Magics Software

Magics Software

LaserCUSING

Version: 08 / 2011 2 / 29 www.concept-laser.de

Contents

1 Important fundamental information ............................................................................ 3 1.1 Introduction .................................................................................................................... 3 1.2 Accompanying documents .......................................................................................... 3 1.3 Storage ........................................................................................................................... 3

2 Safety ......................................................................................................................... 4 2.1 Intended use .................................................................................................................. 4 2.2 Basic safety instructions .............................................................................................. 4 2.3 Operators duties of care ............................................................................................. 5 2.4 Requirements placed on the operating, maintenance and repair personnel ...... 6 2.5 Conventions used in this software reference ........................................................... 6

3 3D-Software Magics ................................................................................................... 7 3.1 Reading the 3D data record into the Magics software ............................................ 7 3.2 Correcting errors in the STL part .............................................................................. 10

3.2.1 Missing triangles .................................................................................................. 10 3.2.2 Inverted / double triangles .................................................................................. 10 3.2.3 Transverse triangles ............................................................................................ 11 3.2.4 Component fixing information ............................................................................ 11

3.3 Positioning for the construction process ................................................................. 13 3.4 Construction of the support without support generator ......................................... 14 3.5 Generating the support with support generator ..................................................... 20 3.5.1 Choose manual or automatic support creation ................................................... 20 3.5.2 XY Offset ................................................................................................................... 21 3.5.3 Hatching .................................................................................................................... 21 3.5.4 hatching teeth / borderline teeth ............................................................................ 22 3.5.5 Fragmentation .......................................................................................................... 22 3.5.6 Perforation ................................................................................................................ 23 3.5.7 Machine library ......................................................................................................... 23 3.5.7.1 Select machine ..................................................................................................... 24 3.5.7.2 Edit parameters .................................................................................................... 24 3.6 Job preparation dental parts ..................................................................................... 25 3.6.1 Supports .................................................................................................................... 25 3.6.2 Slicen ......................................................................................................................... 26 3.6.3 Import the parts ........................................................................................................ 26 3.6.4 Exposure parameter ................................................................................................ 27 3.6.5 Heat treatment ......................................................................................................... 28


1 Important fundamental information

1.1 Introduction

This software reference describes the Magics 3D software. The Magics 3D software is used to prepare the CAD data for the LaserCUSING

component to be produced for the construction

process). The Magics software runs on a standard PC.

This software reference is intended for the operator and user of LaserCUSING machines.

It may also be used as the basis for training the appropriate personnel.

Warning about personal, material and environmental damage! This software reference is valid EXCLUSIVELY in conjunction with the operating manual of LaserCUSING machines.

The procedures and illustrations are examples and may differ from the version installed we reserve the right to make changes. The version which is installed can be seen on the title bar of the respective main graphics window. In the first year updates from CONCEPT Laser GmbH are free of charge; thereafter they are by agreement.

The Magics software is a registered trademark of the company Materialise N.V. and may be registered in different countries. All rights reserved.

Microsoft and Windows are trademarks or registered trademarks of the Microsoft Corporation in the USA and other countries.

Licensed material property of IBM. L-GHUS-5RWNPF Copyright IBM Corporation 1985, 2004. All rights reserved. IBM, the IBM logo, Lotus and Domino are trademarks of the IBM Corporation in certain countries.

Java and all Java-based trademarks are trademarks of Sun Microsystems Inc. in certain countries. All other trademarks are trademarks of the respective companies which own them.

1.2 Accompanying documents

The following documents apply together with this software reference:

Operating manual LaserCUSING machines.

Manual for Magics 3D software

1.3 Storage

The software reference must be stored so that it is at hand at all times close to the M1 cusing machine!


2 Safety

2.1 Intended use

The Magics 3D software is used exclusively to prepare the CAD data for the LaserCUSING

component to be produced for the construction process.

Any other use or use which extends beyond this is deemed not to be intended. The person operating or controlling the machine is responsible for all damage which is caused by non-intended use!

Intended use also includes: reading this software reference and complying with all of the instructions contained within it, in particular the safety instructions.

Warning about personal, material and environmental damage! If the software is NOT used in accordance with these provisions, safe operation is NOT guaranteed! Non-intended use or arbitrary alteration of the software shall cancel any liability on the part of CONCEPT Laser GmbH for any damage resulting from this. This software reference is valid EXCLUSIVELY in conjunction with operating manuals of LaserCUSING machines.

2.2 Basic safety instructions

The safety instructions are intended to prevent any injuries to people and the environment.

All operators are obliged to read these safety instructions and to follow them at all times.

Warning about personal, material and environmental damage! Use the software EXCLUSIVELY to fabricate LaserCUSING components. The SAFETY INSTRUCTIONS in the manuala of LaserCUSING machines must be complied with AT ALL TIMES. Do not make any modifications to the software: if any unauthorised modifications are made, the conformity declaration for the LaserCUSING machines will become invalid!


Liability disclaimers:

CONCEPT Laser GmbH does not accept any liability for personal, material, environmental and / or operational damage caused by the software reference not being complied with or not being complied with in full.

If unauthorised alterations are made, the guarantee shall be cancelled.

Guarantee and liability claims for personal, material and environmental damage shall be excluded if they can be attributed to one or more of the following causes:

non-compliance with the instructions given in the software reference,

non-intended use of the software reference.

Please consult our general terms of delivery or your contract documents for details of the guarantee.

2.3 Operators duties of care

The software is state of the art and guarantees a high level of safety.

The operator must ensure in particular that

the software is only used as intended (see Section 2.1 Intended use).

the software is only operated in perfect, working condition. If any errors are identified in the software, or if safe operation cannot be guaranteed for other reasons, the LaserCUSING machines may only be put back into operation after the errors have been corrected. You should also contact our customer service team if you notice any faults or defects during operation or suspect that the software is not working properly.

the software reference is always available in a legible format and in full to the operating personnel at the place where the LaserCUSING machine is used.

only suitably qualified and authorised personnel operate and maintain the software.

these personnel regularly receive instruction on all the relevant matters of industrial safety, and also that they are aware of and follow this software reference and in particular the safety instructions which it contains.


2.4 Requirements placed on the operating, maintenance and repair personnel

Warning about personal, material and environmental damage! The software may only be operated by trained personnel who have been authorised to do so by the operator. The responsibilities of the personnel for the different activities they undertake in operating the software must be laid down in writing and complied with, so that no unclear areas of competence can arise from the point of view of safety. Any person who is asked to operate the software and its components must have read and understood the software reference. The operator is advised to have the operating personnel confirm in writing that they are aware of the details contained in the software reference. Operating personnel who work with the software must have been instructed on how the software operates and the safety precautions. The operator should have this instruction confirmed in writing.

2.5 Conventions used in this software reference

Cross-references and proper names are printed in italics in this software reference.

Note:

This symbol indicates information which should particularly be noted or helps to improve understanding.


3 3D-Software Magics

The Magics 3D software is a data processing program. The components here first need to be read in in 3D CAD format (file *.stl). After possible data record repair and construction of the support (component support construction), the layer data (slices) are generated for the LaserCUSING

process.

This slice data record which is generated (file *.cls, CONCEPT Laser slice file) can now be transferred to the ConceptLaser machine software (see Chapter 4 Part II ConceptLaser machine software).

X, Y and Z denote the spatial axes for the LaserCUSING

components in the Magics 3D

software and the ConceptLaser machine software. U, V and W denote the moving axes of the construction module. Please see the Magics 3D software manual for further details.

3.1 Reading the 3D data record into the Magics software

After opening the Magics 3D software and reading in the STL part, this is displayed on the screen. The position in the coordinates system is taken from the construction data.

Fig. 1: Magics standard screen


With the command Move to default position, the component is placed against the coordinate axis in the positive range.

Fig. 2: Move part(s)

The component is then aligned in accordance with the coordinate axes. In addition, a flat surface is marked on the component with which it should stand on the construction plate command Bottom

surface/Top surface (see Figure 3).

Fig. 3: Base surface/Top surface


With the aid of the Aline menu, the component is aligned on the axes. Then place the component against the coordinate system with Move (see Figure 4).

Fig. 4: Correct positioning of the component

At this point, you should save in the following way:

The STL part, here Pleuel.stl, should be cancelled in its original state and saved under the component name. The format used for saving can be *.stl or the more compact *.Magics.


3.2 Correcting errors in the STL part

Typical errors in the STL part include:

Missing triangles

Inverted triangles or double triangles

Transverse triangles in the component

3.2.1 Missing triangles

Fig. 5: Missing triangle

3.2.2 Inverted / double triangles

Fig. 6: Inverted or double triangle


3.2.3 Transverse triangles

Fig. 7: Transverse triangle

3.2.4 Component fixing information

Under Component fixing information certain errors can be displayed.

Fig. 8: Component fixing information menu


The following values should be checked here:

Open edges

Open contours

Shells

Open edges or Open contours must display the value 0 after repair.

Shells means surfaces. For example, if the component is a solid ball, it has one surface. If the ball is hollow, it has two surfaces. In our training example, the connecting rod has one surface, not five (see Figure 8).

3.2.5 Component repair

Components are repaired using the repair assistant with the repair combination (see Magics 3D software manual).

If the repair is not successful, individual triangles can be inverted, deleted or the appropriate holes can be filled.


3.3 Positioning for the construction process

It is essential that the following points are noted in order to position the component for the construction process:

Little support construction volume

No relatively long edges parallel to the blades

Allow blades to run up to the component over a corner

Run over narrow sides of the component

Provide support to release the component from the construction plate.

The figure shows the optimum position for the component.

Fig. 9: Position for constructing the support

In the example here, the component is rotated by 45 on the Y axis.

Important: First rotate in the Y direction, then rotate about the Z axis! Then return the component to the Standard position and move upwards by an

appropriate amount in the Z direction in order to be able subsequently to release the component from the construction plate (e.g. 0.5 mm for a wire-cutting machine).

Temporarily save at this point (Pleuel.stl)!


3.4 Construction of the support without support generator

All surfaces at an angle of less than 45 to the construction plate must be supported!

Mark the surfaces.

Fig. 10: Marking the surface to be supported

Extend the surfaces down with the command Extrude

Fig. 11: Extrude menu

Then cut off the component at the height of the construction plate (first in the Sections view, then

with the Cut function) and remove the lower part.


Fig. 12: Part construction of the support

The support construction now features a very thin web which in some circumstances may cause problems during production.

This web can be enlarged again by 10 mm with an Extrude command.

Fig. 13: Enlargement of narrow webs in support

After extrusion mark and delete the front side, cover surface and corresponding triangles of the side area, and use the Gen. triangle (Generate triangle) and Fill holes function to close the surface.

Fig. 14: Optimised support


A support construction now needs to be introduced into the hole. Horizontal holes or cooling channels may be constructed with a diameter of up to 8 mm without internal support construction.

Therefore reduce the hole to 8 mm with a support construction and introduce a step of 0.1 mm in order to lift the original part up from the support:

Delete inner generated surface of the hole. Autofill holes for the two hole surfaces. Provide the resulting marked surfaces with an offset of -0.1 mm on the inside.

Fig. 15: Offset

Use the Standard geometry function to generate a cylinder with a diameter of 8 mm, the same length as the hole or slightly more (15 mm) and a tolerance of 0.01 mm. Use the Arrange function to position the cylinder in the middle of the previously closed hole. Remove the cylinder from the component with the Boolean function.

Fig. 16: Support for a hole greater than 8.0 mm in


Important:

Save the component under the name Pleuel_Sup.stl not under Pleuel.stl!

There are two options here:

The component is fused to the support it is an STL part. Component and support can only be constructed with the same parameters.

If the support should be an autonomous STL part, the part Pleuel.stl (part positioned, but without support construction) must be called up and removed from the part Pleuel_Sup.stl with the Boolean function.

The original part may need to be provided in advance with an offset of approx. 0.02 mm in order to be able to carry out the Boolean operation smoothly.

Save the remaining support under Pleuel_Support.stl.

Fig. 17: Support volume (without component)


3.4.1 Slice generation with the ConceptLaser slicer

The component can now be sliced into slices of typically 30 m with the predefined slice parameter sets.

Fig.18: Parameter menu of the ConceptLaser slicer with cusing standard parameters Slice thickness Layer thickness Beam compensation Distance between the island structure and the original contour Skin core Subdivision of the surfaces in the inner and outer area Additional contours Flush termination of the lasered contour with respect to the

component contour or allowance generation Islands Size of the exposure vectors.

(An island rotation of 45 avoids exposure vectors parallel to the coater blades)

Important:

The subdivision into inner and outer surfaces may not be applied with cooling channel parts as even powder application is then not guaranteed!


Fig. 19: Illustration of the spacings of the laser paths

original conture part

beam compensationborder of the island structure

additional conture inside

end of calculated laserway

a

b

c

conture drive

filli

ng v

ecto

res o

f th

e isla

nds


3.5 Generating the support with support generator

The following support settings create very fine support structures which can be removed very easy. Please note that this support can only be build up with a flexible coater blade. The coater speed has to be adapted for the flexible blade (should be 50% of the standard setting for a steel blade). All parameters have to be adapted to the part size and part form.

3.5.1 Choose manual or automatic support creation

Fig. 20: part with block support

Mark the proper surfaces and choose block support.

Fig. 21: choose support type


3.5.2 XY Offset

As smaller the parts are, as smaller the value can be. The maximum value should not be bigger than 0,3mm, the standard setting is 0.

Fig. 22: choose offset parameter

3.5.3 Hatching

The setting 2 mm in X and Y has the best results. The right rotation angle is 45 degrees.

Fig. 23: choose hatching parameter


3.5.4 hatching teeth / borderline teeth

As bigger the teeth are, as smaller the connection to the part can be set. Following you see the standard settings.

Fig. 24: choose teeth parameter

3.5.5 Fragmentation

The adjustments for the fragmentation correspond to the hatching parameters. 2mm in X and Y create small crosses. The gap between of these crosses is the separation width factor 0,3mm. It is also possible to fragment the borderlines. If you combine both possibilities the separation width factor should be smaller than


3.5.6 Perforation

The value for the beam varies between 0,7 and 0,9mm. This depends on the material. The height is the start height for the perforation. These settings can be changed in the machine library (see later point 8). The solid height is the distance between the perforation and the teeth to the part. Our experience shows that 1mm is a secure value.

Fig. 26: choose perforation parameter

3.5.7 Machine library

All these settings can be predefined and saved in the machine library.



3.5.7.1 Select machine

Select your machine and edit the parameter.


3.5.7.2 Edit parameters

In the shown folders all settings can be done.



3.6 Job preparation dental parts

3.6.1 Supports

Fig. 30: dental part with block support

A block support is used for the parts (see figure). The relevant parameters are:

Hatching (x,y): 1mm

Fragmentation (x,y): 0,5mm

XY_Offset: variegate between 0,1 and 0,8 according to the model/geometry (in doubt less or 0,1)

no borders

It is convenient to place a diminution at the top with the following parameters:

high 2mm

top length 0,4mm

fragmentation 1,0mm

Alternatively the pillars could be minimised, so that the connection could be minimised too (hatching 0,7mm).


3.6.2 Slicen

Slicing in Magics the additional contour inward has to set up to 50m.

M1cusing Mlabcusing

Fig. 31: slice parameters dental parts

3.6.3 Import the parts

Monomial bridges shall be built without islands. Therefore the option open without islands must be chosen (only software 9 old version). For multi-unit bridges it is advise to build with islands to minimise the deformation.

Fig. 32: Open dental parts


3.6.4 Exposure parameter

The following pictured parameter must be used.

Fig. 33a: laser parameter dental parts M1Cusing


Fig. 33b: laser parameter dental parts MlabCusing

3.6.5 Heat treatment

In order to avoid stresses and deformations after taking the building plate it is mandatory to heat-treat multi-unit bridges/crowns. Parameters therefore are: Material treatment gas heating up holding cooling down

remanium star CL

tension arm argon 400C/h 1150C, 1h down to 300C in the oven, than outside (6h from 1150C to 300C)


CONCEPT Laser GmbH An der Zeil 8

96215 Lichtenfels Deutschland

T: +49 (0) 9571 / 1679-0 F: +49 (0) 9571 / 1679-499

[email protected] www.concept-laser.de

2011

All rights are retained by CONCEPT Laser GmbH, even in the event of property right applications. All

powers of disposal, such as copying and forwarding rights, are retained by CONCEPT Laser GmbH.

Printed in Germany

Magics Software

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