filter residues using a slightly dampened cloth.
turned on.

Different metals react to different extents with water to form hydrogen. The extraction of metal powder
with a wet separator when using water as the separating medium, results in the formation of hydrogen
DANGER in the wet separator. If the hydrogen accumulates and mixes with air containing oxygen, an explosive
hydrogen air mixture known as oxyhydrogen is produced.
 Check the water level in the wet separator regularly before and during operation.
 Empty and clean the wet separator and the accessories used as required but at least once a day at
Version 1.1.17 54
6 Operation

injuries.
DANGER  Wear antistatic protective equipment in order to prevent electrostatic discharge!
 Always pick up soot residues, filter residues and reactive metal powders with a slightly dampened
cloth in order to passivate them.
 If possible, remove objects which are contaminated with reactive materials immediately.
 Always store contaminated objects in a fire-resistant environment.
and lungs.
 Particular care must be taken when working on the build chamber and when removing the filter
cartridge of the filter module. Swirling up of powder should be avoided.
Warning about dangers posed by the use of a lifting device!

The inappropriate use of a lifting device may present numerous hazards to the user.
 Note and follow the operating manual for the lifting device, in particular the safety instructions.
WARNING
 Use the correct jacking points for the powder device in order to prevent it from falling off.
 Never place yourself beneath raised loads.
Danger of damage to the skin from contact with metal powders!

The metal powders CL 20ES, CL 50WS, CL 91RW, CL92PH, CL 100NB (Inconel 718) and CL 101NB
(Inconel 625) contain the element nickel. Nickel is a toxic element which causes irreversible damage to
CAUTION the skin. Nickel is suspected of being allergenic and carcinogenic.
 Wear suitable protective gloves when handling these metal powders and their filter dusts.
 Particular care must be taken when working on the build chamber and when extracting the filter
operating manual.
Version 1.1.17 55
6 Operation
Warning about physical injury from carrying heavy loads!

The powder containers are very heavy.
 Only move the containers using suitable equipment aids (lifting device).
CAUTION
 Never attempt to carry the containers yourself.
Danger of injury from falling or tripping over supply lines to the machine!
The electrical cables of the machine, as well as the extraction, inert gas and compressed air lines,
present a trip hazard. A fall may cause serious injuries.
CAUTION  The lines must be secured in place with appropriate covers so that people cannot trip over them or
get their foot caught in them.
 Mark the trip hazards with marker tape.
 Remove any objects which are no longer needed from the working area and in particular from the
area close to the floor.
Danger of injury from slipping on metal dust!

Metal dusts present a slip hazard. A fall may cause serious injuries.
 Keep the working area clean and dry at all times.
CAUTION
6.2 Qualification of the personnel


People whose ability to react is influenced, e.g. by drugs, alcohol or medicine are not allowed to carry out
any work.
User
The operating personnel must be at least 18 years of age, have a good knowledge of the operating
language.
manual.
The user has received instruction in a training session conducted by the operator on operation, the
safety devices and the possible hazards in the event of improper behaviour. The user may only carry out
tasks which go beyond normal operational use if this is specified in the manual and the operator has
explicitly given the user this task. The operator is urged to get users to confirm in writing that they have
received the instruction briefing.
Version 1.1.17 56
6 Operation
6.3 Personal protective equipment

The required personal protective equipment (PPE) is dictated by the metal powders used and the
activities performed on your LaserCUSING® machine.
The personal protective equipment must always be worn when the operator is working with metal
powders and their process-related soots in an atmosphere containing oxygen.
Two groups of metal powders can be processed: reactive and non-reactive metal powders. (See section
3.7 Approved metal powders (classification)) Depending on which group the metal powders used are
assigned to, different requirements result for the personal protective equipment to be worn.
When working with reactive materials (reactive metal powders and soot residues), the extended PPE
must always be worn. You will find an overview of the protective equipment required in each case in the
section Classification of the personal protective equipment.
Description of the personal protective equipment

Protective work clothing is close-fitting and dirt-repellent work clothing with tight sleeves and without
any protruding parts.
Chemical-resistant protective gloves

Protective gloves are used to protect the hands from aggressive chemicals.
Breathing mask (P3)

The particle-filtering half-mask prevents the user breathing in harmful dusts, mists and fumes.
Protective goggles (tight-fitting)

The protective goggles are used to protect the eyes from any powder dust, parts flying around and any
liquid splashing.
Full breathing mask (P3)

The particle-filtering full mask prevents the user breathing in harmful dusts, mists and fumes. The
integrated face protector protects the entire facial area from a sudden flash fire with a jet of flame.

Heat protection gloves are used to protect the hands from thermal risks such as heat and fire.
Antistatic protective equipment (ESD kit; ESD mat; antistatic protective clothing)
Antistatic protective equipment is used to prevent electrostatic charges. The protective equipment
consists of an ESD wristband with an earthing cable and a press stud; in addition ESD protective mats
can be put down in the danger zones.
Version 1.1.17 57
6 Operation
Protective clothing against limited flame propagation

Protective clothing is used to provide protection from thermal risks, in particular from a sudden flash fire
with a jet of flame. The flame-resistant clothing must be chosen so that the specified protection aim is
achieved. (Head and neck protection, body and face protection)
6.3.1 Classification of the personal protective equipment

Standard PPE
Protective gloves
Breathing half-mask P3
Protective goggles, tight-fitting
Extended PPE
Heat protection clothing (heat protection overall with a
hood or heat protection suit and balaclava)
Full breathing mask P3
ESD wristband
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6.3.2 Use of the required protective equipment

Overview of the protective equipment required depending on the metal powders used and the activities
to be carried out.
Note
All activities are performed in an atmosphere containing oxygen.
Metal powder used
Activity non reactive reactive
Brushing, scooping, wiping metal powders Standard PPE Extended PPE
Extracting metal powders Standard PPE Extended PPE
Wiping soot residue deposits Extended PPE Extended PPE
Cleaning the process chamber Extended PPE Extended PPE
Cleaning the filter module Extended PPE Extended PPE
Changing the filter in the process gas circuit (filter

Extended PPE Extended PPE
module / pressure relief valve)
Exhausting the build and powder chamber shafts Extended PPE Extended PPE
Protective work
Protective work
clothing, protective
Working in the closed and inertised glove box clothing and protective
gloves and ESD
gloves
wristband
Protective work
Protective work
Transport in powder bottles or powder clothing, protective
clothing and protective
containers (closed) gloves and ESD
gloves
wristband
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6.4 Shutdown in an emergency

Note on emergency stop switch!
Only press the emergency stop switch when danger exists! The machine is shut down immediately.
 This may result in consequential damage to the machine or the part.
 The emergency stop switch is not designed to be used for normal operational shutdown of the
machine.
In the event of danger to people, property or the environment, the LaserCUSING® machine must be
stopped immediately.
In an emergency, proceed as follows:
1. Press the emergency stop switch.
 The build process is interrupted immediately.
 All drives come to a standstill.
 The laser is switched off immediately.
 The inert gas supply is interrupted immediately.
 All pending control commands are reset.
 The signal strip and the “Emergency stop reset”
flash red.
2. Notify the person responsible at the place of

deployment.
3. Alert the fire brigade and/or rescue service.
4. If there is no danger to your own safety, rescue people

from the danger zone.
5. If necessary, start performing first-aid measures.
6. Switch off the machine and secure it against

reactivation.
7. Make sure that access routes for rescue vehicles are

clear.
8. Point the rescue vehicles in the right direction.
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6.4.1 Switching on machine after emergency stop

DANGER and that all safety devices are in place and in good working order.
 Only unlock the emergency stop switch when there is no longer any danger.
1. Rectify the emergency situation.
2. Close all safety devices.
3. Unlock the emergency stop switch.

 Turn the emergency stop switch to the right and
pull it forwards.
 The emergency stop safety circuit is enabled
again.
4. Press the flashing “Emergency stop reset” button on

the button panel of the machine.
5. Correct all faults displayed on the PLC monitor on the

control panel.
6. Press the flashing "Fault reset” button on the button

panel of the machine.
 Hold the button pressed down for at least one
second.
 All error messages on the PLC monitor are reset.
 For notes on error messages, see section 7.5.
Error messages
7. If an interrupted build process is to be continued, see

section 6.16.2 Continuing the build process
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6.5 Before switching on

In order to ensure safe operation, it is necessary to carry out a number of checks before switching on
the LaserCUSING® machine.
The following checks should be carried out before switching on the machine:
1. Check all feed lines on the LaserCUSING® machine.
 Check all inert gas and compressed air lines for any signs of damage or leaks.
 Check whether a quantity of inert gases sufficient for the build process is available.
2. Open the valves for the supply of compressed air and inert gas to the LaserCUSING® machine.
3. Check the pressure of the compressed air on the compressed air manometer.
 The pressure should be 6 bar.
 If necessary, adjust the pressure to 6 bar.
4. Check the pressure of the inert gas on the manometer of the maintenance unit for the inert gas.
 The pressure should be 5 bar.
 If necessary, adjust the pressure to 5 bar.
5. Check all plug connections on the LaserCUSING® machine.
 Check all electrical lines, data transmission cables and earthing cables for any signs of damage.
 Check that all plug connections are correctly and firmly in place.
6. Check that the key switch on the laser system is in the "REM" position. If not, turn the key switch to
the "REM" position!
7. Check that the filter module is pushed in correctly and is connected.
 Open all manual valves of the process gas circuit on the filter module.
8. Close all protective doors of the LaserCUSING® machine.
9. Check your personal protective equipment to ensure that it is not damaged and is in good working
condition.
 Put aside your protective equipment so that it is ready to be used.
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6.6 Switching on
Requirement
 The machine has been set up and connected properly.
 All of the preparatory measures as described in the chapter 6.5 have been carried out.
 All protective doors are closed.
Implementation
1. Switch on the LaserCUSING® machine.

 Turn the main switch on the electrical cabinet on
the back of the machine to the "I" position.
 The power supply to the laser system is established.
 The machine PC will be switched on and started up.
 The "Controller On" button flashes red.
2. Switch on the machine control voltage.

 Press the "Controller On" button on the control
panel.
 The "Controller On" button lights up green.
 If all systems are working properly, the signal strip,
the “Emergency stop reset” and "Fault reset”
buttons flash red.
Note
If the error message "PLC not connected" is displayed on the monitor of the control panel, switch off the
machine control voltage using the "Controller OFF" button.
Wait for roughly 5 seconds before switching the machine control voltage back on again.
3. Enable the machine controller.

 Make sure that no emergency stop switch has been
pressed and that no hazard situation exists.
 Press the flashing “Emergency stop reset” button on
the control panel of the machine.
 The controllers for the motors for the coater, build
chamber and powder chamber will be enabled.
Note
If the machine controller cannot be enabled, the “Error reset“ button will continue to be lit. Make sure
that:
 the protective doors of the handling and process station are closed.
 the glove box gloves are hanging outside of the glove box.
 the emergency stop switch on the control panel has not been pressed.
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4. Microsoft Windows® user login

 Log in with the user name and the password for the
operating system.
 For details about the machine computer and the
operating system, see the manufacturers' operating
manuals.
5. Start the CL WRX machine software. (For details, see the

CL WRX software manual)
 A link for the software has been created on the
desktop.
 To start the machine software, double-click on the
Concept Laser symbol.
 The CL WRX machine software starts. A connection
to the machine controller is automatically
established.
 The “Emergency stop reset” button goes out when
the connection of the machine software to the
machine has been successfully established.
 The QM coating software is started. (optional, for
details see the "QM coating Setup" manual)
6. Click on the button .

 The Machine control window is called up.
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6.7 Carrying out a reference run

Damage caused by misaligned movement paths!
If the movement paths of the axes are misaligned by objects, e.g. tools, this can lead to collisions and
thus damage to the machine.
CAUTION  Prior to the reference run, ensure that all movement paths of the axes are unobstructed. Remove all
objects from the surface of the build module.
Note on reference run!

A reference run is always required if the control voltage of the LaserCUSING® machine was switched off.
Requirement
 The machine has been switched on and is in its basic state.
 All protective doors are closed.
 There are no error messages for the handling station. (see section 7.5 Error messages)
Implementation
1. Open the Machine control menu.

 Check the PLC monitor.
 Rectify all relevant errors.
 No error messages for the handling station are
displayed.
 In the Machine status area "not referenced” is

displayed.
 Non-referenced axes are shown in grey in the
machine overview.
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2. Reference the axes of the powder chamber, the build

chamber and the coater.
 On the menu bar, click on the command Control |
Reference all axes.
 The coater, the powder chamber and the build
chamber platform will be referenced one after the
other.
 If the powder chamber platform is in its lower final
position, the powder chamber is shown with a
completely green background in the machine
overview.
 If the build chamber platform is in its lower final
position, the build chamber is shown with a
completely red background in the machine
overview.
 In the case of successful referencing, the current
axis position for the respective axis is displayed in
the machine status section.
3. Alternatively, reference the individual axes individually.

 Click in the Machine overview section on the axis
you want.
 The Build chamber / Powder chamber / Coater
section is opened.
 Click on the symbol Reference .

 The axis is referenced.
 In the Machine status section, the current axis

positions for the respective axis are displayed.
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6.8 Preparing the build process

6.8.1 Preparing the build plate
Clean, irradiate and demagnetise the build plate or the hybrid base before using it.
1. Clean the build plate, for example, with a parallel

grinder.
 Remove any firmly adhering contamination and
residues.
 Make sure that the build plate thickness is flat and
even.
2. Irradiate the build plate or the hybrid base until the

entire surface has a shiny matt finish.
 To increase the absorption and avoid reflections,
milled, ground or polished surfaces must always be
irradiated to a matt finish.
 According to scientific studies, the irradiation also
significantly improves the connection of the first
layers to the build plate / the hybrid base.
Note
To avoid impurities and fat deposits, only touch the build plate or the hybrid base after cleaning and
irradiation when wearing clean gloves.
3. Demagnetise the build plate or the hybrid base with a

demagnetiser.
 The demagnetisation of the build plate / the hybrid
substructure must take place after the irradiation.
 Slowly guide the build plate or the hybrid base over
a demagnetiser.
 Check the build plate or the hybrid base for any
residual magnetism with a gauss meter.
 The residual magnetism should be < 10 gauss.
4. Check the recesses for the cylinder head screws on the

build plate.
 Only if the recesses are worked in sufficiently deep,
this means it must be possible to recess the screw
heads fully in the build plate.
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6.8.2 Preparing the handling station

Swirling up of the approved reactive light-metal alloys as well as their process-related soot and filter
DANGER  Always wear the extended PPE when handling reactive metal powders.
 Avoid swirling up of metal powder.
 Always make sure that there is sufficient and continuous inertisation of the reactive metal powders.
 Always wipe off soot residues using a slightly dampened cloth.

Reactive metal powders and soot deposits an catch fire and cause serious to fatal injuries.
 Always wear the extended PPE when handling reactive powders.
DANGER
 Always make sure that there is sufficient and continuous inertisation of the reactive metal powders.
Danger of damage to health when handling metal powders!

When handling metal powders, there is the danger of damage to the respiratory tract and lungs. If the
metal powder or its dusts get into the eyes, there is the danger of damage to the eyes.
DANGER Some metal powders are suspected of having a carcinogenic effect.
 Wear a suitable breathing mask when handling metal powders. We recommend a breathing mask
with a P3 particle filter.
 Particular care must be taken when a direct contact to metal powders. Swirling up of powder should
be avoided.
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Requirement
 The build plate is ready for the LaserCUSING® process. see the section 6.8.1 Preparing the build
plate
 The appropriate metal powder is available.
Implementation
Note
Make sure that you place all of the tools and materials required for preparing, implementing and
following up the LaserCUSING® process into the glove box.
1. Put on your personal protective equipment.

 Standard PPE for non-reactive metal powders
 Exteneded PPE for reactive metal powders
2. Place at least the following tools into the glove box:

Hexagon socket screws for fixing the build plate in
place in the build chamber
– Hexagon socket screwdriver
– Spatula
– Brush and scoop
– Powder chamber sieve
– Powder chamber cover (on the wall mounting)
– Build plate
3. Place the following materials into the glove box:

– The required amount of metal powder in a sealed
powder bottle (Only necessary if the powder is
added via powder bottles!)
– Displacer material (is only required if a hybrid part
is being fabricated)
Note
If a hybrid part is to be created, make sure that you provide a sufficient amount of metal powder as
displacer material.
Note that the cavities and the substructure must be completely filled up with metal powder.
4. Close the glove box flap

 Close the glove box flap.
 Secure it using both knurled nuts.
 When the handling station is closed, the personal
protective equipment can be taken off.
 There is no longer any possibility of contact with
metal powder.
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6.8.3 Inertising the glovebox

Danger from using the wrong inert gas!
If titanium is used as the metal powder for the LaserCUSING® process, nitrogen must not be used as the
inert gas under any circumstances!
DANGER  For titanium powder, only ever use argon as the inert gas.
 Before flooding the machine, check that the stopcock for nitrogen is closed and the valve audibly
engages.
Note
Inertisation of the glove box is only necessary when using reactive powders.
Please find out about their properties before doing any work with metal powders. See section 3.7
Approved metal powders (classification).
Requirement
 The build module is coupled onto the handling station.
 The appropriate inert gas has been connected.
 The glove box is closed.
Implementation
1. Select the appropriate inert gas.

 Check the choice of inert gas used!
For titanium, argon must be used as the inert gas;
for aluminium, nitrogen must be used as the inert
gas!
 Close the stopcock for the inert gas which is not
required until the valve audibly engages.
2. Click in the Machine overview section on the

Inertisation button .
 The Inertisation section is displayed below the
machine overview.
 The Inertisation button is displayed in orange.
3. Activate the inert gas supply.

 Click in the Inertisation section on the symbol.
 Inert gas flows into the glove box until the residual
oxygen level falls below the set oxygen limit value.
 The symbol is now displayed in orange and the Inert
gas status indicator in the Machine status section
switches from red to green.
 The signal strip lights up yellow.
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4. Wait for the glove box to undergo sufficient inertisation.

 The O2 Module output field displays the current
residual oxygen content in the glove box. If the value
is below the set Switch on at value, the O2 Module
output field lights up green.
 The signal strip goes out as soon as the process
chamber is sufficiently inertised.
 If the value falls below the set oxygen limit value,
the software automatically interrupts the inflow of
inert gas.
Note
A maximum oxygen limit value of 2.0% is recommended.
The limit value can be set in the CL WRX machine software.
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6.9 Pouring in powder

Warning about physical injury from the use of metal powders!
The use of metal powders presents various hazards.
 It is essential that you wear the necessary protective equipment during all activities in which you
DANGER come into contact with metal powders, soot deposits, filter residues and their dusts.
 Swirling up of powder should be avoided.
 Before doing any work on the machine, read through the chapter 2 General safety instructions.
 The specifications in the safety data sheets for the metal powder used must be always complied
with.
Wear protective equipment!

During all work on and in the LaserCUSING® machine in which you come into contact directly with metal
powders, soot deposits, filter residues, and their dusts, the prescribed protective equipment must be
worn. Depending on the metal powder used, the protective equipment is divided up into:
 Standard PPE for non-reactive metal powders
 Extended PPE for reactive metal powders
If the glove box is closed and all work is carried out in the glove box through the glove box gloves, the
personal protective equipment no longer needs to be worn as direct contact with the metal powder is
excluded.
The metal powder can be poured into the powder chamber via two alternative methods:
– Pouring via a powder bottle which is placed in the glove box beforehand.
– Pouring via the powder inlet hose in the glove box, using a powder container.
Both methods are described in this subchapter.
Note
The more the powder chamber platform is lowered, the more metal powder the powder chamber can
hold.
If there is no previous experience with the part which is to be created, it is recommended that the
powder chamber should be completely filled with metal powder. The amount of metal powder which is
required for the respective build process cannot be estimated ahead of the build process.
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6.9.1 Filling with powder bottles

Requirement
 The handling station has been prepared. (see section 6.8.2)
 The metal powder in bottles is ready in the glove box.
 The glove box has been closed and inertised. (see section 6.8.3) (only when using reactive metal
powders).
Implementation
Note
If non-reactive metal powders are being used, all of the tasks below can be carried out without
inertisation and with the glove box door open.
Select an appropriate personal protective equipment.
It is generally recommended that, even when using non-reactive metal powders, you work through the
glove box gloves with the glove box closed.

 Standard PPE
 If reactive metal powders are being used, the glove
box is closed and inertised. All tasks are performed
through the glove box gloves.
2. Lower the platform of the powder chamber.

 The platform can only be moved if the coater is in its
left final position.
 Click in the Machine overview section on the
Powder chamber.
 The Powder chamber section is displayed.
 Click on the symbol , to move the platform
continuously downwards.
 Alternatively, lower the platform gradually, by the
amount which is entered in the Step input field.
Note
To avoid swirling up the powder, lower the platform gradually. This keeps the amount of drop of the
metal powder as low as possible and thus prevents dust formation.
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3. Pour the metal powder into the powder chamber.

 The metal powder must be sieved before it is used.
This can be done via a sieving station or a powder
chamber sieve.
 Place the powder chamber sieve onto the powder
chamber.
 Open the screw-cap top of the powder bottle.
 Pour the metal powder into the powder chamber via
the sieve.
 Shake the sieve gently back and forth to sift the
powder.
 Sieve the required quantity of metal powder into
the powder chamber in several stages. Gradually
lower the platform.
4. Once the required quantity of metal powder has been
poured in, close the powder bottle and place it down out
of range of the movement paths of the build module.
5. After the sieving process, remove the powder chamber

sieve from the powder chamber.
 Place the sieve down out of range of the movement
paths of the build module.
6. Compress the metal powder in the powder chamber.

 Compression of the metal powder is necessary to
prevent any subsequent sinking if there should be
any shaking, for example.
If the metal powder were to sink down during an
automatic build process, insufficient powder would
then be available for the following applications of
powder.
 Prick with the spatula several times the powder bed.
 Smooth out the metal powder which has been

poured in using a spatula.
7. Remove the powder chamber sieve and the powder

bottle from the glove box.
 See section 6.10 Opening the inertised glove box
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6.9.2 Filling with powder containers

The inappropriate use of a lifting device may present the danger of injury to the user.
DANGER
 Use the correct jacking points for the powder container in order to prevent it from falling off.
Warning about physical unjury from carrying heavy loads!

CAUTION
Requirement
 The handling station has been prepared. (see section 6.8.2)
powders).
 The metal powder is available in the powder container.
Implementation
Note
Please select the appropriate personal protective equipment.
If the metal powder is provided in powder containers, filling via the powder inlet hose of the glove box is
possible.
It is necessary to use a lifting device to move the powder containers. Please take all of the safety
precautions required for such use.
 Standard PPE
2. Earth the lifting device.

 Open the bottom side door of the handling station.
 Remove the protective cover on the connection for
the earthing cable.
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 Connect the earthing cable of the lifting device to

the machine.
3. Lift up the powder container.

 If the powder container is below the powder
overflow in the LaserCUSING® machine, the powder
container must first of all be removed from the
machine. See section 6.19 Removing the powder
container from the machine
 Move the lifting device with the fork below the
mountings on the powder container.
 Slightly lift up the powder container.
 Secure the powder container with the two securing
strips (lift up the locking bolts to do this) and then
lock the strips with the securing bolt.
 For a more detailed description, please consult the
operating manual for the lifting device.
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4. Connect the powder hose to the powder container.

 Lift the powder container up to roughly chest
height.
 Choose the right powder hose for the metal powder
which is in the powder container.
 Attach the powder hose using the clamp on the
powder outlet of the powder container.
5. Open the service flap above the glove box.

 Pull the handle of the service flap.
6. Lift the powder container over the machine.

 The metal powder must be sieved before it is used.
chamber sieve.
 If the powder is sieved via an external sieving
station, follow the "QM powder" instructions in the
other relevant documents before performing this
step.
 Secure the powder hose using the hook on the
handle of the powder container.
 Use the lifting device to lift the powder container

above the LaserCUSING® machine.
 Position the powder container so that the powder
hose is above the inlet opening to the machine.
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7. Position the powder hose above the powder inlet valve

of the glove box.
 Take the hose from the hook.
 Guide the powder hose through the upper opening
of the handling station.
 If necessary, lower the powder container further
down.
 Step on the brakes on the castors of the lifting
device.
 The lifting device is secured against being moved
accidentally.
8. Connect the powder hose to the glove box.

 Place the sealing ring onto the powder inlet of the
glove box.
 Close the clip around the powder hose.
 Tighten the wing screw.
9. Prepare the powder inlet hose of the glove box.

 Take the powder hose from its mounting on the
glove box wall.
 Open the butterfly valve on the powder inlet of the
glove box.
Danger of fire and explosion from reactive metal powders!

Reactive metal powders can catch fire and cause serious to fatal injuries.
 Only open the butterfly valve on the powder container when the glove box and the powder hose
DANGER have been sufficiently inertised.
10. Wait until the powder hose is filled with inert gas.
 If non-reactive metal powders are used, there is no
need for this step.
 You should wait for approx. 60 s so that the hose
has a chance to be filled with inert gas.
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11. Lower the platform of the powder chamber.

Powder chamber.
 Click on the symbol ,to move the powder
chamber continuously downwards..
 Alternatively, lower the platform gradually, by the
Note
To avoid swirling up the powder, lower the platform gradually. This keeps the amount of drop of the
metal powder as low as possible and thus prevents dust formation.
12. Pour the metal powder into the powder chamber.

chamber sieve.
 Place the powder chamber sieve onto the powder
chamber.
 If the powder has been sieved beforehand via an
external sieving station, there is no need to sieve
the metal powder at this stage.
 Open the butterfly valve on the powder outlet of the
container.
 Allow the required quantity of metal powder to
trickle into the powder chamber.
 If the powder chamber sieve is used, this must be
constantly shaken back and forth in order to sieve
the powder. Sieve the required quantity of metal
powder into the powder chamber in several runs.
 Lower the platform gradually.
 Interrupt the supply of powder from time to time by
closing the butterfly valve at the powder inlet of the
glove box.
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13. Stop the powder feed.

 Close the valves from top to bottom in order to
avoid an accumulation of powder in the powder
outlet hose.
 Close the butterfly valve on the powder outlet of the
powder container.
 Close the butterfly valve on the powder inlet of the
glove box.
14. Disconnect the powder hose from the glove box.

 Undo the wing screw.
 Open the clip around the powder hose.
 Move the powder container up slightly using the
lifting device.
 Remove the sealing ring from the powder inlet of
the glove box.

15. Lower the powder container.

 Move the lifting device with the raised powder
container slowly away from the machine.
 Lower the powder container to roughly chest height
as soon as it is sufficiently far away from the
machine.
16. Close the service flap over the glove box.

 Push the handle of the service flap.
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17. Disconnect the powder hose from the powder container.

 Open the wing screw and the clip around the
powder hose.
 Place the powder hose in an antistatic bag and store
this away in a fire-resistant cabinet.
 Lower the powder container until it is just above the
floor.
 The powder container can now either be inserted
into the LaserCUSING® machine and connected to
the powder overflow or be cleaned and stored away.
18. Compress the metal powder in the powder chamber

 Compression of the metal powder is necessary to
prevent any subsequent sinking if there should be
any shaking, for example.
 If the metal powder were to sink down during an
automatic build process, insufficient powder would
then be available for the following applications of
powder.
 Prick with the spatula several times the powder
bed.
19. Smooth out the metal powder which has been poured in
using a spatula.
20. Remove the powder chamber sieve from the glove box.
 See section 6.10 Opening the inertised glove box
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6.10 Opening the inertised glove box

WARNING come into contact with metal powders, soot deposits, filter residues and their dusts.
 Before doing any work on the machine, read through chapter 2 General safety instructions.
 The specifications provided in the safety data sheets for metal powders used must be always
complied with.

a lack of oxygen. This leads to suffocation!
WARNING  Only work in the open glove box once an oxygen content of approx. 20% has been reached.
 Make sure that you do not breathe in any escaping inert gas.
 Do not insert your head into the glove box.

worn.
Depending on the metal powder used, the protective equipment is divided up into:
It is only necessary to inertise the glove box when reactive metal powders are used for the
LaserCUSING® process.
Requirement
 The glove box is closed and inertised. (see section ) (only when using reactive metal powders)
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Implementation
1. Place the powder chamber cover onto the powder

chamber.
 Lower the powder chamber platform to its lower
final position.
 Place the powder chamber cover onto the powder
chamber.
2. Clean any powder residues off the surface of the build

module and the glove box.
 Clean the build module surface with a brush and
transfer the metal powder into the powder
overflow.
 Clean the glove box surface carefully with a brush.
 The surfaces should be free of any visible
powderdeposits.

 Standard PPE for non-reactive metal powders
 Extended PPE for reactive metal powders
4. Stop the inertisation.

 Click on the symbol in the Inertisation section.
 The Inert gas status display in the Machine status
section changes from green to red.

a lack of oxygen. This leads to suffocation!
WARNING  Never open the glove box when inertisation is switched on.
 Only work in the opened glove box when the oxygen sensor shows an oxygen content of approx.
20%.
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5. Slowly open the glove box flap.

 Only work in the opened glove box when the oxygen
content of approx. 20% is displayed.
 Remove the two knurled nuts on the glove box flap.
 Flip the glove box flap upwards.
6. Remove the objects (powder bottle, powder chamber

sieve, tools which are not required) from the glove box
or place any missing objects into the glove box.
 Avoid coming into contact with the metal powder.
 Avoid any hectic and abrupt movements.
 Carry out your activities calmly but swiftly.
7. Close the glove box flap as soon as you have finished

working.
 Secure it using the two knurled nuts.
protective equipment can be taken off. There is no
longer any possibility of contact with metal powder.

 Click the on the symbol . in the Inertisation
section.
section changes from red to green.
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6.11 Inserting the powder container into the machine

WARNING

CAUTION
The build module has a powder overflow. Not required metal powder which is stripped off during the
build process from the coater blade above the powder overflow or metal powder which gets into the
powder overflow during other steps is captured by a powder container beneath the build module.
Requirement
 The butterfly valve on the powder outlet of the powder overflow is closed.
 The powder container is empty and has been cleaned or the powder container is sufficiently empty
and filled with the same metal powder as is being used on the machine.
 All valves on the powder container are closed.
Implementation

 Move the lifting device with the fork below the
 Lift up the powder container slightly.
 Secure the powder container with the two securing
 For a more detailed description, please consult the
2. Move the powder container up to the left-hand side of

the machine (handling station).

 Open the lower side door of the handling station.
the earthing cable.
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the machine.
4. Move the powder container into the machine.

 Undo both securing strips and unlock the powder
container.
 Move the container carefully into the machine.
 Place the powder container slowly down beneath
the outlet valve of the powder overflow.
 Move the lifting device slowly out of the machine.
5. Connect the powder container to the powder overflow.

 Lock the clamping fasteners on the sides of the
powder container to the build module.
6. Connect the powder outlet of the powder overflow and

the inlet valve of the powder container to the
connecting hose.
 Close the upper wing nut and the clamp in order to
attach the connecting hose.

powder container.
powder overflow.
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7. Disconnect the lifting device from the machine.

 Disconnect the earthing cable of the lifting device
from the machine.
 Place the protective cover onto the earthing socket
connection.
 Remove the lifting device from your working area..
8. Close the lower side door of the handling station.
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6.12 Fitting the build plate

Danger posed by back-reflection of the laser beam on a glossy surface!
Build plates or hybrid bases must not be glossy.
This could cause the impinging laser beam to be reflected back into the optical lenses and guided back
CAUTION to the laser resonator.
Damage to the optical lenses in the beam path and damage to the internal optical lenses in the laser
resonator could be the consequence.
 Always irradiate milled, ground or polished surfaces to a matt finish in order to increase the
absorption and to avoid reflection.
 Irradiate the build plate before use in the LaserCUSING® machine with the appropriate level of care.
If the LaserCUSING® process is carried out with reactive metal powders under a protective atmosphere,
the required build plate and the tools must be placed in the handling station before the glove box is
flooded! (See section 6.8.3 Inertising the glovebox)
The inertised glove box can be opened after the filling of metal powder. (See section 6.10 Opening the
inertised glove box)
Requirement
powders)
 The build chamber platform and the build module surface have been cleaned.
 The build plate / hybrid part have been prepared in accordance with section 6.8.1 Preparing the
build plate.
6.12.1 Cleaning the build chamber platform
Note
Please select the appropriate personal protective equipment.

 Standard PPE
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2. Move the build chamber platform into its upper final

position.
 The build platform can only be moved in the upward
direction if the coater is in the left final position.
 In the Machine overview section, select the Build
Chamber.
 The Build Chamber section is displayed.
 Click on the symbol , to move the build chamber
platform continuously upwards.
 Alternatively, lift the build chamber platform
gradually, by the amount which is entered in the
Step input field.
 Alternatively, move the build chamber platform to
the defined position which is entered in the Target
field.
 If the build chamber is being moved upwards, the
values of the status indicator are getting smaller.
3. Clean the surface of the build chamber platform.

 Wipe the build chamber platform with a dry cloth.
 The build chamber platform must be dry and free of
any contamination in order to ensure a flat contact
surface and an optimum transfer of heat.
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6.12.2 Fitting the standard build plate

The standard build plate can always be screwed onto the build chamber platform, even if it is equipped
with a clamping system.
Note
The screws must be fully recessed in the build plate!
Otherwise there is a risk that the coater blade will collide with the protruding screw heads and be
damaged.
1. Screw the build plate onto the build chamber platform.

 Clean the bottom of the build plate with a slightly
damped cloth.
 Place the build plate onto the build platform.
2. Screw the build plate to the platform of the build

chamber.
 Screw the build plate to the platform.
 Check that all screws are fully recessed into the
plate and do not protrude out.
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6.12.3 Fitting the build plate with clamping system

If your machine is equipped with the clamping system for simple installation of the build plate, please
adopt the procedure described below.
Note about heavy wear!
The clamping chuck on the build chamber platform is very sensitive to contamination and metal powder
deposits.
If metal powder or other pollutants get into the clamping chuck, this leads to increased wear all the way
through to a defect.
 Keep the clamping chuck clean and avoid any work which produces a lot of dust when the clamping
chuck is not covered.
1. Open the clamping chuck.

 Turn the switch for the clamping system on the
handling station 90° in the clockwise direction.
 The clamping chuck is open when the rotary switch
is in its 3 o'clock position.
Note on the sealing ring of the build plate!

The sealing ring of the build plate may slip out when it is being placed on the build chamber platform.
Make sure when placing the build plate on the platform that the seal is inserted correctly.
A build plate which is not placed in flat may be an indicator of a seal that has slipped out.
2. Place the build plate onto the build chamber platform.

 Check whether the clamping system is open.
 Place the clamping spigot on the bottom of the build
plate into the clamping chuck on the build chamber
platform.
 Make sure that the build plate fits properly.
3. Screw the build plate onto the build chamber platform.

 Turn the switch for the clamping system 90° in the
anticlockwise direction.
 If the rotary switch cannot be turned, check that the
build plate is fitted in place correctly and then try
again.
 The build plate is clamped onto the build chamber
platform.
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6.12.4 Final tasks

Note
The build plate must not under any circumstances be higher than the working surface of the build
module as otherwise the coater blade will collide with the build plate when the coater is moved.
The coater blade may then be damaged.
1. Remove all objects and tools from the build module
surface and place them into the tool holders of the
handling station.
 Check that there are no tools, screws or other
objects on the build module.
 Check that the movement paths of the build module
are clear.
Note on the sealing ring of the build plate!

The sealing ring of the build plate may slip out when it is being placed on the build chamber platform.
Make sure when placing the build plate on the platform that the seal is inserted correctly.
A build plate which is not placed in flat may be an indicator of a seal that has slipped out.
2. Pull the glove box gloves forwards out of the glove box.
 The light barrier at the glove box entrance must not
be broken.
3. Move the build chamber platform so that the surface of

the build plate is slightly below the surface of the build
module.
platform continuously downwards
 Alternatively, lower the build chamber platform
Step input field.
 Check the position of the build plate.
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6.13 Defining the zero position of the build plate (scraping)

Danger of fire from reactive metal powders!
Reactive metal powders can catch fire in an atmosphere containing oxygen and cause serious to fatal
injuries.
DANGER  Always inertise the glove box when using reactive metal powders.
The gap between the coater blade and the build plate must be set before the start of the build process.
For an optimum application of powder, we recommend a gap of 30 µm between the coater blade and
the build plate.
In the CL WRX machine software the lowering and delivery values can be defined in one step under the
menu item. Set up machine. (See the CL WRX software operating manual)
Requirement
 The glove box is closed and has been inertised. (see section 6.8.3)(only when using reactive metal
powders)
 The light barrier of the glove box is not broken.
 The build plate is mounted on the build platform.
Implementation
Note
If the machine controller cannot be enabled, the “Error resett" button will continue to be lit.
Make sure that:
 all protective doors of the handling station and the process station are closed, apart from the sliding
door of the handling station.
 the glove box is closed and the glove box gloves are hanging outside of the glove box.
 the emergency stop switch on the control panel has not been pressed. (If the emergency stop
switch has been pressed, it must first be released before enabling the control voltage.)
1. Enable the machine controller.

 Check that all movement paths of the build module
and of the coater are clear.
 Press the flashing “Error reset” button on the
control panel of the machine.
 The controllers for the motors for the coater, build
chamber and powder chamber are enabled.
Note
The build plate must not under any circumstances be higher than the working surface of the build
module as otherwise the coater blade will collide with the build plate when the coater is moved.
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2. Move the build platform with the build plate roughly to

the height of the working surface of the build module.
 Check whether the build plate surface is just below
the build module surface.
 If necessary, correct the position of the build
chamber platform using the machine software.
 The position of the build plate relative to the

working surface of the build module can be gauged
very well using a straight iron rule or a similar tool.
3. Open the Set up Machine window.

Set up Machine.
 The Set up Machine window is opened.
 In this window, all settings for a layer application
can be defined. (see the CL WRX software operating
manual)
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6.13.1 Using the coater blade made of steel

The coater blade made of steel offers, thanks to its material texture, the option of determining the gap
between the coater blade and build plate exactly using a feeler gauge.
1. Move the coater with the coater blade over the build
chamber.
 Enter a low coater speed into the Speed input field.
 Click on the symbol Build chamber.
 The coater is moved over the middle of the build
chamber.
2. Measure the gap between the coater blade and the build
plate with the aid of the feeler gauge.
3. Move the coater to the left final position in the build

module.
 Click on the symbol Left.
 The coater is moved to its left final position.
Note
Only move the build plate upwards in small defined steps.
Otherwise there is a risk of the coater blade colliding with the build plate.
4. Move the build chamber platform up by the measured

difference.
 Example calculation: Measured gap 800 µm. Move
the build platform up by 770 µm in order to produce
a gap of 30 µm.
 The build platform can only be moved upwards if the
coater is in its left final position.
 Enter the calculated difference for the build
chamber platform in the mm input field.
 Click on the symbol .
 The build chamber platform is raised by the value
which is entered.
5. Apply the first powder layer to check the zero position

which is set.
 Proceed then as described in the section 6.13.2
Using the coater blade made of plastic or elastomer.
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6.13.2 Using the coater blade made of plastic or elastomer

When coater blades made of plastic or elastomer are used, the gap between the blade and the build
plate cannot be measured using the feeler gauge because of the flexible material of the blade.
The zero position is defined based only on the applied powder layer. (Scraping)
Note
Note the following for the movement paths of the axes:
Build chamber platform: deliver = negative values lower = positive values
Powder chamber platform: deliver = positive values lower = negative values
1. Check that the build plate surface is just below the build
module surface.
chamber platform using the machine software.
2. Move the powder chamber platform with the metal

powder upwards.
Powder chamber.
 Click on the symbol , to move the platform
continuously upwards.
 Alternatively, move the platform up gradually, by the
 The metal powder should protrude up clearly over
the working surface of the build module.
3. Apply the first powder layer.

 Use the Layer application section to do this.
 Enter in the entry fields on the top row Lower by (on
return) the values for lowering the platforms and
the coater speed for the return run of the coater.
 Enter in the entry fields on the bottom row Position
by the values for moving up the powder chamber
platform, lowering the build chamber platform and
the coater speed for the layer application.
 Start the layer application clicking on the symbol .
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 A complete layer application with the values

entered is carried out.
 If irregularities occur during the layer application,
e.g. if the coater gets stuck, the layer application can
be stopped immediately by clicking on the
symbol .
4. Evaluate the applied powder layer.

 The powder layer must be evenly distributed over
the build platform.
 The surface of the build plate or the hybrid part
must be clearly visible under the powder layer.
Note on powder application

The applied powder layer must be spread evenly over the build plate.
If this is not the case, the build process may not be started.
Causes of an uneven powder layer are:
– a skewed build plate. The build plate was not prepared cleanly and must be ground down before
being used again.
– incorrect installation of the build plate on the build chamber platform. The build plate rests askew
on the build chamber platform, e.g. as a result of a foreign object below the build plate.
Note on layer thickness

The evenly applied powder layer must have assumed the lowest possible layer thickness. This is the
case if the build plate, the part or the hybrid part can be fully made out through the powder layer.
Example of incorrect layer application:

 The powder layer is uneven, i.e. the build plate or
the coater have not been fitted correctly.
 The powder layer applied is too thick for the
exposure process..
 The build module surface should be cleaned and the
build plate and the coater blade checked to make
sure they are fitted correctly.
Example of correct layer application:

 The powder layer is even, i.e. the build plate and the
coater have been fitted correctly.
 The powder layer applied is sufficiently thin for the
exposure process, i.e. the build plate can clearly be
made out under the powder layer.
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5. Repeat the powder application until the powder

application is optimal for the exposure.
 Only move the build chamber platform up by small
amounts as you do this.
 Close the Set up machine window by clicking on
the Close button.
6. Define the position of the build chamber and the powder

chamber as the zero position in the machine software.
 Click on the Machine overview section on the
build chamber of the machine.
 The Build Chamber section is displayed below the
machine overview.
 The Build Chamber is shown with a light green
background.
 Click on the button , next to the position display
indicator of the build chamber platform.
 The current build chamber position is set to zero.
Note on zero position of the powder chamber

The scraping also moves the powder chamber platform upwards. In the process, the zero position of the
powder chamber platform for the start of the automatic build process is automatically set.
The surface of the metal powder in the powder chamber should be even and not contain any gaps or
indentations.
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6.14 Starting the build process

Once the build module is prepared, the build process can be started. To start the build process, the
following tasks are carried out:
– Create the build job
– Determine zero position of the build chamber platform (scraping)
– Move the build module into the process station
– Inertise the process chamber
– Individual layer exposure
– Start the automatic build process
6.14.1 Creating the build job

Note
The machine software of the process station is designed for creating and editing build jobs. Only parts in
a .cls format can be loaded.
Prepare the part and the associated support in software which is suitable for this purpose.
Note on automatic read-in of the support.

If a support file has been created for a component, this is automatically read in with the part if:
– this function has been activated in the software configuration by the service engineer from Concept
Laser GmbH.
– the support file can be uniquely assigned to the part via the file name. Example: part: example. cls
suitable support: s_example.cls
– the support file is in the same folder as the part.
However, the support can also be read in individually separate from the part via the command Edit |
Read in support. (see the CL WRX software operating manual)
Requirement
 The parts and their support are available for import as .cls files.
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Implementation
1. Create the build job.

 The standard build process parameters are
automatically assigned to the new build job.
 Switch to the Concept Laser menu.
 On the menu bar, click on the command Build job|
New.
 Save the build job.
 Fill in the input fields in the Build job designation
section.
 Save the build job.
 The build job is saved in a database on the machine
computer.
 If a build job with similar parameters to those of the
new build job to be created already exists, it is
advisable to use this build job as a template.
2. Select build plate.

 The LaserCUSING® machine is only designed for the
standard build plate with the dimensions 245mm x
245mm.
 On the menu bar, click on the command Build plate |
Select build plate.
 The Build plate selection window is opened.
 Select the standard build plate.
 Click on the OK button to apply the selection.
3. Read in parts.
 The standard part parameters are automatically
assigned to the new parts.
 On the menu bar, click on the command Edit | Read
in part.
 If no new build job has previously been defined, the
Edit menu remains greyed out.
 The Open navigation window is opened.
 Go to where the part is saved.
 Select the part.
 Click on the Open button to read in the part.
 If a support file has been created for a part, this is
automatically read in with the part.
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4. Position the part on the build plate.

 Double-click on the part in the part navigation
section to activate it.
 The part is given a green background.
 On the menu bar, click on the command Edit | Move
part.
 The Move part(s) window is opened.
 Move the part to the target position.
 Confirm the position of the part by clicking on the
OK button.
5. Check the exposure vectors.
6. Save the build job.

 On the menu bar, click on the command Build job |
Save.
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6.14.2 Moving the build module into the process station

Danger of squashing!
If limbs are placed between the build module and the machine when the build module is being moved,
there is a danger of squashing.
WARNING  Close the protective doors of the machine.
 Make sure that there are no people in the machine.
Note
The powder in the build and powder chambers may sink when it is moved.
If this should happen, the powder chamber must be additionally raised to ensure a sufficient layer
application. Check the layer application again.
See section 6.13 Defining the zero position of the build plate (scraping)
Requirement
 The build plate is mounted on the build platform.
 The glove box is closed and the light barrier is not broken.
 The glove box has been inertised. See section 6.8.3 Inertising the glovebox (only when using reactive
metal powders).
 The process chamber and the process station are closed.
 The powder container is connected to the powder overflow and the valve is open.
 The side protective doors of the machine are closed and locked.
Implementation
1. Check the movement path of the build module.

 Remove all objects and tools from the build module
surface.
 Remove the powder chamber cover from the
powder chamber.
 The movement path of the build module must be
clear.
Note
If it is necessary to reach into the handling station again, the controller enabling is cancelled by breaking
the light barrier.
When this happens, the axes of the build chamber and powder chamber sink slightly.
 After completing the work in the handling station, enable the machine controller again.
 Move the build platform and the powder platform back to the previously defined zero positions via
the destination point run of the machine software. (CL WRX software operating manual)
2. Close the handling station.

 If during this movement one of the protective doors
of the machine is opened, the controller enabling is
cancelled and the build module is halted.
 Close the opened protective door and issue the
enabling for the machine controller again. The
process is resumed.
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3. Move the build module from the handling station into

the process station.
 The current position of the build module is displayed
in the Machine overview section.
 On the menu bar, click on the command Machine |
Module into process station.
 The build module is moved from the handling
station into the process station.
Note on interrupted movement process

If the movement of the build module is interrupted prematurely, e.g. by a protective door being opened,
the machine software loses the current build module position. It is not possible to resume the
movement even after the fault has been rectified.
In order to determine the position, the build module must first be moved into the handling station
before the movement process can be restarted.
4. Inertise the process chamber immediately after coupling

on the build module.
 Flooding of the glove box with inert gas
(inertisation) is only necessary when using reactive
metal powders.
 If non-reactive steel powders are used, inertisation
is not necessary.
 If the inertisation of the glove box was active at the
time of the movement process, the process
chamber is automatically inertised after the build
module has been coupled on. See section 6.14.3
Inertising the process chamber.
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6.14.3 Inertising the process chamber

Danger of explosion from insufficient inertisation of the process chamber!
residues in an atmosphere containing oxygen may produce an explosive atmosphere. There is a danger
DANGER of explosion and fire.
 Never open the process chamber door during an ongoing build process or when the ventilator unit is
turned on.
Danger posed by the use of nitrogen, when using titanium materials!

engages.
Note
A maximum oxygen limit value of 2.0% is recommended.
The limit value can be set in the CL WRX software.
Requirement
 The correct inert gas has been selected and a sufficient amount of it is available.
 The build module is in the process station and is coupled to the process chamber.
 The process chamber is closed and locked.
 The door of the process station is closed.
Implementation
1. Click in the Machine overview section on Inertisation.

machine overview.

 Click in the Inertisation section on the symbol .
 Inert gas flows into the process chamber until the
residual oxygen level falls below the oxygen limit
value which is set.
 The symbol is now displayed and the Inert gas
status indicator in the Machine status section
switches from red to green.
 The signal column lights up yellow.
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3. Wait for the process chamber to undergo sufficient

inertisation.
 The O2 module and O2 process chamber displays
display the current residual oxygen content in the
process chamber and directly on the build module. If
the value is below the set Switch on at value, the
displays light up green.
 If the value falls below the oxygen limit value which
is set, the software automatically interrupts the
inflow of inert gas.
 The signal column goes out.
Note on inertisation!
The process chamber must be flooded with inert gas before the extraction process is started. This
prevents the filters from being flushed with oxygen-rich air. The ventilator can only be switched on when
the residual oxygen content is less than 2%. If the residual oxygen content rises above 2%, the ventilator
switches off automatically.
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6.14.4 Carrying out individual layer exposure

Note
Before starting the automatic build process, an individual layer exposure is strongly recommended for
the first layer.
The individual layer exposure is used to check the position of the parts on the build plate or on the
hybrid part.
Repeat the exposure of the first layer at least 1 time to improve the bonding of the support on the build
plate or of the part on the hybrid part.
Requirement
 The first powder layer has been applied. See section 6.13 Defining the zero position of the build plate
(scraping).
 The process chamber has been inertised and the ventilator activated.
Implementation
1. Open the Individual layer exposure window.

 Click on the symbol in the list of commands.
 Alternatively, click on the menu bar on the
command Build job | Individual layer exposure.
 The Individual layer exposure window is opened.
Note on targeting
The positional monitoring of the parts in targeting mode can be carried out with a lower energy input.
This is achieved by having a low laser power at the same speed or the same laser power at a higher
speed. The values can be defined in the input fields for the targeting.
2. Check the position of the parts with the individual layer

exposure in Target mode.
 Enter in the Layer at height input field the layer
height in mm or in the Layer input field the layer
which is to be exposed. The other value in each case
is automatically calculated and entered by pressing
the Enter key.
 When a new build job is started, the input fields are
prepopulated with:
– Layer at height: 0 mm
– Layer (=Layer): 1
 Enable the Target checkbox.
 In the with input field enter the laser power, and in
the and input field enter the exposure speed.
 In Target mode, only the contours of the parts or the
support are exposed. This is for checking the
position of the parts.
 Click on the Expose button.
 The individual layer exposure in Target mode is
started.
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3. Check the position of the parts.

 Monitor the exposure process and check the correct
position of the parts or the support on the build
plate or the hybrid part.
 If the position is correct, the individual layer
exposure can be continued.
 If the position is not correct, the individual layer
exposure must be interrupted and the position of
the parts corrected.
4. Expose the first layer in normal mode of the individual

layer exposure.
 Enter in the Layer at height input field the layer
height in mm or in the Layer input field the layer
which is to be exposed. The other value in each case
is automatically calculated and entered by pressing
the Enter key.
 When a new build job is started, the input fields are
prepopulated with:
– Layer at height: 0 mm
– Layer (=Layer): 1
 Disable the Target checkbox.
 The settings from the saved build job are used for
the exposure.
 Click on the Expose button.
 The individual layer exposure in normal mode is
started.
5. Repeat the individual layer exposure for the first layer at

least 3 times.
 Switch here between layers 1 and 2 to achieve the
most even layer application possible in the build
process. No new powder layer needs to be applied
here.
 The parts or the support are better connected to
the build plate or the hybrid part as a result.
 After this, close the Individual layer exposure
window by clicking on the Close button.
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6.14.5 Starting the automatic build process

Requirement
 A build job has been loaded. see section 6.14.1
 No faults are displayed on the PLC monitor.
 The first powder layer has been applied and exposed. see section 6.14.4
Implementation
1. Start the automatic build process.

 Click in the list of commands on the symbol .
command Build job | Start.
 The automatic LaserCUSING® process is started.
 The signal strip lights up green during fault-free

operation.
Note on watching the build process!

It is recommended that you observe at least the first 5 layers of a newly started build process.
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6.15 Observing the build process

The build process can be observed safely through the viewing window of the process chamber.
For a better view, there is lighting which can be switched on in the process chamber.
1. Switch the lighting of the process chamber on or off.

 Click on the symbol above the process station in
the Machine overview section.
command Machine | Light in process chamber on.
 The lighting in the process chamber is switched on.
When observing, pay particular attention to the following processes:
6.15.1 Observing the movement path of the coater

During its movements from the powder chamber to the build chamber, the coater must neither snag
nor get stuck.
If the coater is impeded on its movement path between the powder chamber and the build chamber,
the fault must be rectified.
Description of the fault How to rectify the fault
Coater blade gets caught on the part.  Abort and finish the build process.
 Check the coater blade.
 Change the coater blade if necessary.
 Start a new build process.
6.15.2 Observing the powder application and the applied layer of powder
Die The newly applied layer of powder must be flat and even. The layer of powder should be thick
enough that the part can still be made out.
If too little powder is applied, the powder delivery factor is too low. The powder delivery factor increases
with the size of the area which is to be exposed.
Uneven powder application due to Adhering powder remains behind as a pile when
powder adhering to the coater blade the powder is applied to the exposed surface.
 Abort and finish the build process.
 Check the coater blades (grease, magnetism).
 Clean the coater blade if necessary.
 Demagnetise the coater blade if necessary.
 It is imperative to sieve the powder used in this build
process before using it again.
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Powder layer applied is too low  Increase the powder delivery factor by 20%.
 Watch the next application of powder.
 The new powder layer must again be applied flat
and evenly.
 The layer of powder must be thick enough that
the part can still be made out.
 If necessary, increase the powder delivery factor by
another 10%.
 Watch the application of powder again.
 If the fault cannot be rectified, the build process must
be aborted.
Build plate is not fitted flat and powder There may be foreign bodies between the build platform
application is therefore not even and the build plate, meaning that the build plate does not
rest flat on the build platform.
 Take out the build plate.
 Remove all contamination on the build plate and the
build platform.
 Fit the build plate again and start a new build process.
Build plate is not fitted flat and powder The coater blade is worn and needs to be replaced after
application is therefore not even the build job.
 Replace the coater blade after the end of the build
job.
Uneven powder application due to worn The powder layer applied is uneven and too thick. The
coater blade. part is built up with a different thickness and unevenly.
 Change the coater blade.
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6.15.3 Observing the melting process

The melt pattern of the powder surface which is machined by the laser beam must have a shiny silvery
appearance.
If the melt pattern has a black and matt appearance, the laser power is too low.
The flying sparks produced during the melting process must, similar to a table firework, spray out, reach
a certain height and appear yellow to light orange.
If the sparks are dark orange and are only formed with a low spray height, the laser power is too low.
Black-matt melt pattern as a result of  Abort and finish the build process.
insufficient or no laser power  Check the access glass of the scan head for any
contamination.
 Clean the access glass if necessary.
Start a new build process.
(See section 6.14 Starting the build process)
Sparking too weak due to insufficient  Abort and finish the build process.
laser power  Check the access glass of the scan head for any
contamination.
 Clean the access glass if necessary.
Start a new build process.(See section 6.14 Starting
the build process)
6.15.4 Observing the part

Parts/geometries turned in unfavourably Defective structures may arise as a result of edges or

cooling channels parallel to the blades.
 Correct the part position or part geometry.
Broken or bent details on the part Broken or bent details can be caused by partial exposure
in the powder (e.g. after tearing off a web)
 If possible, deactivate the defective part during the
build process.
 Correct the part geometry.
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6.15.5 Observing the extraction / inertisation

The soot which is produced during the LaserCUSING® process must be removed from the process
chamber effectively via the ventilator.
The soot/inert gas mixture is extracted from the process chamber, the soot is filtered out through a
cartridge filter and the inert gas is then returned back to the process chamber.
If during the LaserCUSING® process increased amounts of soot deposits or soot can be observed in the
process chamber, the ventilator is no longer working effectively enough. The ventilator volume flow is
too low.
Lack of inert gas  Note the error message on the PLC monitor.
 Check the inert gas feed lines.
 Check the content of the inert gas tanks or generator.
 Reactivate the inert gas supply.
 Check the part.
 Continue the build process.
(See section 6.14 Starting the build process)
Evolution of soot in the process  Ventilator is no longer effective enough.

chamber  Increase ventilator rotation speed.
 Observe evolution of soot.
 If there is no noticeable improvement, abort and
finish the build process.
 Contact the customer service department.
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6.16 Interrupting and continuing the build process

6.16.1 Interrupting and continuing the build process
The entire build process is controlled in the Machine operation window of the CL WRX machine
software. (See the CL WRX software operating manual).
1. Interrupt the automatic build process.
command Build job | Interrupt.
 The build process will be halted after the
currentpowder application or exposure process has
completed.
 The inert gas supply and the ventilator are active.
 The laser is switched on.
2. Carry out the necessary tasks on the Laser CUSING®

machine.
6.16.2 Continuing the build process

Once the cause of the interruption to the build process has been rectified, the LaserCUSING ® process
can be continued. (See CL WRX software operating manual)
If the cause of the interruption to the build process cannot be rectified, the build process must be
aborted.
Proceed in the manner described in section 6.17 Completing the build process.
Danger of explosion from insufficient inertisation of the process chamber!

turned on.
Danger of injury and material damage if the fault is not rectified!

If the automatic build process is resumed without all faults being rectified, this may result in injuries or
material damage.
CAUTION  Rectify all faults on the LaserCUSING® machine before continuing the automatic build process.
Note
Rapid resumption of the build process is recommended.
The build plate and the part should not cool down.
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1. Check that the process chamber is inertised correctly

and fully.
 If the inertisation of the process chamber has been
interrupted, start flooding the process chamber
again.
 See section 6.14.3 Inertising the process chamber.
Note on scraping
The build plate with the part must not under any circumstances be higher than the working surface of
the build module which will otherwise knock the coater blade against the build plate when the coater is
moved.
2. Determine the position of the build chamber platform

and check the application of powder.
 Carry out the scraping in the process chamber.
 See section 6.13 Defining the zero position of the
build plate (scraping)
 Repeat the scraping as many times as required until
the surface of the part protrudes considerably out of
the powder bed.
 The actual current position of the build chamber
platform may deviate by up to 100 µm from the
target position!
 If the surface of the part is readily visible, exposure
can start.
Note
Before continuing the automatic build process, an individual layer exposure is strongly recommended
for the first layer of the resumed build process.
The individual layer exposure is used to check the position of the layer on the part which has already
been fabricated, to preheat the part and to provide better bonding of the part.
3. Expose the first powder layers manually as a single

layer.
 See section 6.14.4 Carrying out individual layer
exposure.
 If a build job which has been commenced is
continued, the Layer at height and Layer input
fields are prepopulated with the data of the layer
exposed most recently.
 Expose 1 – 2 layers additionally with individual layer
exposure before you continue the build process.
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4. Continue the automatic build process.

command Build job | Continue.
 The Continue build job dialogue window is
opened.
 The Layer at height and Layer input fields are

prepopulated with the data of the layer exposed
most recently.
 If necessary, correct the layer height at which the
build job is to be continued.
 Click on the OK button.
 The automatic build process is continued.
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6.17 Completing the build process

Once the build process has ended, a corresponding message is displayed on the monitor and the signal
strip of the LaserCUSING® machine flashes green.
The inert gas supply and the ventilator are automatically switched off.
If in the material parameters in the Powder section the property "reactive" was enabled, the
inertisation of the process chamber continues to be maintained even after the end of the build job.
The following tasks are carried out:
– Moving the build module into the handling station
– Cleaning any metal powder off the part / build module
– Removing the part
– Emptying the powder overflow
6.17.1 Moving the build module into the handling station

Danger of squashing!
If limbs are placed between the build module and the machine when the build module is being moved,
there is a danger of squashing.
WARNING  Close the protective doors of the machine.
 Make sure that there are no people in the machine.
Note on the danger of collision!

Under no circumstances move up the build platform with the part in the process chamber.
There is a risk of the part colliding with other machine components, in particular when the build module
is moved into the handling station. The part and the machine may be damaged in the process.
Requirement
 The build process has been completed.
 The process chamber and the process station are closed.
 All required tools are in the glove box.
 The side protective doors of the machine are closed and locked
Implementation
1. Check the movement path of the build module.

 The movement path of the build module must be
clear.
Note on interrupted movement process

If the movement of the build module is interrupted prematurely, e.g. by a protective door being opened,
the machine software loses the current build module position. It is not possible to resume the
movement even after the fault has been rectified.
In order to determine the position, the build module must first be moved into the handling station
before the movement process can be restarted.
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2. Move the build module from the process station into the
handling station.
 The current position of the build module is displayed
in the Machine overview section.
 On the menu bar, click on the command Machine |
Module into process station.
 The build module in the Machine overview section
is shown in the middle and flashes.
 The build module is moved from the handling
station into the process station.
Danger from using the wrong inert gas!

engages.
3. Inertise the glove box immediately after coupling of the

build module.
 Flooding of the glove box with inert gas
(inertisation) is only necessary when using reactive
metal powders.
 If non-reactive steel powders are used, inertisation
is not necessary.
 If the inertisation of the process chamber was active
at the time of the movement process, the glove box
is automatically inertised after the build module has
been coupled on.
 See section 6.8.3 Inertising the glovebox
6.17.2 Cleaning metal powder off the part

 The specifications in the safety data sheets on the used metal powder must always be complied
with.
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Danger of injury from hot surfaces!

The surfaces may be very hot.
 Wait until the part / build module have cooled down before doing any work in the glove box.
WARNING

worn.
If the glove box is closed and all work is carried out in the glove box through the glove box gloves, the
personal protective equipment no longer needs to be worn as direct contact with the metal powder is
excluded.
Requirement
 The build module is located in the glove box.
 The glove box has been inertised.
 See chapter 6.8.3 Inertising the glovebox (only when using reactive metal powders).
 The parts and the build module have cooled down.
Tools required for cleaning:
 Scoop
 Brush
 Wet separator
Implementation
1. Empty the powder chamber.

 The metal powders used may remain in the powder
chamber for a short while for a subsequent process.
For this purpose, the powder chamber should be
moved into its bottom final position and covered.
 Storing metal powder in the build module over a
prolonged period of time is prohibited.
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Note on danger of collision with the coater blade!

The part must not under any circumstances be higher than the working surface of the build module as
otherwise the coater blade will collide with the part when the coater is moved.
The coater blade must not collide with the powder chamber cover when it is moved.
The part and/or the coater blade may be damaged in the process.
 If necessary, move the build chamber platform downwards until the part is fully below the build
module surface.
 Remove the powder chamber cover each time before the coater is moved.
2. Transfer metal powder from the powder chamber into

the powder overflow using coater.
 Open the Set up machine window.
Set up machine.
 The Set up machine window is opened.
 Empty the powder chamber. The build chamber is
not lowered here and the powder chamber is moved
up.
 Enter in the entry fields on the top row Lower by
(on return) the values for lowering the platforms
and the coater speed for the return run of the
coater.
 Enter in the entry fields on the bottom row Move
for the values for moving up the powder chamber
 Start the layer application by clicking on the symbol
.
 Repeat the steps until the powder chamber
platform has reached its upper final position.
3. Move the powder chamber platform into its lower final

position.
 This step is only permitted when using non-reactive
metal powders!
 If reactive metal powders are being used, the
powder chamber must be emptied!
 In the Machine overview section, select the
Powder chamber.
 Tap on the symbol to move the powder

chamber platform continuously downwards.
 As the powder chamber platform is moved
downwards, the values shown in the status display
get smaller and smaller.
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4. Move the coater into its right final position.

 In the Machine overview section, select the coater.
 The Coater section is displayed.
 Click on the symbol Right.
 The coater moves to its right final position behind
the powder chamber.
5. Expose the part from the powder bed.

 Transfer fairly large quantities of metal powder into
the powder overflow using a scoop.
 Move the build chamber platform gradually into its
upper final position..
 The build platform can only be moved upwards if the
coater is in its final positions and the light barrier in
the glove box is not broken.
6. Carefully clean any adhering metal powder off the

surface of the part.
 Remove all visible metal powder residues using a
brush.
 Carefully clean any metal powder off the screw
heads.
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6.17.3 Disassembling the build plate

Requirement
See chapter 6.8.3 Inertising the glovebox (only when using reactive metal powders).
 The part, the build plate and the build module surface have been cleaned.
 The powder chamber is free of metal powder and has been cleaned.
(Only when using reactive metal powders)
 The powder chamber is covered with the powder chamber cover.
If the LaserCUSING® process is carried out with reactive metal powders under a protective atmosphere,
the build plate and the required tools must be placed into the handling station before flooding the glove
box! (See section 6.8.3 Inertising the glovebox)
The inertised glove box can be opened after the filling with metal powders.
(See section 6.10 Opening the inertised glove box)
Implementation
1. Move the build chamber platform into its upper final

position.
 The build chamber platform can only be moved
upwards if the coater is in the left final position.
 In the Machine overview section, select the Build
chamber.
 The Build chamber section is displayed.
 Click on the symbol to move the build chamber

platform continuously upwards.
 Alternatively, lift the build chamber platform
Step input field.
 Alternatively, move the build chamber platform to a
defined position which is entered in the Target field.
 If the build chamber is moved upwards, the values
of the status indicator are getting smaller and
smaller.
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Disassembling the standard build plate

The standard build plate can always be screwed onto the build chamber platform, even if it is equipped
with a clamping system.
1. Release the build plate from the build chamber platform.

 Remove the four screws at the corners of the build
plate
 Place the screws in the tool storage compartment.
 The build plate is disconnected from the build
chamber platform.
Releasing the build plate with clamping system

If your machine is equipped with the clamping system for simple installation of the build plate, please
adopt the procedure described below.
Note about heavy wear!
deposits. If metal powder or other pollutants get into the clamping chuck, this can lead to increased
wear all the way through to a defect.
 Keep the clamping chuck clean and avoid any work that produces lots of dust.
 Only remove the build plate when it and the build module surface are free of metal powder
residues.
 The build chamber platform with clamping system must be covered with a suitable cover plate, e.g.
a build plate before the powder chamber is filled in and emptied.
1. Open the clamping chuck.

 Turn the switch for the clamping system on the
handling station 90° in the clockwise direction.
 The clamping chuck is open when the rotary switch
is in its 3 o'clock position.
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Final tasks
Residual metal powder on or in cavities of the part must be removed before the removal of the part.
1. Carefully rotate the build plate by 180° so that the part
is pointing downwards.
 Rotate the build plate slowly over the powder
overflow.
 Shake the build plate with the part to remove metal
powder from the cavities.
 If necessary, carefully tap the handle of the brush
against the build plate.
 Keep repeating this procedure until metal powder
no longer trickles out of the cavities of the part.
 Place the build plate aside.
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6.18 Removing the part

 The specifications provided in safety data sheets for the metal powders used must be always
complied with.
Danger of explosion from incorrect use of the wet separator!

Swirling up of the approved reactive light-metal alloys in an atmosphere containing oxygen may produce
an explosive atmosphere. There is a danger of explosion and fire.
DANGER  Before starting work, the wet separator must be checked to ensure it is working properly.
 It may only be operated with approved accessories and if the device and the operator are earthed.
 The extraction of the powder and build chamber shafts may only be carried out by specially trained
maintenance personnel.
 The extraction of soot deposits is prohibited.
 During extraction work, always wear the full personal protective equipment which is appropriate for
the metal powder being used.
 If possible, work in pairs when handling reactive materials. People working on their own are to be
suitably monitored, e.g. by providing suitable emergency call facilities.
 Always comply with the prescribed cleaning intervals.

During all work on and in the LaserCUSING® machine in which you come into direct contact with metal
worn.
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Requirement
See section 6.8.3 Inertising the glovebox (only when using reactive metal powders)
 The part, the build plate and the build module surface have been cleaned.
 The powder chamber is free of metal powder and has been cleaned.
(only when using reactive metal powders)
Implementation
1. Clean all surfaces using a brush.

transfer the metal powder into the powder
overflow.
 Clean all surfaces of visible metal powder residues
and transfer them into the powder overflow.
2. Move the coater to its left final position.

 The coater moves to its left final position behind the
powder chamber.
3. Cover the powder chamber with the powder chamber

cover.
 If metal powder is left in the powder chamber for a
follow-up process, it must be lowered to its lower
end position and covered.
 When working with reactive metal powders, it is
essential to do this before stopping the inertisation
 Remove the powder chamber cover from its
mounting on the glove box wall.
 Place the powder chamber cover onto the powder
chamber.
 The metal powder can remain in the powder
chamber until the next build process.
 Storing metal powder in the powder chamber over a
prolonged period of time is prohibited.

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5. Close the powder overflow.

 Close the powder overflow directly after the
inertisation has been stopped.
powder conatiner.
powder overflow.

– Standard PPE for non-reactive metal powders
– Extended PPE for reactive metal powders
7. Open the handling station.

 Flip the door completly upwards.
 Push the door until it stops to the side of the
handling station.
8. Open the glove box flap.

 Only work in the open glove box when the oxygen
content of approx. 20% has been reached.
 Remove both knurled nuts on the glove box flap.
9. Remove the build plate with the part.

 Carefully lift the build plate off the build chamber
platform.
 Remove the build plate with the part from the glove
box and place it aside for further processing later
on.
 Please note that build plates with clamping spigots
can only be stored aside.

Swirling up of the approved reactive metal powders as well as all process-related soot residues in an
atmosphere containing oxygen may produce an explosive atmosphere.
DANGER  Earth all working equipment and yourself to prevent electrostatic discharge!
 Avoid swirling up metal powder or metal dust and soot residues.
 Never extract metal powders using a standard commercial vacuum cleaner or industrial vacuum
cleaner. Always use an approved wet separator.
 Never extract fairly large quantities of metal powder.
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10. Clean any residual metal powder off the part, the build
plate and the build module.
 The wet separator must be checked according to
the manual before being used!
 Earth the wet separator on the handling station.
 Activate the wet separator.
 Exhaust the part and the build plate completely.
 Carefully clean the part.
 Switch off the wet separator.
 Disconnect the wet separator from the glove box
and place it aside.
11. Clean the build module surface and the glove box.
 Then thoroughly wipe down the surfaces with
damped cloths.
 Keep cleaning the surfaces until all visible powder
residues have been removed.
 Extract the smallest residual quantities with the wet
separator.
 Keep cleaning the surfaces until all powder residues
have been removed.
12. Close the glove box flap.

 If no work is being carried out in the glove box, it
should always be closed.
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6.19 Removing the powder container from the machine

WARNING

 Only move containers using suitable equipment aids (lifting device).
CAUTION
 Never attempt to carry containers yourself.
It is necessary to use the lifting device to move powder containers. Please take all safety precautions
required for such use.
Requirement
 The butterfly valve on the powder outlet of the powder overflow is closed.
 All valves on the powder container are closed.
Implementation

the earthing cable.

the machine.
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2. Disconnect the connection hose between the powder

outlet of the powder overflow and the inlet valve of the
powder container.
 Open the upper wing nut and the clamp in order to
release the connecting hose.
 Plug the end into the stopper on the powder
container.
3. Disconnect the powder container from the powder

overflow.
 Open the clamping fasteners on the sides of the
powder conatiner.
4. Remove the powder container.

 Raise the powder container up slightly using the
lifting device.
 Move the lifting device out of the machine carefully
with the container attached.
 Secure the powder container with both securing

 For a more detailed description, please consult the
Note
Sieve the metal powder out of the powder overflow before using it again in the LaserCUSING® process.
If the powder is to be stored for subsequent use, the powder container can be placed in a fireresistant
cabinet or on a shelf which is specially provided for it.
If the powder in the powder container is used directly for filling the powder chamber, follow the handling
instructions in chapter 6.9.2 Filling with powder containers.
If the powder is sieved via an external sieving station, follow the "QM powder automatic sieving station"
instructions in the other relevant documents.
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6.20 Changing powder

Different metal powders can be processed on the M2 cusing LaserCUSING® machine. If the machine is to
be changed from one powder to another powder, a series of measures must be carried out for your
safety and to guarantee that the quality of the part produced remains high.
If a different metal powder is envisaged for the follow-up process, complete cleaning of the Laser-
CUSING® machine is required.
Note on the sequence for changing powder

The sequence listed below for changing powder is recommended by Concept Laser GmbH.
 The prescribed sequence should be followed to guarantee a safe procedure.
This comprises the following measures:

– Powder removal
– Cleaning of the powder container (if the same powder container is being used)
– Cleaning of the handling station in atmosphere
– Replacement of the glove box gloves
– Replacement of all powder hoses (powder inlet hose to the handling station, connecting hose
between the powder overflow and powder container …)
– Replacement of the coater blade
– Cleaning of the filter module
– Replacement of the filter cartridges in the filter module
– Cleaning of the process chamber
– Replacement or cleaning of all tools which come into contact with powder.
Once the LaserCUSING® machine has been completely cleaned and is free of metal powder and soot
deposits and the required filters have been changed, the new build process with new metal powder can
be prepared.
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6.21 Switching off

Reactive metal powders, soot deposits, filter residues and their dusts can catch fire and cause serious to
fatal injuries.
DANGER  Only switch off the LaserCUSING® machine if there are no longer any reactive metal powders in the
machine.
 If reactive metal powders have been processed, the LaserCUSING® machine must be cleaned
before it is switched off.
 If reactive metal powder is stored in the machine, correct and sufficient inertisation must be
ensured.
Never switch off the LaserCUSING® machine if there is still reactive metal powder in the machine.
Non-reactive metal powders can be stored in the LaserCUSING® machine for a short time even after it
has been switched off.
First check the condition of the build module:
– Has the part been removed from the build chamber?
Check whether there are any reactive metal powders in the build module:
– Has the build module been cleaned of all reactive metal powder residues?
– – Has the powder container beneath the powder overflow been removed?
If it has, the LaserCUSING® machine can be switched off in the following way.
2. Close all machine doors.
3. Shut down the machine PC.
 Exit all applications of the CL WRX machine software and shut down the machine PC.
4. Switch off the machine control voltage.
 Press the "Controller OFF" button on the control panel.
5. Switch off the LaserCUSING® machine.
 Turn the main switch on the electrical cabinet on the back of the machine to the "0" position.
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6.21.1 Standby mode

If reactive metal powder is to be stored in the LaserCUSING® machine for a short period of time, the
machine can be operated in a standby mode.
During this time, sufficient inertisation is maintained in the process chamber of the Laser CUSING®
machine.
This is necessary for example if:

– a part must remain with metal powder surrounding it in the build chamber.
1. Move the build module into the process chamber.

(See section 6.14.2 Moving the build module into the process station)
2. Check the inertisation of the process chamber.
3. Switch off the laser system.
Turn the key switch on the laser system to the "0" position.
Note
The machine PC and the LaserCUSING® machine must remain switched on in order to guarantee the
inertisation of the process chamber.
If an interrupted build process is to be recommenced after standby mode, proceed in the manner
described in section 6.16.2 Continuing the build process).
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7 Faults
The following chapter describes possible causes of faults and what needs to be done to rectify them.
If faults occur repeatedly, the maintenance intervals should be shortened in accordance with the actual
problem occurring.
In the event of any faults which cannot be rectified by following the instructions below, contact the
manufacturer (see the contact details in chapter 11 Support and Customer Service).
7.1 Safety instructions for troubleshooting

Danger to life posed by dangerous electrical voltage!
DANGER  Before any work is carried out on the electrical equipment, the LaserCUSING® machine must be

DANGER  Wear antistatic protective equipment in order to prevent electrostatic discharge.
 Avoid swirling up metal powder, soot deposits or filter residues.

injuries.
DANGER  Do not smoke within the danger area and the immediate surroundings. Do not produce any naked
flames or ignition sources.
 Have a suitable fire extinguisher on hand. To extinguish a fire, only use metal fire-extinguishing
powder of the fire class D.
 Never attempt to put out the fire using water!
 In the event of a fire, stop work immediately. Vacate the danger area until the all-clear is given.
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WARNUNG
 Never carry out work with the laser system switched on!
be kept closed at all times.
 Never look directly at the laser beam or the scatter beam.
 Always use suitable laser protection goggles in the danger range of the laser. (Laser protection
class 4, wavelength 1070nm)
 Never place parts of the body in the path of the laser beam. This also applies to parts of the body
covered with clothing.
and lungs.
WARNUNG If the metal powder or its dusts get into the eyes, there is the danger of damage to the eyes.
 Particular care must be taken when working on the build chamber and when removing the filter
 The recommended protective equipment must always be worn!
Danger of injury from squashing on moving parts!

If body parts are situated in the movement path of the build module or the coater, this can lead to
squashing.
WARNING  During the movement of the build module or the coater, there must not be any people, body parts
or objects in the movement path.

CAUTION
 Wear protective gloves!

 When removing the filters and cleaning the chambers, heat-resistant gloves must be worn.
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Inappropriate troubleshooting
Danger of injury from inappropriate troubleshooting!

Troubleshooting work which is carried out in an inappropriate way can lead to serious injuries and
considerable material damage.
WARNING  Faults may only be rectified by people who have received instruction and are qualified to do so.
 If parts have been replaced, make sure they have been fitted correctly.
 Only carry out troubleshooting work in accordance with the specifications in this operating manual.

out any work.
User
The operating personnel must be at least 18 years of age and have a good knowledge of the operating
language.
manual.
The user has received instruction in an instruction briefing by the operator on use, the safety devices
and the possible hazards in the event of incorrect behaviour. The user may only carry out tasks which go
beyond normal operational use if this is specified in the manual and the operator has explicitly given the
user this task. The operator is urged to get users to confirm in writing that they have received the
instruction briefing.
Manufacturer
Certain pieces of work may only be carried out by specialist personnel from the manufacturer. Other
personnel are not authorised to carry out this work. To arrange for the required work to be carried out,
contact our customer service department. (See chapter 11 Support and Customer Service)
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7.3 Troubleshooting tasks

7.3.1 What to do in the event of a fault
1. In the case of faults which present an immediate danger to people or property, perform an
emergency stop immediately.
2. Determine the cause of the fault.
3. If necessary, put the machine into standby mode in accordance with this operating manual.
4. If necessary, point out the fault on the control panels and make them safe and secure with warning
signs.
5. Make the maintenance area safe with a wide cordon.
6. Notify the responsible person at the place of deployment about the fault immediately.
7. Depending on the nature of the fault, get it repaired by an authorised specialist or rectify it yourself.
7.3.2 Measures prior to operation following faults

Once the fault has been rectified, the LaserCUSING® machine can be started up again. Please perform
the following steps to restart the machine:
1. Reset the emergency stop device.
2. Acknowledge the fault by pressing the “Error reset" button.
 Press the button for at least 1 second.
 All pending commands of the controller are reset.
3. If necessary, activate the ventilator and the inert gas supply.
 If the build process has been interrupted, the process gas circuit and the inert gas supply are
automatically switched off.
 If the "Reactive" checkbox for the reactive material has been checked in the material
parameters, the inert gas supply remains switched on even in the event of fault.
(See the CL WRX software manual)
4. If possible, continue the build process.
 See section 6.16.2 Continuing the build process
5. Otherwise cancel the build process and prepare a new build process.
 See section 6.17 Completing the build process
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7.4 General handling of error messages

If a fault is registered by the safety devices of the LaserCUSING® machine, the current build process is
interrupted and the controller enabling for the machine controller is cancelled.
 The signal strip flashes red.
 The “Error reset” button lights up.
 A warning or an error message is displayed on the PLC monitor of the control panel.
Warning and error messages
All warning and error messages are logged in the PLC (programmable logic controller).
Please note all error messages in the PLC monitor in the build job protocol of the machine software.
Please note all warning and error messages of the laser system. To rectify the error, please follow the
operating manual for the laser system in the other relevant documents.
Procedure for rectifying errors

1. The error is displayed with a code and message text on the control panel.
2. Look for the error message in the list of error messages and open up the page with tips on how to
rectify the error.
3. Rectify the error.
4. Acknowledge the error message.
5. If there are further errors, repeat steps 2 – 4.
6. Once all errors have been rectified and acknowledged, the build process can be resumed.
Note
Once all error messages have been rectified, the automatic build process and work on the M2
LaserCUSING ® machine can be resumed. Information about the error messages, their effects, causes
and remedies is provided in this chapter.
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7.5 Error messages

Code Message text Cause Remedy
M2FL_01_01 Emergency stop! Emergency stop switch has been Pull emergency stop, reset.
pressed.
M2FL_01_02 Ventilator not enabled! Follow-up error, mostly open door. Open and then close again then
doors.
M2FL_01_03 Light barrier broken Light barrier broken. Vacate the range of the light
barrier, reset.
M2FL_01_04 Side doors open 2 channels safety switch has not closed Open and then close again the
correctly or safety circuit is defective. door. Both safety curcuits must
be closed simultaneously.
M2FL_01_05 Door switch glove box! Glove box cover has been closed too Open and then close again the
slowly or switch / wiring is defective. glove box cover.
M2FL_01_06 Sliding door glove box! Sliding door has not been closed Close the sliding door correctly.
correctly.
Positioning or wiring of the safety
switch is incorrect.
M2FL_02_01 Protective door of the Protective door has not been closed Close the protective door
monitor! correctly. Positioning or wiring of the correctly.
safety switch is incorrect.
M2FL_02_02 Filter unit not closed! One of the protective doors around the Close the protective doors
filter unit has not been closed correctly correctly.
or the safety switch has been
incorrectly positioned or it is defective.
M2FL_02_03 Process chamber Protective door has not been closed Close the protective door
protective door! correctly. Positioning or wiring of the correctly.
safety switch is incorrect.
M2FL_02_04 Laser key switch! Laser has not been released by key Turn the key switch to ON.
switch. Wiring of the key switch
isincorrect.
IPG_01 Data connection to the COM connection to the laser in not
laser missing connected or is connected to the
wrong COM port, laser has no power/ is
defective.
IPG_02 Laser not ready! Safety circuit has been closed but not
released yet (reset error!).
IPG_03 Laser power supply not Safety circuit is broken.
enabled
IPG_04 Back reflection error! Highly reflective material/surface/
melting result, problems in optics (e.g.
mirror damaged).
M2_4_0 Build chamber not Safety circuit not closed, controller is
released! defective, cable is defective, PILZ is
defective (controller).
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M2_4_1 Build chamber is in Build chamber is still moving (e.g. "Stop" button in the software
movement: not enabled during the layer application) and a new
notification is sent; software is hanging
during the layer application and the
build chamber must be moved
manually
M2_4_10 Build chamber error I2T error, contouring error => axis has
while moving stepwise been stuck while moving stepwise
M2_4_11 Build chamber error I2T error, contouring error => axis has
while moving been stuck while moving continuously
continuously
M2_4_2 Build chamber has Build chamber is in bottom final
reached bottom final position of the controller
position of the
controller
M2_4_3 Build chamber has Build chamber is in upper final position
reached upper final of the controller
position of the
controller
M2_4_4 Build chamber has Build chamber is in bottom software
reached bottom final position
software final position
M2_4_5 Build chamber has Build chamber is in upper software final
reached upper software position
final position
M2_4_7 Build chamber not Wiring error (enable input), another
active axis error is pending
M2_4_8 Build chamber not Another axis error is pending
ready
M2_4_9 U-(build chamber-) axis I2T error, contouring error => axis has
error while moving to been stuck while moving to target
target position position.
M2_5_0 V-(powder chamber-) Drive is not released. Release is Analyse further PLC messages.
axis not enabled granted by Pilz. Reissue release.
M2_5_1 V-(powder chamber-) Drive was disabled while moving Analyse further PLC messages
axis is in movement:
Not enabled
M2_5_10 V-(powder chamber-) Drive was disabled while moving. Analyse further PLC messages
axis error while moving
stepwise
M2_5_11 V-(powder chamber-) Drive was disabled while moving. Analyse further PLC messages
axis
error while moving
continuously
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M2_5_2 V-(powder chamber-) Axis has reached positive final position Check whether the final
axis position configuration is
final position plus correct. New referencing and
removing powder from the
shaft may be carried out.
M2_5_3 V-(powder chamber-) Axis has reached positive software final Check whether the final
axis position position configuration is
final position minus correct. New referencing and
M2_5_4 V-(powder chamber-) Axis has reached negative software Check whether the final
axis software final final position. position configuration is
position plus correct. New referencing and
M2_5_5 V-(powder chamber-) Axis has reached negative software Check whether the final
axis software final final position. position configuration is
position minus correct. New referencing and
M2_5_7 V-(powder chamber-) Axis has been disconnected from the Rectify initial cause of the error.
axis not active controller. The error results from
another error (e.g. safety circuit
broken).
M2_5_8 V-(powder chamber-) Controller still has a drive command Click on the "Stop" button in the
axis not idle pending. software. Afterwards, reset the
error.
M2_5_9 V-(powder chamber-) Drive was disabled while moving.
axis error while moving
to target position
M2_6_0 W coater not enabled Drive is not released. Release is Analyse further PLC messages.
granted by Pilz. Reissue release.
M2_6_1 Coater is in movement: Drive was disabled while moving. Analyse further PLC messages
not enabled
M2_6_10 W coater error while Drive was disabled while moving. Analyse further PLC messages
moving stepwise
M2_6_11 W coater error while Drive was disabled while moving. Analyse further PLC messages
moving continuously
M2_6_12 W coater error power Canbus connection is defective. Check bus connection
setting reference run
M2_6_13 W coater error basic Canbus connection is defective. Check bus connection
power setting
setting operation
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not found
M2_6_2 W coater final position Axis has reached postive final position. Check whether the final
plus position configuration is
correct. New referencing and
M2_6_3 W coater final position Axis has reached negative final Check whether the final
minus position. position configuration is
M2_6_4 W coater software final Axis has reached postive software final Check whether the final
position plus position. position configuration is
M2_6_5 W coater software final Axis has reached negative software Check whether the final
position minus final position position configuration is
M2_6_7 W coater not active Axis has been disconnected from the Rectify initial cause of the error.
controller. The error results from
another error (e.g. safety circuit
broken).
M2_6_8 W coater not idle Controller still has a movement Click on the "Stop" button in the
command pending. software. Afterwards, reset the
error.
M2_6_9 W coater error while Drive was disabled while moving.
moving to target
position
M2_80_3 Module not in process Final position switch of the module is Replace final position switch of
station not set correctly. It looses contact the module or set it correctly
during the build process
M2_80_4 Module not in position Problems while moving the module Rectify stiffness or problems
for docking (mechanical stiffness, compressed air is with compressed air
faulty).
M2_80_5 Module not in position Problems while moving the module Rectify stiffness or problems
for undocking (mechanical stiffness, compressed air is with compressed air
faulty).
M2_80_6 Docking of the Move module was clicked while the Click on the "Stop" button in the
moduleis in progress; module was moving. software. Afterwards, move the
not enabled module.
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M2_80_7 Minimum temperature Messed temperature is below At actual temperature of 0
of the build plate minimum temperature set in degree: configuration of the
surpassed configuration. heating is faulty or there is a
problem of bus connection to
the controller. Check
connection and configuration.
M2_80_8 Maximum temperature Error heating activation or defect of the Check whether target and
of the build plate controller. maximum temperature values
exceeded correspond to permitted values.
If necessary, readjust target
value (earlier too high). Or
defect of the controller ->
replace controller.
M2_84_0 Error air pressure No compressed air connected or
pressure is too low.
M2_84_1 Error process gas Nitrogen selected, nitrogen pressure Check gas selection and
not OK. respective gas pressure.
M2_84_10 Error process gas argon Argon selected, argon pressure not OK. Check gas selection and
respective
gas pressure.
M2_84_2 INI CUBE67 failed
M2_84_3 Command unknown in Incompatible PLC version.
PLC
M2_84_4 Emergency stop Machine emergency stop has
beenactivated.
M2_84_5 Collective fault Internal measurement of differential Switch on ventilator head,
ventilator pressure of the ventilator head, change filter, check whether
ventilator head is not switched on, turbine is in good working
ventilator head is not rotating/ has condition.
been stuck.
M2_84_6 Error protective door Left door open, light grid is broken. Close left door, press reset.
K3
M2_84_7 Fault final position Coater is not in final position even Safety switch has been stuck.
switch S90 though the safety switch has been Release the safety switch and
activated. clean it if necessary.
M2_84_9 Fault temperature mperature sensor of the danger Check and replace the
sensor defective controller is defective or the cabel temperature sensor if
connection is loose. necessary.
M2_86_8 E2 4 PZ13neg driving Problems while moving the module Rectify mechanical stiffness of
module missing (mechanical). the module.
M2_86_9 E2 5 PZ13pos driving Problems while moving the module Rectify mechanical stiffness of
module missing (mechanical). the module.
M2_87_0 Fault drive build plate Error message from the controller, Rectify initial error, replace the
controller is defective or there is a controller.
follow-up error.
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M2_87_1 Fault drive powder Error message from the controller, Rectify initial error, replace the
chamber controller is defective or there is a controller.
follow-up error.
M2_87_10 Fault CAN01 murr knot Murr knot is defective. Replace the murr knot.
M2_87_11 Fault CAN03 axis build Error of the drive controller or bus Check controller and bus
plate. connection. connection.
Read error memory if
necessary.
M2_87_12 Fault CAN04 axis Error of the drive controller or bus Check controller and bus
powder chamber connection connection.
necessary.
M2_87_13 Fault CAN05 axis Error of the drive controller or bus Check controller and bus
coater connection. connection.
necessary.
M2_87_14 Fault CAN82 input Error of ELC55 IO module. Replace module.
module 3
M2_87_15 Fault CAN19 output Error of ELC55 IO module. Replace module.
module 3
M2_87_2 Fault drive coater Controller error. Read and analyse the error
memory in the controller.
M2_87_3 Fault drive JAT infeed Controller error. Read and analyse the error
memory in the controller.
M2_87_4 Fault drive JAT Controller error. Read and analyse the error
intermediate circuit memory in the controller.
M2_87_5 Fault CAN 80 input Error of ELC55 IO module. Replace module.
module 1
M2_87_6 Fault CAN 81 input Error of ELC55 IO module. Replace module.
module 2
module 1
module 2
M2_87_9 Fault CAN52 analog Error of ELC55 IO module. Replace module.
module 1
M2_88_0 Position of the powder Axis does not reach the target position Rectify stiffness of the axes,
chamber not reached after expiration of a deadline, without check parametrisation.
further error messages.
M2_88_1 Position of the coater Axis does not reach the target position Rectify stiffness of the axes,
not after expiration of a deadline, without check
reached further error messages. parametrisation.
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M2_88_2 Position of the build Axis does not reach the target position Rectify stiffness of the axes,
plate after expiration of a deadline, without check
not reached further error messages. parametrisation.
module 4
module 2
module 3
M2_88_6 Error temperature Defective sensor. Replace sensor.
sensor
122A1
M2_88_7 Error temperature Defective sensor. Replace sensor.
sensor
122A2
M2_88_8 Error oxygen sensor Defective sensor. Replace sensor.
2DA1
M2_88_9 Gloves damaged Inertisation of the glove box lasts too Check whether the gloves are
long. damaged.
M2_89_0 Only allowed if the Protective doors or protective cover Close protective doors and
protective door is open. cover.
closed
M2_89_1 Coater not in safe The selected action is allowed only Move the coater to safe
position left when the coater is in safe position. position.
M2_89_2 Alert heating unit Error in danger heating element. Analyse further heating error
messages.
M2_89_3 Alert temperature Jumo temperature limiter has been Confirm release of the limiter.
limiter trigged. Check the temperature display
on the Jumo temperature
limiter and compare with actual
temperature.
Check and replace the sensor if
necessary.
M2_89_4 Protective doors open! Process chamber doors open Close process chamber doors.
M2_90_0 U-(build chamber-) axis Controller is defective. Replace and send back the
error 1 internal cause controller.
M2_90_1 U-(build chamber-) axis Controller is defective. Replace and send back the
error 2 internal cause controller.
M2_90_10 U-(build chamber-) axis Short circuit or overcurrent of motor Check controller display. Check
error 11 short circuit phases. motor and feed lines. Check
phase B whether the shielded cable is
placed correctly.
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M2_90_11 U-(-build chamber-) axis Defect or excessive temperature of the Check voltage on the enabling
error 12: short circuit brake resistor signal.
or
overloading of the
brake
control.
M2_90_12 U-(build chamber-) axis Enabling signal of the controller is Check voltage on the enabling
error 13: Error in missing. signal.
external release.
M2_90_13 U-(build chamber-) axis Axis may be stiff. Check mobility of the axes.
error 14 contouring Remove powder from shafts if
error necessary.
M2_90_14 U-(build chamber-) axis Error in the axis operation. Check parametrisation and
error 15 speed to high other error messages of the
controller.
M2_90_15 U-(build chamber-) axis Defect of the encoder motor or the Check the encoder and the
error 16 commutation encoder cable. The motor may be stiff. encoder cable.
problem
error 3 X8 encoder encoder cable. encodercable.
error
error 4 encoder encoder cable. encoder cable.
counting
error
error 5 encoder encoder cable. encoder cable.
counting
error
M2_90_5 U-(build chamber-) axis Temperature of the controller is too Check air conditioning of the
error 6 controller high. electrical cabinet.
excessive temperature
M2_90_6 U-(build chamber-) axis 24V supply volatge of the controller is Check 24V supply.
error 7 error logic faulty.
voltage
M2_90_7 U-(build chamber-) axis Load power supply or ballast resistor is Check resistance and
error 8 overvoltage X10 faulty. connection of the ballast
resistor.
M2_90_8 U-(build chamber-) axis Load power supply or ballast resistor is Check resistance and
error 9 undervoltage faulty. connection of the ballast
X10 resistor.
M2_90_9 U-(build chamber-) axis Short circuit or overcurrent of motor Check controller display. Check
error 10 short circuit phases. motor and feed lines. Check
Phase A whether the shielded cable is
placed correctly.
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M2_91_0 V-(powder chamber-) Controller is defective. Replace and send back the
axis controller.
error 1 internal cause
M2_91_1 V-(powder chamber-) Controller is defective. Replace and send back the
axis controller.
error 2 internal cause
M2_91_10 V-(powder chamber-) Short circuit or overcurrent of motor Check controller display. Check
axis phases. motor and feed lines. Check
error 11 short circuit whether the shielded cable is
Phase B placed correctly.
M2_91_11 V-(powder chamber-) Defect or excessive temperature of the Check connection and
axis brake resistor. temperature of the brake
error 12: short circuit resistor.
or
overloading of the
brake
control
M2_91_12 V-(powder chamber-) Enablesignal des Reglers fehlt Check voltage on the enabling
axis signal.
error 13: error in
external
release
M2_91_13 V-(powder chamber-) Error in the axis operation. Check mobility of the axes.
axis Remove powder from shafts if
error 14 contouring necessary.
error
M2_91_14 V-(powder chamber-) Error in the axis operation. Check parametrisation and
axis other error messages of the
error 15 speed to high controller.
M2_91_15 V-(powder chamber-) Defect of the encoder's motor or the Check the encoder and the
axis encoder cable. The motor may be stiff. encoder cable.
error 16 commutation
problem
axis encoder cable. encoder cable.
error 3 X8 encoder
error
error 4 encoder
counting
error
error 5 encoder
counting
error
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M2_91_5 V-(powder chamber-) Temperature of the controller is too Check air conditioning of the
axis high electrical cabinet.
error 6 controller
excessive temperature
M2_91_6 V-(powder chamber-) 24V supply volatge of the controller is Check 24V supply.
axis faulty.
error 7 error logic
voltage
M2_91_7 V-(powder chamber-) Load power supply or ballast resistor is Check resistance and
axis faulty. connection of the ballast
error 8 overvoltage X10 resistor.
M2_91_8 V-(powder chamber-) Load power supply or ballast resistor is Check resistance and
axis faulty. connection of the ballast
error 9 undervoltage resistor.
X10
M2_91_9 V-(powder chamber-) Short circuit or overcurrent of motor Check controller display. Check
axis phases. motor and feed lines. Check
error 10 short circuit whether the shielded cable is
Phase A placed correctly.
M2_92_0 W-coater axis error 1 Controller is defective. Replace and send back the
internal cause controller.
M2_92_1 W-coater axis error 2 Controller is defective. Replace and send back the
internal cause controller.
M2_92_10 W-coater axis error 11 Short circuit or overcurrent of motor Check controller display. Check
short circuit phase B phases. motor and feed lines. Check
whether the shielded cable is
placed correctly.
M2_92_11 W coater axis error 12: Defect or excessive temperature of the Check connection and
short circuit or brake resistor. temperature of the brake
overloading of the resistor.
brake
control
M2_92_12 W coater axis error 13: Enabling signal of the controller is Check voltage on the enabling
error in external release missing. signal.
M2_92_13 W coater axis error 14 Axis may be stiff. Check mobility of the axes.
contouring error Remove powder from shafts if
necessary.
M2_92_14 W coater axis error 15 Error in the axis operation. Check parametrisation and
rotation speed to high other error messages of the
controller.
M2_92_15 W coater axis error 16 Defect of the encoder's motor or the Check the encoder and the
commutation problem encoder cable. The motor may be stiff. encoder cable.
M2_92_2 W coater axis error 3 X8 Defect of the encoder's motor or the Check the encoder and the
encoder error encoder cable. encoder cable.
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encoder counting error encoder cable. encoder cable.
encoder counting error encoder cable. encoder cable.
M2_92_5 W coater axis error 6 Temperature of the controller is too Check air conditioning of the
controller excessive high. electrical cabinet.
temperature
M2_92_6 W coater axis error 7 24V supply volatge of the controller is Check 24V supply.
error logic voltage faulty.
M2_92_7 W coater axis error 8 Load power supply or ballast resistor is Check resistance and
overvoltage X10 faulty. connection of the ballast
resistor.
M2_92_8 X coater axis error 9 Load power supply or ballast resistor is Check resistance and
undervoltage X10 faulty. connection of the ballast
resistor.
M2_92_9 W coater axis error 10 Short circuit or overcurrent of motor Check controller display. Check
short circuit phase A phases. motor and feed lines. Check
whether the shielded cable is
placed correctly.
M2_93_0 U-(build chamber-) axis Bus connection to the drive controller Check bus connection cable.
error 17 bus error is faulty.
M2_93_1 U-(build chamber-) axis Power consumption exceeded. Axis is stiff.
error 18 I²t
M2_93_2 V-(powder chamber-) Bus connection to the drive controller Check bus connection cable.
axis is faulty.
error 17 bus error
M2_93_3 V-(powder chamber-) Power consumption exceeded. Axis is stiff.
axis
error 18 I²t
M2_93_4 W coater axis error 17 Bus connection to the drive controller Check bus connection cable.
bus error is faulty.
M2_93_5 W coater axis error 18 Power consumption exceeded. Axis is stiff.
I²t
M2_99_1 Filter is full! Filter is full. Clean the filter.
M2_99_10 Coating control Software problem QM coating. Restart QM coating.
breakdown!
M2_99_11 Sliding door open! Sliding door open. Close sliding door.
M2_99_12 O2 Sensor build Sensor range monitoring causes the Check sensor.
chamber out of range error.
M2_99_13 O2 threshold value Threshold value exceeded. Check sensor.
monitoring in the build
chamber
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M2_99_14 O2 Sensor process Sensor range monitoring causes the Check sensor.
chamber out of range error.
M2_99_15 O2 threshold value Threshold value exceeded. Check sensor.
monitoring in the
process chamber
M2_99_16 Temperature sensor of Sensor range monitoring causes the Check sensor.
the process chamber error.
(above) out of range
M2_99_17 Threshold monitoring Threshold value exceeded. Check sensor.
of the temperature
sensor in the process
chamber (above)
M2_99_18 Temperature sensor of Sensor range monitoring causes the Check sensor.
the process chamber error.
(below) out of range
M2_99_19 Threshold monitoring Threshold value exceeded. Check sensor.
of the temperature
sensor in the process
chamber (below)
M2_99_2 Differential pressure in Filter is full. Clean the filter.
ventilator too high!
M2_99_20 Clamping system open! Clamping system open. Close clamping system.
M2_99_21 Glove box doors open! Glove box doors open. Close glove box doors.
M2_99_22 Laser power Connection cover in the process Close cover.
measurement cover chamber has not been connected
open! correctly.
M2_99_23 Differential pressure in Filter is not inserted correctly, filter is Check filter.
ventilator too low! missing, filter is torn.
M2_99_24 Resiual O2 value to Leak, inetrruption of communication Check communication PLC/PC,
high! PLC/PC. search for a leak.
M2_99_25 Error in the layer Data error of the cls files. Check cls file generation.
calculation
M2_99_26 Temperature sensor Temperature sensor or PILZ input Replace temperature sensor or
build module out of defective. PILZ input components.
range!
M2_99_27 Time limit laser Laser emission will not be completed. Check laser.
system!
M2_99_28 Excessive temperature Cooler is defective. Check cooler.
of the laser!
M2_99_29 Temperature sensor Temperature sensor or PILZ input is Replace temperature sensor or
clamping system out of defective. PILZ input components.
range!
M2_99_3 Oxygen sensor values Sensor is defective. Check sensors.
differ greatly!
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M2_99_30 O2 content too high for Must not occur again. Alert SW.
ventilator to start
M2_99_4 Process gas sensor Sensor is defective or aligned Check sensors.
values differ greatly! incorrectly.
M2_99_5 Temperature sensor Sensor is defective. Check sensors.
values differ greatly!
M2_99_6 Coating process not Process has been cancelled after time Check axes, check
successful! limit. parametrisation.
M2_99_7 Extinguishing system Fire. Extinguish the fire.
triggered!
M2_99_8 Inertisation lasts too Leak. Search for a leak.
long!
M2_99_9 Check gas Leak. Search for a leak.
consumption!
SPI_01 Interlock laser open! Laser safety circuit broken. Check safety circiut.
SPI_02 Laser connection error! COM connection to the laser is broken. Replace laser, check laser.
SPI_03 Error while setting Laser is defective. Check laser.
power! Check values!
SPI_04 General laser system Laser is defective. Check laser.
error
RTC_01_1 Self-calibration sensor Scan system is not using the ASC Deactivate automatic self-
not found! option or ASC is defective. calibration in configuration.
RTC_01_2 ASC values differ too Error while executing the command Carry out ASC again.
much!
RTC_01_3 ASC command not Scan system may not contain drift
possible! compensation calibration.
RTC_01_4 ASC reference data not ASC has not been initially carried out in Carry out ASC again.
found! configuration.
RTC_01_5 ASC calibration error! Error while executing the command. Carry out ASC again.
RTC_01_6 ASC parameter error! Error while executing the command. Carry out ASC again.
RTC_01_7 ASC status error! Error while executing the command. Carry out ASC again.
MEL_01 No connection to If there is connection between the Check IP and port in
Meltpool 3D machine software and QM meltpool, it MeltpoolConfig.
is checked every 100ms whether the
connection is still active. If it is noticed
during the ongoing build process that
the connection is not active anymore,
the build process will be interrupted
with an error message depending on
the setting in configuration or it will
continue without the QM meltpool
functions.
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7 Faults

MEL_02 Error during This error is diaplayed when a problem Check rights, remove write
initialisation occurs during initialisation of the build protection.
of the build job job at the build job start or build job
continuation. In following steps
Buildconfig and Parameter files must
be created and uploaded on the FTP
server; when the problems occur an
error message should be displayed.
MEL_03 Waiting time exceeded. This error occurs when no feedback Restart PXI and/or CK Software.
The server doesn't from QM meltprool 3D has not been
respond! receieved after 15 seconds during the
build job start or build job continuation.
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8 Maintenance
Maintenance comprises all inspection, maintenance and repair work.
It is recommended that this work is recorded after it has been carried out.
(See the maintenance record enclosed to this operating manual)
8.1 Safety instructions for maintenance

Danger to life posed by dangerous electrical voltage!
If you touch live parts, there is an immediate danger to life posed by electric shock.
Any damage to the insulation or individual parts may be life-threatening.
DANGER
 Before any work is carried out, all of the components of the LaserCUSING® machine must be
disconnected from the mains power supply via the main switch.
 Secure the main switch against unintentional reactivation with a padlock, remove the key and
attach an appropriate warning sign.
 Work on the electrical equipment may only be carried out by a qualified electrician.

components:
– Mains cables
– Power units
– Drive amplifier
– Laser supply
Danger to life from unintentional restart!

If the machine is switched on again during maintenance work, in particular in the danger areas, there is
a danger to life.
DANGER  Before carrying out any maintenance work, switch off all of the main switches within the machine
and secure the main switches against unintentional reactivation.
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8 Maintenance
Danger of explosion from reactive metal-air mixtures!!

DANGER  Wear antistatic protective equipment in order to prevent electrostatic discharge!
 Avoid swirling up metal powder or metal dust, soot residues and filter residues.
 Never extract metal powder using a conventional vacuum cleaner or industrial vacuum cleaner;
always use an approved wet separator.
 Never extract soot deposits or filter residues.
 Always wipe off soot residues or filter residues using a slightly dampened cloth.
turned on.

with water will result in the formation of small amounts of hydrogen. When metal powder is extracted
DANGER with a wet separator when using water as the separating medium, this results in the formation of
hydrogen in the wet separator. If the hydrogen accumulates and mixes with air containing oxygen, an
explosive hydrogen-air mixture known as oxyhydrogen is produced.
 Only ever store water/metal mixtures and moist metal residues in open containers outdoors or in
 Check the water level in the wet separator before and regularly during operation.
 Empty and clean the wet separator and the accessories used as required, but at least once a day at

injuries.
DANGER  When carrying out maintenance work within the LaserCUSING® machine, the build plate and the
part should be removed.
 All metal powder residues must be cleaned from the machine before any repair work is carried out.
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8 Maintenance

Escaping toxic gases or inert gas, such as the colourless and odourless protective gases nitrogen and
argon, can cause a lack of oxygen.
GEFAHR  Close the inert gas supply before all maintenance measures.
 Ventilate the process chamber of the machine before you carry out maintenance work in this area
of the machine.
 If a gas leak is discovered, the room must be vacated immediately and you may only re-enter it
wearing suitable breathing equipment.
and lungs.
 When carrying out maintenance work within the LaserCUSING® machine, the build plate and the
part should be removed.
 All metal powder residues must be cleaned from the machine before any repair work is carried out.

WARNING
 The laser system must be switched off and secured against reactivation before all repair work.
not be opened.

Warning about injuries caused by hoses spinning around, swirled-up dust and movement of the
pneumatic drives.
WARNING  Depressurise the pneumatic system before all maintenance work.
 Watch out for any residual energies which may be released.
Danger of injury from squashing on moving parts!

If body parts are situated in the movement path of the build module or the coater, this can lead to
squashing.
WARNING  During the movement of the build module or the coater, there must not be any people, body parts
or objects in the path of movement.
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8 Maintenance

CAUTION

 When removing the filters and cleaning the chambers, heat-resistant gloves must be worn.
Maintenance measures carried out incorrectly
Danger posed by maintenance measures carried out incorrectly!

Incorrect maintenance can lead to serious injuries and considerable material damage.
 Make sure you maintain order and cleanliness at the place of installation. Loose parts and tools
WARNING lying around or on top of one another can cause accidents.
 When parts have been removed, make sure the machine is put back together correctly, fit all
securing elements again and ensure the screws are tightened to the correct torques. Depressurise
the pneumatic system before all maintenance work.
 All maintenance work may only be carried out in accordance with the information and specifications
in this operating manual.
 Before switching the machine on again, check that all safety devices are installed and are in good
working condition.
Spare parts
Danger of injury from the use of incorrect spare parts and non-approved operating
materials!
The use of incorrect or defective spare parts or non-approved operating materials can present dangers
WARNING to the personnel involved and cause damage, malfunctions or a total failure.
 Only use original spare parts from the manufacturer or spare parts which are approved by the
manufacturer.
 Only use operating materials with the same mechanical, physical, chemical and electrical
properties.
Loss of guarantee!
The manufacturer's guarantee shall be cancelled if non-approved spare parts and operating materials
are used.
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8 Maintenance

out any work.
User
The operating personnel must be at least 18 years of age and have a good knowledge of the operating
language.
manual.
The user has received instruction in an instruction briefing by the operator on use, the safety devices
and the possible hazards in the event of incorrect behaviour. The user may only carry out tasks which go
beyond normal operational use if this is specified in the manual and the operator has explicitly given the
user this task. The operator is urged to get users to confirm in writing that they have received the
instruction briefing.
Maintenance personnel
The maintenance personnel is authorised to carry out tasks which go beyond normal operational use.
These include special maintenance work.
Only people who have received an operator training session and an additional instruction briefing by the
manufacturer are permitted to carry out special maintenance work. The operator is strongly urged to
get maintenance personnel to confirm in writing that they have received the instruction briefing.
Manufacturer
Certain pieces of work may only be carried out by specialist personnel from the manufacturer.
Other personnel are not authorised to carry out this work. To arrange for the required work to be carried
out, contact our customer service department. (See chapter 11 Support and Customer Service).
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8 Maintenance
8.3 Maintenance schedule

The sections below describe the maintenance work required to ensure optimum and faultless operation
of the machine.
If regular checks reveal an increased level of wear, shorten the required maintenance intervals in
accordance with the actual signs of wear. If you have any questions about maintenance work and
intervals, contact the manufacturer. (See chapter 11 Support and Customer Service)
Interval Components Maintenance work
Daily Wet separator Empty and clean the wet separator.

 see the manufacturer's operating manual
LaserCUSING® machine Visual inspection for any damage and check for
unusual
noises
Compressed air supply Check all lines and cylinders for any damage or
wear
and tear.
 To be replaced only by the manufacturer
Check the pressure applied (5-8 bar).

 Adjust the pressure if necessary.
Inert gas supply Check all lines and cylinders for any damage or
wear
and tear.
 To be replaced only by the manufacturer.
Check the pressure applied (5-8 bar).

 Adjust the pressure if necessary.
Flow meter Check the volume flow.

 Adjust the volume flow if necessary.
Weekly LaserCUSING® machine Clean the machine.

 See chapter 8.4 Cleaning the LaserCUSING®
machine
Coater blade Check the coater blade for any wear or tear.
 If necessary, rotate or replace the coater
blade.
 see section 8.7.6 Rotating or replacing the
coater blade
Scan head Clean the protective glass of the scan head lens.
 See section 8.4.9 Cleaning the protective glass
of the scan head lens
Maintenance unit for Check the fill level of the water separator.
compressed air  If necessary, empty the water separator.
 see section 8.7.5 Checking / emptying the
condensate container on the maintenance
unit
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8 Maintenance
Interval Components Maintenance work

Monthly LaserCUSING® machine Have all safety devices checked to make sure
they are in full working condition.
Filter module Change the filter cartridge.
 see section 8.5.2 Changing the filter cartridge
Clean the filter module.

 see section 8.5 Cleaning the filter module
Laser system Check the filter mats.

 Clean (exhaust) the filter mats.
 If necessary, replace the filter mats.
Machine PC Check the filter mats.

 If necessary, replace the filter mats.
 See the manufacturer's operating manual.
Wall-mounted cooler Check the air cooler for any contamination.

 If necessary, replace the air cooler.
Coater Clean the coater guides.

 See section 8.4.5 Cleaning the guide rails and
drive belt of the coater
Quarterly Process gas circuit Replace the pressure relief valve.

 see section 8.7.7 Replacing the excess
pressure filter of the process chamber
Yearly Residual oxygen analyser Check that it works.

Glove box filter Replace the filter

 To be replaced only by the manufacturer.
Every 3 years flexible plastic hoses Replace the hoses.

every 2000 Focusing lens Clean the surface of the lens.
operating hours  To be done only by the manufacturer.
Table 8-1: Maintenance schedule
Note
Consult the separate operating manuals of the respective manufacturers for details of the maintenance
instructions for the components from suppliers.
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8 Maintenance
8.4 Cleaning the LaserCUSING® machine

Users of the M2 cusing LaserCUSING® machine come into contact with reactive metal powders and their
process products when working on the LaserCUSING® machine.
Always note the general safety instructions in chapter 2 General safety instructions. For handling
reactive materials, note the instructions given in the section 2.6 Handling reactive metal powders.
Danger of explosion from incorrect use of the wet separator!

 Before starting work, the wet separator must be checked to ensure it is working properly.
 It may only be operated with approved accessories and if the device and the operator are earthed.
 Connecting the wet separator to the suction port of the glove box is fundamentally prohibited.
 Extraction of the powder and build chamber shafts may be carried out only by the maintenance
personell who have received a special training.
 The extraction of soot deposits is prohibited.
 During extraction work, always wear the full personal protective equipment which is appropriate for
the metal powder being used.
 If possible, work in pairs when handling reactive materials. People working on their own must be
suitably monitored, e.g. by providing suitable emergency call facilities.

worn.
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8.4.1 Powder removal

WARNING come into contact with metal powders, soot deposits, filter residues and their dusts.
 Cleaning by blowing off is fundamentally prohibited.
 When using reactive metal powders, only ever work with a closed and inertised glovebox.
Note on clamping system!

deposits. If metal powder or other pollutants get into the clamping chuck, this can lead to increased
wear all the way through to a defect.
 Keep the clamping chuck clean and avoid any work that produces lots of dust.
 The build chamber platform with clamping system must be covered with a suitable cover plate, e.g.
a build plate, before the powder chamber is emptied.
Requirement
 The machine is switched on.
 The build module is in the handling station.
 The glove box has been inertised,
See section 6.8.3 Inertising the glovebox (only when using reactive metal powders).
 The build module is disarmed.
Tools required
 Scoop
 Brush
Implementation
1. Empty the powder chamber.

 For reactive metal powders, the following tasks are
carried out with the glove box closed and inertised.
 If there is still some metal powder on the build
module, it is essential for this to be removed before
the machine is cleaned.
2. Remove the powder chamber cover from the powder

chamber.
 Store the powder chamber cover in its mounting on
the glove box wall.
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8 Maintenance
Note on danger of collision with the coater blade!

The movement path of the coater must be clear.
In the event of a collision the coater blade may be damaged.
 If necessary, move the build chamber platform downwards until it is fully below the build module
surface.
 Remove the powder chamber cover each time before the coater is moved.
3. Transfer the metal powder from the powder chamber

into the powder overflow using the coater.
 Open the Set up machine window.
Set up machine.
 The Set up machine window is opened.
 Empty the powder chamber. The build chamber is
not lowered here and the powder chamber is moved
up.
 Enter in the entry fields on the top row Lower by
(on return) the values for lowering the platforms
and the coater speed for the return run of the
coater.
 Enter in the entry fields on the bottom row Position
by the values for moving up the powder chamber
 Start the layer application by clicking on the symbol
.
 Repeat the steps until the powder chamber
platform has reached its upper final position.
4. Move the coater into its right final position.

 Click on the symbol Right.
 The coater moves to its right final position behind
the powder chamber.

 Reach into the glove box through the glove box
gloves and clean the build module surface with a
brush and transfer the metal powder into the
powder overflow.
 Clean all surfaces of visible metal powder residues
and transfer them into the powder overflow.
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8 Maintenance

7. Close the powder overflow.

 Close the powder overflow directly after the
inertisation has stopped.
powder container.
powder overflow.
8. Remove the powder container from the machine.

 see section 6.19 Removing the powder container
from the machine


 Flip the door completely upwards.
 Push the door until it stops to the side of the
handling station.

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8 Maintenance
8.4.2 Transferring the metal powder into powder bottles

The inappropriate use of a lifting device may present a danger of injury to the user.
WARNING

CAUTION
Metal powder can be stored both in the powder containers and in powder bottles.
The choice of vessel is dependent on the amount of powder. Larger quantities of metal powder should
be stored in powder containers, smaller quantities of metal powder should be stored in powder bottles.
Note on using powder bottles!

When using powder bottles, make sure that the maximum volume of the powder bottles is not
exceeded.
Requirement
 The machine is switched on and is in its basic state.
 The build module is coupled onto the handling station.
 The right inert gas is connected.
 The metal powder in the powder container is available.
 The build module is disarmed.
tools required
 Powder bottles
 Scoop
 Brush
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8 Maintenance
Implementation
Note
Make sure that the correct personal protective equipment is chosen.
glove box gloves with the glove box closed
If the metal powder is provided in powder containers, filling via the powder inlet hose of the glove box is
possible.
– Extended PPE for reactive metal powders.
2. Place the tools required into the glove box:

– Powder bottles
– Brush and scoop

protective equipment can be taken off. There is no
longer any possibility of contact with metal powder.
4. Select the suitable inert gas.

 Check the choice of inert gas used!
For titanium, argon must be used as the inert gas;
for aluminium, nitrogen must be used as the inert
gas!
 Close the stopcock for the inert gas which is note
required until the valve audibly engages.
5. Click on the Inertisation button in the Machine

overview section.
Machine overview.
6. Activate the inert gas feed.

 Inert gas flows into the glove box until the oxygen
value falls below the set limit value.
 The symbol is now displayed in orange and Inert gas
status display in the Machine status section
changes from red to green.
 The signal column lights up yellow.
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8 Maintenance
7. Wait for the glove box to undergo sufficient inertisation.

 The O2 Module output field displays the current
residual oxygen content in the glove box. If the value
is below the set Switch on at value, the O2 Module
output field lights up green.
 The signal column goes out as soon as the process
chamber is sufficiently inertised.
 If the value falls below the set oxygen limit value,
the software automatically interrupts the inflow of
inert gas.

 Remove the protective cover of the earthing cable.

the machine.

 If the powder container is below the powder
overflow in the LaserCUSING® machine, the powder
container must first of all be removed from the
machine. (See section 6.19 Removing the powder
container from the machine)
 Lift up the powder container slightly.
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8 Maintenance
 Secure the powder container with both securing

10. Connect the powder hose to the powder container.

 Lift the powder container up to roughly chest
height.
 Select the suitable powder hose for the metal
powder which is in the powder container.
 Attach the powder hose using the clamp on the
powder outlet of the powder container.
11. Open the service flap above the glove box.

 Pull the handle to open the service flap.
12. Lift the powder container over the machine.

chamber sieve.
 If the powder is sieved via an external sieving
station, follow the "QM powder" instructions in the
other relevant documents before performing this
step.
 Use the lifting device to lift the powder container
above the LaserCUSING® machine.
 Position the powder container so that the powder
hose is above the inlet opening to the machine.
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8 Maintenance
13. Position the powder hose above the powder inlet valve
of the glove box
 Take the hose from the hook.
 Guide the powder hose through the upper opening
 If necessary, lower the powder container further
down.
 Step on the brakes on the castors of the lifting
device.
 The lifting device is secured against being moved
accidentally.
14. Connect the powder hose to the glove box.

 Place the sealing ring onto the powder inlet of the
glove box.
 Close the clip around the powder hose.
 Tighten the wing screw
15. Prepare the powder inlet hose of the glove box.

 Take the powder hose from its mounting on the
glove box wall.
glove box.
Danger of fire and explosion from reactive metal powders!

Reactive metal powders can catch fire and cause serious to fatal injuries.
 Only open the butterfly valve on the powder container when the glove box and the powder hose
DANGER have been sufficiently inertised.
16. Wait until the powder hose is filled with inert gas.
 If non-reactive metal powders are used, there is no
need for this step.
 Wait for approx. 60 s so that the hose has a chance
to be filled with inert gas.
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8 Maintenance
17. Pour the metal powder into the powder bottles.

container.
 Allow the required quantity of metal powder to
trickle into the powder bottle.
 When the powder bottle is full, interrupt the supply
of powder for a little while by closing the butterfly
valve at the powder inlet of the glove box.
18. Stop the powder feed.

 Close the valves from top to bottom in order to
avoid an accumulation of powder in the powder
outlet hose.
powder container.
glove box.
19. Close the powder bottles.

transfer the metal powder into the powder bottles.
 Clean all surfaces of visible metal powder residues.
21. Disconnect the powder hose from the glove box.

 Undo the wing screw.
 Open the clip around the powder hose.
 Move the powder container up slightly using the
lifting device.
 Remove the sealing ring from the powder inlet of
the glove box.
22. Lower the powder container.

 Move the lifting device with the raised powder
container slowly away from the machine.
 Lower the powder container to roughly chest height
as soon as it is sufficiently far away from the
machine.
23. Close the service flap above the glove box.

 Push the handle to close the service flap.
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8 Maintenance
24. Disconnect the powder hose from the powder container.

 Open the wing screw and the clip around the
powder hose.
 Place the powder hose in an antistatic bag and store
this away in a fire-resistant cabinet.
 Lower the powder container until it is just above the
floor.
 The powder container can now either be inserted
into the LaserCUSING® machine and connected to
the powder overflow or be cleaned and stored away.

 Click the symbol in the Inertisation section.


28. Take the closed powder bottles from the glove box.
 Store the metal powders in a fire-resistant cabinet.
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8 Maintenance
8.4.3 Cleaning the machine surface (outside)

Requirement
 The machine is switched off and secured against reactivation.
 The machine is not disconnected from the mains power and has effective explosion protection.
 The machine is disconnected from the compressed air and inert gas supply.
Required material and tools
 Personal protective equipment (standard PPE or extended PPE)
 Dry paper towels
 Cleaning product (glass cleaner)
Implementation

– Standard PPE for non-reactive metal powder
– Extended PPE for reactive metal powder
2. Close all protective doors of the LaserCUSING® machine.
3. Clean the outer machine surface.

 Slightly moisten a clean, lint-free cloth.
 Thoroughly clean all of the outer surfaces of the
4. Wait until the surfaces have dried completely before

switching the machine on again.
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8 Maintenance
8.4.4 Cleaning of the handling station

Danger from entering the machine!
Serious physical injury can be caused by entering the machine via the bottom service door of the
handling station.
DANGER
 The glove box must be only cleaned from outside.
 The machine must be not entered for cleaning work.
Warning about material damage!

Use only a small amount of cleaning product and make sure that the cleaning product does not then
penetrate into electrical parts and ventilation slots.
Requirement
 The build module is disarmed and is situated in the handling station.
 All of the work described under section 8.4.1 Powder removal has been carried out.
 Wet separator
 Allen key, size 5
Implementation

2. Earth the wet separator on the handling station.

 The wet separater must be checked in accordance
with the manual before its use!
3. Open the glovebox flap.

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8 Maintenance
4. Clean all surfaces of the handling station, the build

module surface and the glove box.
 Extract fairly large quantaties of metal powder with
a damp cloth.
 Extract fairly small quantities of metal powder with
the wet separator.
 Thoroughly wipe then the surfaces down with damp
cloths.
 Keep cleaning the surfaces until all visible powder
residues have been removed.
5. First clean all freely accessible surfaces of the glove box

and the build module, in particular:
– Build chamber and powder chamber (when empty)
– Powder chamber cover
– Powder outlet with valves
– Powder inlet with valves
– Powder chamber sieves
– Glove box flap
– Seal of the glove box flap
– Glove port.
6. Once the surfaces of the handling station are clean, the

following components should also be cleaned:
– Guide rails and drive belt of the coater.
(See section 8.4.5 Cleaning the guide rails and drive
belt of the coater)
– Coater with coater blade
(see section 8.4.6 Cleaning the coater blade)

 If no wok is being carried out in the glove box, it
must remain closed.
 Secure it with both knurled nuts.
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8 Maintenance
8.4.5 Cleaning the guide rails and drive belt of the coater
Requirement
 All of the work described under section 8.4.4 Cleaning of the handling station has been carried out.
 Wet separator
 Allen key, size 2.5
Implementation


 The wet separator must be checked in accordance
with the manual before its use!

4. Remove the metal sheet cover of the front and rear

guide rails.
 Undo the two hexagon socket screws on the left and
right on the metal sheet cover.
 Carefully lift up the metal sheet cover.
5. Clean the metal sheet cover carefully with dampened

cloths and place it down away from the handling
station.
6. Clean the surfaces below the cover.

 Pick up visible powder deposits with a slightly
dampened cloth.
 Wipe down all accessible surfaces below the metal
sheet cover.
 Extract the smallest residual quantities of metal
powder with the wet separator.
have been removed.
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8 Maintenance
7. Fit in the metal sheet cover of the front and rear guide
rails.
 Place the metal sheet cover carefully onto the build
module.
 Insert two hexagon socket screws on the left and
right on the metal sheet cover and tighten them so
they are hand-tight.
8.4.6 Cleaning the coater blade

CAUTION

Use only a small amount of cleaning product and make sure that the cleaning product does not then
penetrate into electrical parts and ventilation slots.
Requirement
 The handling station has been cleaned. (See section 8.4.4 Cleaning of the handling station)
Material and tools
Implementation

2. Select the Machine control menu interface.
3. Reference all axes.

See section 6.7 Carrying out a reference run
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8 Maintenance
4. Move the coater over the middle of the build chamber.

 The coater can only be moved when the glove box is
closed and the light barrier is not broken.
 Click on the symbol Target build.
chamber.
5. Clean the coater blade thoroughly until it is clean and

free of any grease.
 Pour a little spirit cleaner onto a clean, lint-free
cloth.
 Carefully wipe several times across the coater blade
below the coater.
6. Move the coater to the left final position in the build

module.
 The coater is moved to its left final position.
8.4.7 Cleaning emptying openings of the build and powder chamber shafts
Danger to life from exhausting the build and powder chamber shafts!
If metal powders are exhausted via the emtying openings of the build and powder chamber shafts, there
is a danger to life from the formation of an explosive atmosphere! There is a danger of explosion and
DANGER fire.
 During the extraction process maintain a safe distance of at least 2 m around the extraction site
and the wet separator.
 Make sure that no people enter the danger zone.
 Supervise the extraction process.
Requirement
 You have received certified instruction from CONCEPTLaser.
 The build and powder chamber are free of metal powder.
 The build module has been cleaned and is located in the handling station.
 The build and powder chamber platforms are in their bottom final position.
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8 Maintenance
Material and tools

 Personal protective equipment (extended PPE)
 Allen key, size 10 or flat spanner, size 30
 Wet separator
 Suction tube frame adapter
Implementation

– – Extended PPE

 Check the wet separator in accordance with the
manual before using it!
3. Clean the surfaces around the emtying openings with a

slightly dampened cloth.
4. Open both emptying openings of the build chamber

shaft.
 Unscrew the screw caps anticklockwise or take off
the plastic caps.
 Make sure that no powder residues drop out of the
emptying openings.
Note
Always open both emptying openings of the chamber shafts in each case as otherwise a dangerous
negative pressure is produced in the shafts during the extraction process.
5. Plug or screw the adapter on the left-hand emptying

opening of the build chamber shaft.
 The adapter is fitted in different ways depending on
the design of the emptying openings.
6. Plug the suction hose of the wet separator onto the

installed adapter.
 Check that the suction hose is fitted securely.
Note
Supervise the extraction process. Make sure that no people enter the danger zone.
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8 Maintenance
7. Extract the metal powder from the build chamber shaft

with the wet separator.
 During the extraction process, a safe distance from
the extraction site and the wet separator of at least
2 m must be maintained.
 Switch on the wet separator.
 Step away 2 m from the machine and the wet
separator.
 Supervise the extraction process!
 Allow the wet separator to extract for approx. 15
minutes.
 Switch off the wet separator.
8. Remove the suction hose of the wet separator from the

adapter.
9. Pull off or unscrew the adapter from the emptying

10. Plug or screw the adapter onto the right-hand emptying

 The adapter is attached in different ways depending
on the design of the emptying openings.
11. Repeat steps 6.-9.
12. Perform a visual check to establish whether the build

chamber shaft is free of powder residues.
 Exhaust the shaft again, if necessary.
13. After extraction, seal the emptying openings of the build

chamber shaft with the screw caps.
 Screw on the screw caps clockwise or push on the
plastic caps.
 Check that the screw caps are fitted correctly and
securely.
14. Clean the powder chamber shaft.

 Repeat steps 4.-13. with the powder chamber shaft.
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8 Maintenance
8.4.8 Cleaning of the process chamber

Danger of explosion from extracting soot deposits!
The extracting and swirling up of the soot deposits in the process chamber may produce an explosive
atmosphere. This may lead to an explosion.
DANGER  Never vacuum out the process chamber.
 Never extract soot deposits.

DANGER
 The laser system must be switched off and secured against reactivation before all repair work.
 Work on the laser lens may only be carried out by the manufacturer.
Requirement
Material and tools
Implementation

– Extended PPE
 The extended PPE should be worn to clean the
process chamber as the user comes into contact
with the reactive soot of the metal powders.
2. Open the process chamber.

 Open the process station door.
 Earth the ESD wristband on the process station.
 Unlock the process chamber door.
 Open the process chamber door.
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3. Clean all surfaces of the process chamber.

 Pick up fairly large quantities of powder deposits
using dry cloths.
 Thoroughly wipe down the process chamber with
dampened cloths.
 Keep cleaning the surfaces until all deposits have
been removed.
4. Place dirty cloths immediately in an antistatic bag.
5. When cleaning, pay particular attention to the following

components of the process chamber:
– Seals on the process chamber door
– Soot deposits in and below the process chamber.
Protective glass of the scan head lens
(See section 8.4.9 Cleaning the protective glass of
the scan head lens)
6. Close the process chamber.

 The process chamber door should only ever be
opened to do cleaning and maintenance work.
 Once the work has been completed, the process
chamber door should be closed.
 Close and lock the process chamber door.
 Close the process station.
8.4.9 Cleaning the protective glass of the scan head lens

Note
The protective glass of the scan head lens is very sensitive.
Deposits such as dirt and skin grease or scratches will diminish the laser power and reduce the useful
life of the protective glass.
 Do not contaminate or scratch the protective glass.
 Only touch the protective glass with clean cotton or plastic gloves.
 Never clean the protective glass by blowing off.
 Never blow on the protective glass with your mouth as drops of saliva will contaminate it even
more.
Requirement
 The process chamber has been cleaned.
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Material and tools

 Clean, lint-free cloth
Implementation

– Extended PPE
 The extended PPE should be worn to clean the
process chamber as the user comes into contact
with the reactive soot of the metal powders.
2. Open the process chamber.

 Open the door of the process station.
 Earth the ESD wristband on the process station.
 Unlock the process chamber door.
 Open the process chamber door.
3. Clean the protective glass of the scan head lens.

 First remove the dust around the protective glass
with a cloth
 Wipe down the protective glass carefully and
completely with a clean, soft, lint-free and dry cloth.
4. Close the process chamber.

 The process chamber door should only ever be
opened to do cleaning and maintenance work.
 Once the work has been completed, the process
chamber door should be closed.
 Close and lock the process chamber door.
 Close the door of the process station.
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8.5 Cleaning the filter module

Users of the M2 cusing LaserCUSING® machine come into contact with reactive metal powders and their
process products when working on the LaserCUSING® machine.
Always note the general safety instructions in chapter 2 General safety instructions For handling
reactive materials, note the instructions given in section 2.6 Handling reactive metal powders.

with water will result in the formation of small amounts of hydrogen. If the hydrogen accumulates and
DANGER mixes with air containing oxygen, an explosive hydrogen-air mixture known as oxyhydrogen is produced.
 Always leave the valve on the process gas return pipe open by a small gap to prevent any
accumulation of hydrogen within the filter module.
 Only ever store water / metal mixtures and moist metal residues in open containers outdoors.
 Empty the filter module promptly, after the flooding.

powders, soot deposits, filter residues and their dusts, the prescribed protective equipment must be
worn.

The filter cartridges of the filter module can be used over several build processes.
Cleaning is only necessary when one of the following situations occurs:
– The soot deposits increase on account of the low level of extraction.
– The differential pressure decreases.
The basic rule is:
– The filters should be replaced every six months if the LaserCUSING® machine is used regularly!

It is recommended that, for the purpose of removing a filter, a second person is always in attendance
who can assist with lifting up the filter module lid and packing up the used filter cartridge.
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8.5.1 Separating and flooding the filter module

Requirement
 No build process is being carried out in the process chamber.
 The build module is in the process station.
 A warning sign has been placed on the control panel of the process station to provide notification of
the imminent cleaning work.
Implementation
1. Start the inertisation of the filter module.

 see section 6.14.3 Inertising the process chamber
 Wait until the residual oxygen content is constantly
adjusted to less than 4%.
 The filter module has been fully inertised.
 Switch on the ventilator when the residual oxygen
value is below 4%.
 Wait until the residual oxygen value display has
reached a constant value (less than 2%).
2. Perform the filter cleaning.

 Click in the Inertisation section on the Filter
cleaning button.
 The cartridge filters in the filter module are cleaned
of any loosely adhering powder particles with a
blast of compressed air.
4. Stop the extraction.

 Perform the following tasks within a period of 30
min in order to maintain the inertisation in the filter
module.

– Extended PPE
6. Close the butterfly valves between the filter module and

the process chamber.
 Open the service door to the excess pressure filter
on the back of the handling station.
 Close both butterfly valves.
 The process gas feed pipe is closed.
 Open the service doors to the filter module on the
back of the handling station.
 Close both butterfly valves.
 The process gas return pipe is closed.
7. Close the manual valves of the plug-in connections for

the filter cleaning.
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8. Disconnect the process gas feed and return.

 Undo the wing screws and open the connecting clips
on the process gas feed.
 Undo the wing screws and open the connecting clips
on the process gas return.
9. Detach the earthing connection on the filter module

cover.
10. Detach the plug-in coupling for the connections for the
filter cleaning.
 Remove both plug-in couplings in the upward
direction.
 The filter module is disconnected from the process
chamber.
11. Roll the filter module out of the machine.

 Carefully pull the filter module out of the machine
from the machine side.
 Make sure that no pipes or cables get caught on the
filter module.
 Get a second person to help you if necessary.

Flooding of the filter module with water results in the formation of hydrogen.
 Always leave the valve on the process gas return pipe open by a small gap to prevent any
DANGER accumulation of hydrogen within the filter module.
 Empty the filter module after passivation as soon as possible.
Flood the filter within 30 min after disconnection from the machine!
The filter module is not 100% gas-tight. After stopping the inertisation and disconnecting the filter
module, inert gas can escape from the filter module continuously.
Flood the filter module within a timespan of 30 min after disconnection from the machine.
12. Flood the filter module.

 Place the hose adapter onto the pipes for the filter
cleaning and fix them in place using the connecting
clips.
 Connect the plug-in coupling of the water hose to
the hose adapter.
 Open the water feed.
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8 Maintenance
 Open the manual valves on the pipes for the filter

cleaning.
 Open the valve on the process gas return pipe by a
small gap so that the hydrogen which is produced
can escape from the filter module.
 This will ensure that the pressure is equalized when
the filter module is flooded.
 The gas in the filter module is emitted filtered into
the surrounding atmosphere.
 The filter module is flooded with water.
 The reactive filter residues are passivated as a
result of the flooding with water.
 Flood the filter module slowly until the upper mark
on the water level indicator is reached.
 Stop the water feed.
Danger of fire from non-passivated filter cartridges!

Filter residues are highly reactive and can ignite in an atmosphere containing oxygen.
 The filter cartridges must be passivated for at least 60 min as prescribed prior to removal.
DANGER
 Make sure you adopt the correct procedure for the specific material!
13. Remove the filter residues in the filter module.

 Keep the maximum water level in the filter module
constant for approx. 60 min.
 If necessary, top up the water to maintain the
maximum water level.
 The reactive soot is removed.
Note
The valve on the process gas return pipe must remain open in order to equalise the volume in the filter
module when the water is drained!
14. Empty the filter module.

 Place a suitable collecting vessel below the outlet
opening of the filter module.
 Undo the wing screw and open the clip on the outlet
opening.
 Remove the cover.
 Open the butterfly valve on the outlet.
 Allow the water to flow out completely.
 Then close the butterfly valve and place the cover
back onto the outlet opening of the filter module.
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8.5.2 Changing the filter cartridge

Note on changing the filter cartridge!
The water must be removed directly following passivation of the filter residues and then the filter
cartridge must be removed from the filter module. The damp filter cartridges must be removed from the
filter module no longer than 5 min after it has been flood.
Requirement
 The filter module is disconnected from the machine and the filter residues have been removed.
Material and tools
 Spanner
 2 new cartridge filters
 New H14 filter
Implementation

– Extended PPE
2. Release the earthing connection between the filter

module cover and the lower housing.
3. Open the cover of the filter module.

 Open the clamping fasteners on the cover (two on
each side of the filter module).
 Carefully remove the cover of the filter module and
place it aside.

The cover of the filter module is heavy and bulky.
 The cover must only be carried by two people.
CAUTION
4. Remove the cover of the filter module.

 Work in pairs.
 Remove the cover upwards holding the handles.
 Place it aside on a suitable, flat working surface.
5. Remove the filter cartridges from the filter module.

 Undo the three nuts respectively on the filter
module frame.
 Remove the filter cartridge up and out of the filter
module.
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 Remove the filter cartridge and place it in an

antistatic bag.
 For details on storing and disposing of the filter
cartridge, please note the instructions given in
section 8.5.3 Storage and disposal of the filter
cartridge.
6. Remove the H14 filter out of the cover of the filter

module.
 Undo the two screws of the clamping plates.
 Remove the clamping plate from the filter.
 Take the H14 filter out of the cover.
 Place the used H14 filter in an antistatic plastic bag.
 Work swiftly and without any breaks.
 Prolonged storage outside of a fire-resistant
container should be avoided at all costs.
 Store the H14 filter in an antistatic bag for at least
72 h in a fire-resistant container.
 The H14 filter must be stored in a fire-resistant
container until full oxidation has taken place.
 After this, any risk of fire or explosion of the filter
residues is ruled out and the H14 filter can be
disposed of.
 Dispose of the filter in accordance with the local,
official regulations.
Note
Allow all parts to dry in the air for at least 24 h before you reassemble the filter module.
7. Clean the filter module housing.

 Thoroughly wipe down the surfaces with damp
cloths.
 Keep cleaning the surfaces until all residues have
been removed.
When cleaning, pay particular attention to the following

components of the filter module:
– Cover of the filter module
– All valves and connecting elements
– Sealing rings
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8. After drying, insert new filter cartridges into the filter

module.
 Insert the filter cartridge into the opening from
above.
 Make sure that the filter cartridge is correctly
aligned.
 Fix the filter module in place using the three nuts.
 Tighten the nuts so they are hand-tight.
 Repeat the steps with the second filter cartridge.
9. Insert a new H14 filter into the cover of the filter

module.
 Insert the H14 filter into the cover.
 Rotate the clamping plates onto the filter frame.
 Tighten the two screws so they are hand-tight and
fix the filter on the cover.
10. Assemble the filter module.

 Work in pairs.
 Lift up the cover holding the handles.
 Place it onto the filter module.
 Close the clamping fasteners on the sides of the
filter module.
11. Connect the earthing connection on the filter module

cover to the lower housing.
Note on storage and disposal of the dirty paper towels!

Store the dirty paper towels for at least 72h in an antistatic bag in a safe container for spontaneously
combustible substances.
Dispose of dirty paper towels in accordance with the official regulations. When you do so, notify the
disposing authority that the substances involved are spontaneously combustible, in some cases
carcinogenic.
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8.5.3 Storage and disposal of the filter cartridge

The further storage and disposal of the removed filter cartridge is dependent on the metal powder used
on the LaserCUSING® machine.
You will find a list and classification of the approved metal powders in section 3.7 Approved metal
powders (classification).
Non-reactive metal powders
 Store the filter cartridges until they can be disposed of in an antistatic bag in a fire-resistant
container.
 Dispose of the filter cartridge and the water contaminated with filter residues in accordance
with the local, official regulations.
Reactive aluminium metal powders

Aluminium powders react with water to form hydrogen. If the hydrogen accumulates and mixes with air
containing oxygen, an explosive hydrogen-air mixture known as oxyhydrogen is produced.
DANGER  Always wear the extended PPE when handling soot and filter residues.
 Check the water level in the container regularly.
 Store the removed filter cartridge and the water contaminated with filter residues for at least
two weeks in a water-filled cool-down basin.
 Then store the filter cartridge until it can be disposed of in an antistatic bag in a fire-resistant
container.
Reactive titanium metal powders
Danger of fire and explosion from reactive filter residues!

Filter cartridges which have been removed and have dried again and filter residues of titanium powders
are reactive. They can catch fire and cause serious to fatal injuries.
DANGER  Always wear the extended PPE when handling soot and filter residues.
 Make sure that the filter cartridge is constantly wetted with a sufficient amount of water.
 Drying out of the filter cartridge and the filter residues must be avoided.
 Store the damp, removed filter cartridge in a gas-tight container for disposal and dispose of it as
soon as possible.
 The water contaminated with filter residues must be disposed of as soon as possible.
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8.5.4 Connecting the filter module to the machine

Requirement
 The machine has been switched on in accordance with section 6.6 Switching on and is in its basic
state.
Material and tools
Implementation

– Extended PPE
2. Roll the filter module back into the machine.

 Make sure that no pipes or cables get caught on the
filter module.
 Get a second person to help you if necessary.
 The filter module is positioned in such a way that
the pipework behind the process chamber fits onto
the inlet valve of the filter module.
Note
During assembly, make sure that the sealing rings are used.
The leak-tightness of the system can only be guaranteed if sealing rings are put in place.
3. Connect the filter module to the machine.

 Place the sealing ring onto the process gas return
pipe.
 Place the process gas feed pipe onto the filter
module inlet.
 Close the clip and tighten the wing screw so that it
is hand-tight.
 Place the sealing ring onto the process gas return
pipe.
 Position the process gas return pipe over the filter
module outlet.
 Close the clip and tighten the wing screw so that it
is hand-tight.
4. Connect the plug-in connectors to the filter cleaning

hoses.
 Plug the plug-in couplings onto the filter module
from above.
 Open the butterfly valves for the filter cleaning.
5. Connect the earthing connection on the cover to the

machine.
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6. Open the butterfly valves between the filter module and

the process chamber.
 Open the right-hand protective door of the process
station.
 Open both butterfly valves.
 The process gas feed pipe is open.
 Open both process gas return butterfly valves.
 The process gas feed pipe is open.
7. Close the service doors to the filter module.
8. Close the service door to the excess pressure filter.
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8 Maintenance
8.6 Cleaning the powder container (master container)

Note on the powder container!
Concept Laser GmbH supplies two types of powder container, the master powder container and the
standard powder container.
Only the master powder container is suitable for cleaning.

The inappropriate use of a lifting device may present numerous hazards to the user.
WARNING
 Use the correct jacking points for the powder device in order to prevent it from falling off.

CAUTION
 Never attempt to carry the containers.
Requirement
 The powder container has been emptied.
 The powder container has been removed from the machine.
Tools required
 Wet separator
 Paper towels dampened with water
 Flat-head screwdriver or socket spanner, size 7
Implementation


 Check the wet separator in accordance with the
manual before its use!
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3. Remove the powder hose on the upper butterfly valve of

the powder container.
 Release the hose clip on the upper butterfly valve.
 Remove the hose from the butterfly valve.
 Store the hose in the antistatic bag in a fire-
resistant cabinet.
4. Clean the butterfly valve on the lid.

 Thoroughly wipe down the surfaces on the outside
using cloths dampened with water.
5. Open the lid of the powder container.

 Undo the four knurled nuts on the lid.
 Remove the lid upwards.
 Place the lid aside on a flat working surface.
6. Clean the lid.

 Thoroughly wipe down the surfaces using cloths
dampened with water.
have been removed.
7. Clean the powder container.

 Thoroughly wipe down the surfaces using cloths
dampened with water.
have been removed.
 Extract the smallest residual quantities of metal
powder using an approved wet separator.
 If no more visible powder residues can be seen,
rinse out the container with water.
 Collect water in an appropriate vessel and disposen
of it in accordance with the official regulations.
 Wipe down the surfaces with cloths until they are
dry.
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Allow all parts to dry in the air for at least 24 h before you reassemble the powder container.
8. Reassemble all components of the powder container.

 Place the lid on the powder container.
 Screw on the four knurled nuts and tighten them so
they are hand-tight.
 Place a new hose onto the butterfly valve on the lid
and fix it in place with a hose clip.
 Close all butterfly valves on the powder container.

Always store the dirty paper towels in a safe container for spontaneously combustible substances.
disposing authority that the substances involved are spontaneously combustible, in some cases
carcinogenic.
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8.7 Inspection and maintenance work

8.7.1 Visual inspection for any damage or wear
Note
The machine should be checked regularly for any sign of wear.
It makes sense to perform this inspection when the machine is being cleaned.
Requirement
Implementation
1. Check the machine for any signs of damage and pay

attention to any unusual noises during a pending
LaserCUSING® process.
2. Check all lines and valves of the compressed airm supply

for any damage or wear. Pay particular attention o the
sealing rings of the valves.
 Replace the sealing rings of the connections if
necessary.
 Replace any defective supply lines if necessary.
3. Check all lines and valves of the inert gas supply for any
damage or wear. Pay particular attention to the sealing
rings of the connections.
 Replace the sealing rings of the connections if
necessary.
 Replace any defective supply lines if necessary.
4. Check the seal of the glove box flap for any damage or
wear.
 Replace the seal of the glove box if necessary.
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5. Check the seal of the process chamber door for any

damage or wear.
 Replace the seal of the process chamber door if
necessary.
6. Check the glove box gloves for any damage or wear.

 Replace the glove box gloves if necessary.
 see section 8.7.4 Replacing glove box gloves
7. Check the expansion seal of the glove box for any

damage or wear.
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8 Maintenance
8.7.2 Checking / setting the pressure of the gas connections

Note
The pneumatic connections are mounted on a pneumatic plate.
The M2 cusing LaserCUSING® machine has three gas connections which are controlled via three
maintenance units.
The gas connections are labelled.
Requirement
 Compressed air and inert gas are connected.
 The machine is in its basic state.
Implementation
1. Open the upper right protective door of the handling

station.
2. Select the maintenance unit you want.

 (1)… Compressed air maintenance unit
 (2)…Argon maintenance unit
 (3)…Nitrogen maintenance unit
3. Read off the set gas pressure.

 Read off the gas pressure on the manometer (1).
 The gas pressure of the compressed air connection
should be 6 bar.
 The gas pressure of the inert gas connections
should be 5 bar.
4. Reset the gas pressure if necessary.
 Pull up the control knob (2) and set the target gas
pressure by rotating it.
 The pressure applied is displayed on the
manometer.
 Press down the control knob (2).
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8 Maintenance
8.7.3 Checking / setting the pressure of the expansion seal

Requirement
 Compressed air and inert gas are connected.
 The machine is in its basic state.
 The build module is docked in the handling station.
Implementation
1. Open the upper protective door of the handling station.
2. Read off the pressure of the expansion seal of the build

module on the manometer of the pressure control valve.
 3 bar of compressed air should be applied.
 If 3 bar of compressed air is not applied, the air
pressure applied must be set to 3 bar via the control
valve.
3. Adjust the pressure of the expansion seal to 3 bar if

necessary.
 Turn the adjusting screw of the compressed air
control valve until the manometer shows 3 bar.
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8.7.4 Replacing glove box gloves

Requirement
Material and tools
 Spare parts (glove box gloves, item no. 94012;
O-ring for glove box gloves, item no. 90810)
Implementation

2. Remove the O-ring around the glove box glove.
3. Remove the glove box glove from the glove port of the
glove box.
 Deposit the used glove box gloves in an antistatic
bag.
 If the gloves are replaced due to a change of powder
on the machine, they can be reused with the same
powder. Appropriate labelling of the gloves is
recommended.
4. Fold the new glove over the glove port of the glove box.
5. Pull the O-ring over the glove box glove and over the
glove port of the glove box.
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8.7.5 Checking / emptying the condensate container on the maintenance unit

Note
The condensed water in the condensate container of the maintenance unit may rise up to no more than
10 mm below the filter element.
Requirement
Implementation
1. Open the upper protective door of the handling station.
2. Place a collecting container below the maintenance unit

which is to be emptied.
3. Loosen the drain screw in the anticlockwise direction

(seen from below).
 The condensed water will flow away.
4. Tighten the drain screw in the clockwise direction (seen

from below).
 The condensate container is emptied.
 The pneumatic equipment of the M2 cusing
LaserCUSING® machine has a total of three
maintenance units.
 The condensate containers of the maintenance
units must be emptied separately, as required.
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8 Maintenance
8.7.6 Rotating or replacing the coater blade

Two types of blades are available for the LaserCUSING® process:
 Steel blade
We recommend the use of steel blades when using hot-work steel as the metal powder for massive
parts such as tool inserts.
 Plastic and elastomer blades
We recommend the use of plastic and elastomer blades when manufacturing parts with supprot or
delicate structures.
There is a special blade holder available for every type of blade:
1 2 3
Fig. 8-1: Blade holders
1 Blade holder for plastic blade

2 Blade holder for elastomer blade
3 Blade holder for steel blade (with blade)
The choice of the right blade is dependent on the metal powder used and the structure of the part
which is to be created.
The issue of which blade should be used for the particular build process is a matter of experience and
must be tested by the user in a build process!
Coater blades are parts which are subject to wear and tear and they must be rotated or replaced on a
regular basis. The steel blades have two ground edges and can be rotated. The flexible coater blades
must be replaced if there are any signs of wear.
Check the coater blade for any signs of wear on a regular basis.
Indications of a worn coater blade are:
– The coater increasingly becomes caught on the part.
– Uneven application of powder.
If while observing a process you notice any indications of a worn coater blade, it must be rotated or
replaced after the end of the build process. Steel blades can be rotated once before they need to be
replaced.
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CAUTION
Requirement
 The build module is in the handling station.
 The build plate has been mounted on the build chamber platform.
 The glove box is closed and has been inertised. (see section 6.8.3)
(only when using reactive metal powders)
 The light barrier of the glove box is not broken.
Implementation

2. Clean the build module and the handling station.

 see section 8.4.4 Cleaning of the handling station
Removing the blade holder
1. Move the build platform with the build plate roughly to

the height of the working surface of the build module.
 The build chamber platform can only be moved with
the glove box opened if the coater is in the left final
position.
 In the Machine overview section, select the build
chamber.
 The Build chamber section is displayed.
 Click on the symbols , to move the build
chamber platform continuously.
 Alternatively, lower or raise the build chamber
platform gradually, by the amount which is entered
in the Step input field.
 Alternatively, move the build chamber platform to a
defined position which is entered in the Target field.
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8 Maintenance
 Check whether the build plate surface is just below

the build module surface.
chamber platform.
2. Move the coater centrally over the build chamber.

 The coater can only be moved if the glove box is
closed and the light barrier is not broken.
 Click on the symbol below Build.
chamber.
3. Remove the blade holder.

 Loosen the two fastening screws on the left side of
the coater blade.
 The two clamping jaws spring out and their red
marking becomes visible.
 The blade holder is loose.
 Carefully remove the blade holder.

 Clean the blade holder if necessary.
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8 Maintenance
Rotating / replacing the steel coater blade
Note
Steel blades have two ground edges and can be used on both sides.
1. Remove the steel coater blade.

 The steel blades have two ground edges and can be
rotated.
 Loosen the 4 fastening screws of the coater blade.
 Remove the coater blade from the blade holder.
2. Clean the coater blade thoroughly until it is clean and

free of any grease.
 Pour a little amount of the cleaning agent onto a
clean, lint-free cloth.
 Carefully wipe several times across the coater blade
below the coater.
3. Rotate the coater blade by 180° by swapping over the

top and bottom.
 Only rotate the steel coater blade if it has not been
rotated previously and is thus only worn on one
side.
4. Replace the steel coater blade.

 If the steel coater blade has already been rotated
once and both sides are thus worn, the blade must
be replaced.

Always fit the coater blade with the due level of care. Make sure that it fits properly.
 The blade must point to the left, towards the build chamber!
5. Mount the coater blade in the blade holder.

 Insert the coater blade into the blade holder as far
as it goes.
 Check that the blade is aligned correctly.
 As you do this, press the blade against the coater
from below.
 Secure the blade in place with the 4 fastening
screws.
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8 Maintenance
Changing plastic and elastomer blades
1. Remove the flexible blade from the guide rail.

 The plastic and elastomer coater blades must
always be replaced if there are any signs of wear.
 The flexible blade is pushed onto a guide rail on the
blade holder.
 Carefully pull the flexible blade forwards out of the
guide rail.
2. Slide the new flexible blade into the guide rail.

 First slide the flexible blade a slight amount into the
guide rail.
 Then pull the blade by its rear end fully onto the
guide rail on the blade holder.
3. If necessary, shorten the flexible blade with a suitable

tool.
4. Check that the flexible blade fits correctly on the blade

holder.
 The lip of the L blade must be positioned on the side
of the fixing pin.
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8 Maintenance
Fitting the blade holder
1. Check the position of the coater and the build chamber

plate.
 The coater must be above the build chamber.
 The build plate must be as high as the working
surface of the build module.
2. Fit the blade holder with a new blade in the machine.

 The fixing pin of the blade holder must point to the
right.
 Carefully insert the blade holder into the coater.
 Press the blade holder and the clamping jaws

downwards.
 Doing so, tighten the fastening screws on the left

side of the coater.
3. For each newly installed blade, check the zero position

and the next powder application.
 Evaluate the applied powder layer.
 Readjust the coater blade if necessary.
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8 Maintenance
Readjust the position of the blade holder
1. Undo the adjusting screw.
2. Readjust the position of the blade holder.

 By turning the adjusting screw clockwise, the
respective side of the balde holder is adjusted
upwards.
 By turning the adjusting screw anticlockwise, the
respective side of the balde holder is adjusted
downwards.
 Turn the adjusting screw in the respective direction.
3. Tighten the adjusting screw.
4. Check again the zero psition of the blade and the next
powder application.
Version 1.1.17 206

8 Maintenance
8.7.7 Replacing the excess pressure filter of the process chamber

Requirement
 No build process is being carried out in the process chamber.
 Inertisation and extraction are deactivated.
Material and tools
 Spare filter Picolino (Item no. 90606)
Implementation

2. Open the service door to the excess pressure filter on

the back of the handling station.
3. Open the filter housing of the excess pressure filter.

 Undo the wing screw on the cover of the cartridge
filter.
 Remove the cover of the cartridge filter upwards
and place it aside.
4. Check the level of contamination of the excess pressure

filter.
 If the surface of the filter is contaminated, it needs
to be replaced.
 If the surface is white to light yellow, the excess
pressure filter can continue to be used.
Note
If the excess pressure filter is contaminated, the filter cartridge of the filter module must be also
checked and replaced if necessary.
 See section 8.5 Cleaning the filter module
Version 1.1.17 207

8 Maintenance
5. Remove the filter insert from the filter housing..
6. Place the used filter in an antistatic plastic bag.

 Work swiftly and without any breaks.
 Prolonged storage outside of a fire-resistant
container should be avoided at all costs.
 For details on storage and disposal of the filter
insert, please consult specifications given in section
8.5.3 Storage and disposal of the filter cartridge.
Note on storage and disposal of the filter insert!

The further storage of the filter insert depends on the metal powder used in the machine.
7. Clean the filter housing.

 Thoroughly wipe down the surfaces with damp
cloths.
have been removed.
 Deposit the cloths contaminated with soot in an
antistatic bag.
 Store the antistatic bag for at least 72 h in a
fireresistant container.
 After this, the contents can be disposed of safely in
accordance with the local, official regulations.

Store the dirty paper towels in a safe container for spontaneously combustible substances.
disposing authority that the substances involved are spontaneously combustible, in some case
carcinogenic.
8. Insert the new Picolino filter into the filter housing.
9. Close the filter housing of the cartridge filter.

 Place the cover on the filter housing.
 Secure the cover with a wing screw and tighten it so
that it is hand-tight
10. Close the service door to the excess pressure filter.
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8 Maintenance
8.7.8 Checking the level of contamination of the build and powder chamber shafts
Danger to life from exhausting the build and powder chamber shafts!
If reactive metal powders are exhausted via the emptying openings of the build or powder chamber
shaft, there is a danger to life from the formation of an explosive atmosphere! There is a danger of
DANGER explosion and fire.
 Exhausting of the powder and build chamber shafts may only ever be carried out by specially
trained maintenance personnel.
Note on checking the level of contamination!

The level of contamination must be checked at least once a month.
To prevent metal powder from getting into the build or powder chamber shaft, a felt seal is fitted around
the build or powder chamber platform.
However, if metal powder still manages to get into the shafts, it is deposited at the bottom.
To check the level of contamination, please apply the following procedure:
Requirement
 The build module has been disarmed and cleaned.
Material and tools
 Personal protective equipment (extended PPE or standard PPE)
 Measuring tool (e.g. folder ruler)
Implementation
1. Reference the axis of the build chamber.

 Click on the target axis in the Machine overview
section.
 The Build chamber section is opened.
 Click on the symbol Reference .
 The axis of the build chamber is referenced.
 The axis is moved downwards via the machine
software.
Version 1.1.17 209

8 Maintenance
 In the Machine status section, the current axis

positions for the respective axis are displayed.
2. Lower the build chamber platform into its lower final

position.
platform continuously downwards.
 The message "U axis software final position plus" is
displayed on the PLC monitor.


 Flip up the door completely forwards.
 Push the door to the side of the hadling station up
to the stop.

 Remove both knurled nuts from the glove box flap.
6. Calculate the height of the build chamber.

 The build chamber height should always be
calculated without a build plate.
 Use a suitable measuring tool, e.g. a folding ruler, to
measure the gap between the build chamber
platform and the build module surface.
 Note the measured height of the build chamber.
Version 1.1.17 210

8 Maintenance
7. Calculate the height of the powder chamber.

 Repeat steps 1 – 6 for the powder chamber.
 When the lower final position for the powder
chamber platform is reached, this is confirmed with
the following message on the PLC monitor: "W axis
software final position minus".
Assessing the calculated values

1. Compare your calculated values with the specifications in the technical data (see section 3.2 Build
module).
 If you identify a deviation of more than 10 mm from the values specified in your operating
manual, put your machine into standby.
 Have the powder or build chamber shaft cleaned by specially trained maintenance personnel.
(See section 8.4.7 Cleaning emptying openings of the build and powder chamber shafts)
2. Compare your calculated values with the values from the previous measurements.
 If you identify a deviation of more than 10 mm from the values from the previous
measurements, put your machine into standby.
 If you identify a continuous decrease in the height of the build or powder chamber, put your
machine into standby.
 Have the powder or build chamber shaft cleaned by specially trained maintenance personnel.
(See section 8.4.7 Cleaning emptying openings of the build and powder chamber shafts)
Version 1.1.17 211

9 Dismantling, storage and disposal

After the machine has come to the end of its operational life, the machine needs to be dismantled and
disposed of in an environmentally friendly way.
The dismantling work may only be carried out by specially trained expert personnel.
Work on the electrical equipment may only be carried out by qualified electricians.
9.1 Safety instructions for dismantling

Danger posed by electrical energy!
Switch off the LaserCUSING® machine and disconnect all components from the power supply.
DANGER has been switched off and disconnected from the power supply.
After all main switches have been switched off, life-threatening voltages may still exist on the following
components:
– Main cables
– Power units
– Drive amplifiers
– Laser supply
Danger of suffocation from inert gas!

Inert gas may escape from the LaserCUSING® machine.
Inert gas may have accumulated in the process chamber.
DANGER
 Shut off and disconnect the inert gas supply before doing any dismantling work.
 Make sure there is a sufficient supply of fresh air.
 Follow the safety data sheets for the inert gases which are used.
Danger of damage to health from the contact with metal powders and filter dust!
and lungs.
 Before any dismantling work is carried out, the machine must be cleaned and all powder and soot
residues must be removed from the machine and the area immediately surrounding it.
 The recommended safety equipment must always be worn.

Warning about injuries caused by hoses spinning around, swirled-up dust and movement of the
pneumatic drives.
WARNING  Shut off and disconnect the compressed air supply.
Version 1.1.17 212

Danger of injury if safety devices are not working properly!

If safety devices are no longer installed or are not in good working order, there is the danger of serious
injury.
WARNING  Never switch on the machine without safety devices that are installed and are in a full working
order.

The different tasks described in this instruction make different demands against the qualification of
people, who are entrusted with these tasks.
Danger if the personnel is insufficiently qualified!

Electricians
Electricians are able, on account of their professional training, knowledge and experience, and
knowledge of the relevant standards and provisions, to carry out work on electrical systems and they
can independently identify and prevent possible hazards.
Electricians are trained specifically for the field in which they work and they are familiar with the
relevant standards and provisions.
Trained experts
Trained experts are able, on account of their professional training, knowledge and experience, as well as
knowledge of the relevant standards and provisions, to carry out the tasks which are assigned to them
and they can independently identify possible hazards and prevent hazardous situations from arising.
Manufacturer
Certain pieces of work may only be carried out by specialist personnel from the manufacturer. Other
personnel are not authorised to carry out this work. To arrange for the required work to be carried out,
contact our customer service department (See chapter 11 Support and Customer Service).
Version 1.1.17 213

9.3 Dismantling the product

Before the start of the dismantling:
– Switch off the LaserCUSING® machine and secure it against reactivation.
– Shut off and disconnect the inert gas supply.
– Shut off and disconnect the compressed air supply.
– Clean the LaserCUSING® machine completely of all powder residues.
Clean in particular the build module with powder chamber, build chamber and coater.
Clean the process chamber.
Clean the filter module.
– Physically disconnect the entire energy supply from the machine and discharge any stored residual
energies.
– Remove any operating materials and consumables and dispose of them in an environmentally
friendly manner.
Then dismantle assemblies and parts in a professional way in compliance with the relevant local
occupational health and safety and environmental protection regulations.
Note
Consult the separate operating manuals of the respective manufacturers for details of the maintenance
instructions for the components from suppliers.
9.4 Storage
In order to keep a machine which is not protected in working order over a prolonged period of time, the
following conditions must be met:
– Storage location: The place of storage must be clean and dry.
– Storage temperature: +15 - + 35 °C
– Temperature change: max. 2 °C
– Relative atmospheric humidity: max. 80 %
– Place the machine or machine parts on a flat base in order to prevent warping.
– Secure the machine or machine parts to prevent tipping over and unintentional start up.
– Clean the machine completely and protect exposed metal parts from corrosion.
– Cover the machine or machine parts in order to avoid dust and dirt deposits.
Version 1.1.17 214

9.5 Disposal of the Product

If no return or disposal agreement has been made, dismantled components should be recycled:
– Dispose of the used powder as hazardous waste.
– Scrap metals.
– Take plastic elements for recycling.
– Sort and dispose of the remaining components according to their material properties.
Note about the danger to the environment!

Incorrect disposal can cause environmental hazards.
 Have any waste electrical products, electronics components, lubricants and other auxiliary
materials disposed of by approved specialist companies.
 If in doubt, you can obtain information about environmentally friendly disposal from your local
municipal authority or specialist waste disposal companies.
Version 1.1.17 215

10 Accessories, wearing and spare parts
10 Accessories, wearing and spare parts

Loss of a guarantee!
When you replace defective components, they should be replaced exclusively by original parts with the
same mechanical data as otherwise safety and correct functioning are no longer guaranteed.
This also applies to accessories and attachments.
For orders of spare parts and accessories our service is at your disposal:
Address Concept Laser GmbH
Department Customer service
An der Zeil 8
Adress
96215 Lichtenfels
Telephone +49 9571 1679 444
Fax +49 9571 1679 499
E-Mail service@concept-laser.de
Internet www.concept-laser.de
Version 1.1.17 216

11 Support and Customer Service
11 Support and Customer Service

Our customer service department is available to provide you with any technical information you
may need.
Address Concept Laser GmbH
Department Customer service
An der Zeil 8
Adress
96215 Lichtenfels
Telephone +49 9571 1679 444
Telefax +49 9571 1679 499
E-Mail service@concept-laser.de
Internet www.concept-laser.de
In addition, we are always interested in receiving information and experience which are produced from
use of the machine and may be valuable in helping us to improve our products.
Version 1.1.17 217

12 Table of figures
12 Table of figures
Figure 2-1: Location oft he emergency stop switch ................................................................................................................................ 19
Figure 2-2: Location of the main switch ...................................................................................................................................................... 20
Figure 2-3: Safety notices on the machine (front view) ......................................................................................................................... 22
Figure 2-4: Safety notice on the machine (detailed view of the filter module) ............................................................................ 23
Figure 2-5: Safety notice on the machine (rear view closed) .............................................................................................................. 23
Figure 3-1: Front view with closed handling and process stations ................................................................................................... 29
Figure 4-1: Example part 1 ................................................................................................................................................................................ 30
Figure 4-6: Absorption ........................................................................................................................................................................................ 31
Figure 4-7: Spontaneous emission ................................................................................................................................................................ 31
Figure 4-8: Stimulated emission ..................................................................................................................................................................... 31
Figure 4-9: Characteristic structure of laser active medium, mirrors and pump source ......................................................... 32
Figure 4-10: Front view with the handling and process stations closed ........................................................................................ 33
Figure 4-11: Rear view (model displayed: dual laser) ............................................................................................................................. 34
Figure 4-12: Overview of the process station ........................................................................................................................................... 36
Figure 4-13: Overview of the process chamber ........................................................................................................................................ 37
Figure 4-14: Overview of the handling station .......................................................................................................................................... 38
Figure 4-15: Overview Glove box .................................................................................................................................................................... 39
Figure 4-16: Overview of the build module (working surface) ............................................................................................................ 40
Figure 4-17: Overview of the build module (bottom) ............................................................................................................................. 41
Figure 4-18: Overview of the laser system (model displayed: single laser) ................................................................................... 43
Figure 4-19: Overview of the filter module with solid piping of the process gas circuit........................................................... 44
Figure 4-20: Overview of the pneumatic plate ......................................................................................................................................... 45
Figure 4-21: Overview of the control panel ................................................................................................................................................ 48
Version 1.1.17 218

13 Maintenance record
13 Maintenance record
Stamp /
Date Monthly Half-yearly Annually Maintenance work carried out
Signature
Version 1.1.17 219

Suggestions
Suggestions
We are constantly seeking to improve our products and the information provided with our products.
If when operating the M2 cusing LaserCUSING® machine or when working with this operating manual
you have any questions or suggestions in relation to it, please copy this page, fill it in and send or fax it
to:
Concept Laser GmbH,
An der Zeil 8
D-96215 Lichtenfels
Fax: +49 (0) 9571 / 1649-499
Email: info@concept-laser.de
Sender:
Company::
Street:
Postcode/ City:
Tel. / fax.
Error on page(s): . . . . . . . . . . . . to . . . . . . . . . . .
Remark:
Suggestion for improvement on page (s): . . . . . . . . . . . to . . . . . . . . . . . .

Comment:
Version 1.1.17 220

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 M2 cusing installation manual

Concept Laser GmbH

© Concept Laser GmbH 2017

2 General safety instructions ...................................................................................4

3 Technical data ....................................................................................................... 26

4 Structure and function ........................................................................................ 30

5 Transport, installation and initial commissioning .......................................... 52

Version 1.1.17 iii

6.15 Observing the build process ........................................................................................................ 109

7 Faults .................................................................................................................... 133

8.4 Cleaning the LaserCUSING® machine ..................................................................................... 159

9 Dismantling, storage and disposal .................................................................. 212

10 Accessories, wearing and spare parts ............................................................. 216

11 Support and Customer Service ........................................................................ 217

12 Table of figures ................................................................................................... 218

13 Maintenance record ........................................................................................... 219

1.1 Purpose of the operating manual

1.2 Storage of the operating manual

1.3 Conventions of presentation and explanation of symbols

Danger Immediate hazard with a high risk.

Structure of the safety instuctions

List of warning symbols used

Warning about a danger spot Warning about the risk of squeezing

Warning about dangerous electrical Warning about potentially explosive

Warning about laser radiation Warning about the risk of slipping

Warning about harmful and irritant Warning about flammable substances

Warning about hand injury

 Indicates the consequence of an action

–,,▪ Bullet point

1.4 Indication of liability

1.5 Copyright protection

1.6 Figures and drawings

2 General safety instructions

2.1 Designated use

2.2 Improper use

2.3 Basic safety instructions

2.3.1 Dangers posed by electrical energy

Danger posed by stored charges!

2.3.2 Dangers posed by pneumatic equipment and inert gas supply

Danger posed by compressed air!

2.3.3 Dangers posed by explosion and fire

Danger of explosion from formation of oxyhydrogen!

Danger of fire from highly flammable substances!

2.3.4 Danger posed by laser radiation

2.3.5 Dangers posed by mechanisms

Danger of injury from squashing on the build module!

Hand injury caused by squashing on the coater!

Hand injury caused by cutting on the coater blade!

2.3.6 Dangers posed by harmful, chemical substances

Danger of damage to the skin from contact with metal powders!

2.3.7 Dangers posed by high temperatures

2.3.8 Gerneral dangers at the workspace

Danger of injury from slipping on metal dusts!

2.4 Responsibility oft he operator

2.5 Qualification oft he personnel

2.6 Handling reactive metal powders

2.6.2 Rules of behaviour when handling reactive materials

2.6.3 Appropriate storage

2.7 Personal protective equipment

Protective work clothing

Chemical-resistant protective gloves