Buildstation 5.0 Release Notes - 3D Systems

Release Notes—Buildstation 5.0 SLA Control Software

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Buildstation 5.0 Release Notes

Welcome to Buildstation 5.0

Buildstation 5.0 is 3D Systems’ newest version of SLA controlsoftware for SLA 350, SLA 500, SLA 3500, SLA 5000, as well asour new flagship platform, the SLA 7000. Buildstation 5.0, withessentially the same user interface as its predecessor,Buildstation 4.1.1, fixes some program defects and builds onthe powerful functionality of version 4.1.1 by adding new powerand convenience in features like:

ü Smaller BFF files. The new build file eliminatesredundencies within the file structure that allows BFFfiles that are from one-half to one-tenth the size ofMaestro build files.

ü Integrated motion control dialog.ü More compact and easier to use logging, including

automatic purging.ü Support for the high-power SLA 7000 dual spot size

laser....And, much more.

IMPORTANT NOTE!

Buildstation 5.0 accepts only BFF build files produced by thecorresponding release of SLA file preparation, 3D Lightyear 1.0.Maestro-produced BFF build files require the SLA system to berunning Buildstation 4.x. For that reason, upgrade customersshould follow the Installation Instructions for Buildstation 5.0carefully. Doing so, preserves the copy of Buildstation 4.x sothat if the need should arise, it will be available for running filesprepared with Maestro.


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Supported Operating Systems

The Buildstation 5.0 SLA Control software runs equally wellunder Windows NT® 3.51 with Service Pack 5, andWindows NT 4.0 with Service Pack 3 or higher. Support for bothOSs allows users with NT 3.51 to be able to upgrade to the newcontrol software without having to also upgrade toWindows NT 4.0.

Both Windows NT 3.51 with Service Pack 5, and Windows NT4.0 with Service Pack 4 have been declared “Year 2000 Compli-ant” by Microsoft®. Customers who want to upgrade to WindowsNT 4.0, should contact 3D Plus Customer Service for moreinformation.

System Requirements

Customers using SLA 500 sytems with a i486-based controllerwith at least 32MB of RAM and running Windows NT 3.51,should be able to run Buildstation 5.0. Generally, if a systemcould run Buildstation 4.1.1, it should be able to runBuildstation 5.0.

Major Program Changes

Below we list several significant changes in Buildstation 5.0compared with Buildstation 4.1.1.

Improvement in System Logging Functions

With Buildstation 5.0 we have modified the user-accessiblelogs as well as the diagnostic logs. BuildLog has been removedfrom the database, since its existence contributed to the data-base’s growing to unmanageable sizes over time— a familiarcomplaint of users of earlier versions of Buildstation. Now, asusers have requested, build log information is available as areadily accessible text file.


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Much of the old configurable logging has been removed tostreamline the interface. It has been replaced with self-purgingbinary system logs. The new logs work continually without userintervention. These logs allow 3D Systems to diagnose problemseven weeks after they’ve occurred with minimal customerinteraction, and will allow better preventive maintenance proce-dures in the future.

Streamlined User Interface

The following items have been removed from the user interface.

ü Set Elevator Start Position dialogü Event Logging dialogsü Laser Logging dialogsü Smart Laser Powerü Stir resin (from the toolbar)

System Licensing

Unlike previous versions of the control software which were notlicensed, we have implemented licensing for Buildstation 5.0.The software is licensed per site, therefore, once your siteobtains the software, you may install and license it on all the SLAsystems you own. Buildstation 5.0 desktop does not require alicense to run.

Software Defects

Buildstation 4.1.1 had, as does all software, a few softwaredefects, many of which have been corrected withBuildstation 5.0. Specifically, it corrects:

ü Sweeping fully, to the front or back of the machinecontinually while Smart Sweeping

ü Resin Parameter and Blade Gap problemsü Waiting for layer endü Database growing too large

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Other Changes

Other changes have been made to improve the performanceand usability of the software. Some examples are:

ü The Motion Control dialog has been rewritten tointegrate all motion related dialogs. Recovering fromblade crashes, setting start position, and serviceactivities can now be performed with a single visit to thisdialog.

ü Build Time Estimator rewritten for higher accuracy.ü SLA Performance Dialog has been rewritten to allow

saving and loading of a machine’s performancecharacteristics. This allows better preventativemaintenance, and allows desktop build time estimates tohave high accuracy by using the performancecharacteristics from the machine where the building willoccur.

ü Improved build sequencing, which incorporates flexibilityin power setting and various delay times.

ü “Delayed” build function which allows you to specify whattime you want the build to start.

ü Build options that are dignostic in nature have beenremoved from the standard interface. The “AdvancedBuild Options” checkbox in the “Customize...” dialogunder the “Setup” pulldown allows access to the full setof options.

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Outstanding Issues

The following lists the known issues in this release ofBuildstation 5.0, and specifies workarounds where available.We are always striving to improve our products. If you find aproblem with the software, or have a suggestion for an enhance-ment, please e-mail your request or suggestion [email protected].

Running Buildstation from a Non-Administrator User Account

There have been reported problems during Beta testing whenBuildstation 5.0 is run from a user account that does not haveAdministrator priviledges. In these situations, the Main window iscompletely inactive, although the clock on the status bar contin-ues running.

Workaround: Run Buildstation 5.0 from a user account that hasAdministrator privileges. Contact 3D Plus Customer Support ifthis solution is not practical.

Part Positioning

In the part positioning dialog, the spacing between parts some-times reverts to 0.25 inches even though the user has specifieddifferent spacing.

Workaround: Avoid changing the spacing between parts.

Build Time Estimates

The Build Time Estimates for Buildstation 5.0 running on an SLA7000 can be very accurate. Unfortunately, they can also rangeas high as ±20% error. Our Engineering Department is con-stantly refining the algorithm to improve accuracy. As ourdatabase of builds expands, the Estimator function will improve.We will be forwarding patches to the estimator to the installeduser base as they become available.


6© 1999 3D Systems. All rights reserved. P/N 22135-C04-00 July 1999

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Buildstation Version 5.1 Release Notes and Installation Instructions

Buildstation� 5.1 Release Notes andInstallation Instructions

Overview

Buildstation 5.1 software succeeds Buildstation 5.0 software as the SLA® control softwarefor SLA350, SLA3500, SLA500, SLA5000, and SLA7000 systems running the WindowsNT operating system.

The Buildstation software allows the user to set up and start build jobs on the SLAmachine. Once a job is started, the Buildstation software interprets the build (.BFF) fileproduced by the 3D Lightyear� Build File Preparation Software, and controls the SLAsystem during the building process.

Enclosed you will find information on:

� Compatibility with previous versions of software and hardware

� New features and functions in the Buildstation 5.1 software

� Installation and licensing of this software

Please read these instructions carefully before attempting to install or use the software.

Compatibility

To install this software, your SLA system must:

� Be running the Microsoft® Windows NT 3.51 with Service Pack 5 or Windows NT 4.0with Service Pack 4 operating system on the SLA system controller.

Buildstation 5.1 software accepts .BFF files from either 3D Lightyear 1.0 or 3D Lightyear1.1 software. It will not accept .BFF files from Maestro file preparation software.

Changes and Additions in Buildstation 5.1 Software

Most changes in the Buildstation 5.1 software are transparent to the user. There is nosignificant change to the user interface, and therefore users familiar with Buildstation5.0 software should have no difficulty in transitioning to Buildstation 5.1 software.


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The most important change is that Buildstation 5.1 software accepts .BFF files with thenew FinePoint� Supports, which are produced by the 3D Lightyear 1.1 software. The3D Lightyear 1.1 User�s Guide Addendum and 3D Lightyear 1.1 Online Help Systemfully describe the new support structures.

Tip!

With very complicated geometries it is best to turn off the views that are displayed in theIMAGE region in the lower left portion of the Buildstation screen because refreshing the screenuses some of the CPU time and can slow down the build. FinePoint supports are constructedusing many tiny vectors, so BFF files in which FinePoint supports were generated may alsobuild more quickly with these views disabled.

To disable the views, click with the right mouse button in the IMAGE region and select Setup.In the View Setup dialog box, deselect each of the Visible checkboxes and then each of theEnabled checkboxes.

Beyond that, Buildstation 5.1 software incorporates new code for controlling Z-axismovement on the SLA7000 system and updated electronics on SLA3500 and SLA5000machines, improves some field service diagnostics, fixes various software defects,and includes the feature and function changes that are listed below. Please see theBuildstation 5.1 User�s Guide Addendum for more information.

Upfacing & Downfacing Surface Finish

Select either Standard Surface Finish (Maximum Throughput) or Best SurfaceFinish in the Customize dialog box. The Best Surface Finish option will eliminatethe lines that occur tangential to holes and bosses on upfacing surfaces, but does resultin a throughput penalty.

Platform Drawing Sequence

The default drawing sequence for each layer is to draw the border vectors for all parts,then draw the hatch vectors for all the parts, and then the fill vectors for all parts, etc. Ifyou wish to draw border, hatch and fill vectors for one STL file or copy before proceedingto the next component, click the Complete each component before drawing thenext option in the Customize dialog box. For some build styles, on the SLA7000 andSLA5000 systems, enabling this option results in significantly longer build times.

Restart Position Selectable

The user can now input the restart layer value. Be sure to input a value that is withinthe build range of the part.

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Build Status Recorded to Disk

The system now writes build history and status files (BuildLog.txt and Status.txt) tothe C:\Winsla5\Output directory on the hard disk. These files can be used to monitorthe SLA system.

Bug Fixes

Buildstation 5.1 software corrects various defects from the Buildstation 5.0 software,including changes to scanning on the SLA7000 which improve sidewalls on long, straightsections, modifications to vat stirring, and corrections to InterHatch Delay timing.

Outstanding Issues

There are very few known remaining issues with the Buildstation 5.1 software.

� Daylight Savings Time Adjustment�If the SLA control computer is set to automaticallyadjust for Daylight Savings Time, and a build is in progress during the time change, thebuild will possibly fail, and the log files will be corrupted.

Workaround: Do not set the automatic daylight savings time adjustment setting on thecomputer that is running Buildstation software. The time can later be adjusted manuallywhen it is convenient, and the machine is not building.

� Build Time Estimator�The build time estimator yields inconsistent results. The causeof the erratic performance is under investigation..

Installing Buildstation 5.1 Software

As with most Windows programs, Buildstation 5.1 has an automated setup routine.During installation, this setup routine checks on your system, asks a series of questionsabout how you want to configure the Buildstation 5.1 software, and, based on youranswers to these questions, copies several files to the SLA system�s hard disk. It thendecompresses the files, writes data to areas of your system�s registry, and createsshortcuts to the program in the Windows Start menu or Program Group.

Your SLA system may be running Windows NT 3.51 or Windows NT 4.0. Buildstation5.1 software runs equally well with either operating system. Regardless of whichoperating system is running, the installation steps are the same. The followinginstructions will serve as instructions for both operating systems.


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Note!

At this time, 3D Systems does NOT recommend using the Windows NT Add/RemovePrograms functionality to uninstall old versions of Buildstation software as you run the risk ofremoving files that have been tuned or set up for the specific SLA system. Instead you shouldback up several files that are critical to your machines calibration and operating parametersand then delete the old directory as described below.

Uninstalling Buildstation 5.0 Software

1. Back up the params.dat file from the C:\WinSLA5 directory and any.GEO and .CAL files from the C:\WinSLA5\Config folder. Place themin a folder that is not in the C:\WinSLA5 directory structure such asC:\Backup.

Warning!

You must back up these files before continuing, or you run the risk of eliminating files that arecritical to your machine�s calibration and performance.

2. Delete the entire C:\WinSLA5 directory structure using eitherWindows NT Explorer or File Manager.

Installing the Software

Important!

Before you begin installing Buildstation 5.1 software, make sure that you have created a backup copy of params.dat and all of the .CAL and .GEO files as suggested in the �UninstallingBuildstation 5.0 Software� section.

Note!

If you normally use a virus protection program on your PC, turn it off, or override its monitoringof the system before installing Buildstation 5.1. After Buildstation 5.1 installation is complete,you can restart the virus protection program.

1. Insert the CD labeled �Buildstation 5.1 SLA Control Software for 350/500/3500/5000/7000 Systems� into the CD-ROM drive of the SLAsystem.

2. If you are running Windows NT 3.51, go to the Windows ProgramManager, and click File>Run.

If you are running Windows NT 4.0, click on the Windows Startbutton, in the lower-left corner of the Windows Taskbar then clickthe Run command.

3. Click inside the Open box and type the command �D:\Setup.exe�

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where D is the letter designation for your CD-ROM drive.(Alternatively, you can use the Browse button to browse to theSetup.exe file.) Click the OK button. This launches the Buildstationsoftware setup program.

4. When the Welcome screen appears, click the Next button.

5. When the Choose Destination Location screen appears, notice thatC:\WinSLA5 appears as the default Destination Folder. You can usethe Browse button to change the location of the Buildstation 5.1software installation, if desired. When ready, accept the locationand continue the installation by clicking the Next button. (Note thatif for some reason you did not uninstall Buildstation 5.0 software,you should choose a different directory path for installing Buildstation5.1 software.)

6. When the SLA Machine Selection window appears, click the radiobutton next to your SLA machine type, then click Next. Answer anyother question(s) about your SLA machine that may be presented.

7. When the Select Program Folder screen appears, click Next. Bydefault, this will place a program icon in the Buildstation 51 programgroup to aid in the launching of the program.

8. When the Start Copying Files screen appears, click Next to begin thetransferring and installing the program files.

9. At the conclusion of all activity, the Setup Complete screen appears.Click Finish.

Preserving Your Calibration Files

The next steps are very important in preserving your machine-specific calibration data.

1. Copy the params.dat file that you previously backed up into theC:\WinSLA5 folder.

2. Copy all the .CAL and .GEO files into the C:\WinSLA5\Config folder.

Your software is now installed and you are ready to obtain and install your license file.

Obtaining and Installing Your Buildstation 5.1 Software License

Warning!

DO NOT ATTEMPT TO LAUNCH Buildstation 5.1 until you have installed the correct licensefile. Obtaining a license is a multi-step process. Before starting, make sure you have successfullycompleted the steps to install the software.

1. Open a Command Prompt (DOS window). In Windows NT 3.51, youwill find the MS-DOS Prompt icon in the Main program group ofProgram Manager.


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In Windows NT 4.0, you will find the Command Prompt icon on theTaskbar�s Start menu.

2. Type the command �cd C:\WinSLA5� and press <Enter>. (If you didnot install the software in the default folder, then type in the folderwhere you installed Buildstation 5.1 software instead.)

3. Type the command �lmutil lmhostid� and press <Enter>. Thiscommand queries your system and returns the unique serial number(HOSTID) from your network card.

4. RECORD THE HOSTID CODE. Later, you will install the license fileon this machine. License files are machine-specific. If you areinstalling Buildstation software and requesting license files for morethan one machine, take steps now to be able to identify this machinelater by its unique host identification code.

5. REPEAT Steps 1 through 4 of this procedure for each SLA machinethat will be running Buildstation 5.1 software.

6. Go to the 3D Systems website at www.3dsystems.com and navigateto the Customer Services>Software Licenses page. Type in theAuthorization Code that was included in the software package andclick Next. The Authorization Code must be typed in all capital letters.

Note!

Authorization Codes are specific to machine type, so be sure to match HOSTID codes withappropriate Authorization Codes.

7. In the second screen type in the HOSTID code you obtained fromthe computer. The HOSTID must be entered in lower case letterswith no hyphens or spaces.

8. The license generator will return the text of the license file. Copyand paste it into a text file using Notepad (NOT Wordpad) and saveit as license.dat. Repeat for each machine for which you need alicense. Remember that each SLA machine requires a unique license,so make sure you have a way of distinguishing between them if youobtain multiple licences.

9. Copy the appropriate license.dat file to the C:\WinSLA5 folder foreach machine.

Verify and Complete the Installation of Your New Software

Once the software is successfully installed and licensed, you will have a Buildstation51 program item in your Windows Start menu or program group.

1. If Buildstation 5.1 software is not already open, double-click theprogram icon to launch it.

2. From the menu bar, select Setup > Choose Geometric CalibrationFile�

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3. From the Choose Geometric Calibration File dialog, select and openthe latest .GEO file in the C:\WinSLA5\Config folder.

You are now ready to begin building parts on your SLA system.

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©2000 by 3D Systems. All rights reserved. Specifications subject to change without notice. The 3D logo andSLA are registered trademarks of 3D Systems. Buildstation, 3D Lightyear, and FinePoint are trademarks of 3DSystems. All other products names or services are registered trademarks of their respective companies.PN 22135-N01-00

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Buildstation™ 5.3 Software Release Notes and Installation InstructionsP/N 22135-N12-00

Buildstation™ 5.3 Software Release Notes and Installation Instructions

Overview

Buildstation™ 5.3 software supports the following SLA® systems:

Enclosed you will find information on:• Compatibility between Buildstation 5.3 software and Lightyear™ software

• Functional changes since the release of Buildstation 5.1 and Buildstation 5.2 software

• Issues that have been resolved since Buildstation 5.1 and Buildstation 5.2 software

• Outstanding issues not resolved in this software release

• Installation instructions

Please read these instructions carefully before attempting to install or use the software.

Compatibility

Buildstation 5.3 software accepts BFF files created in 3D Lightyear 1.3, 1.2, 1.1, and 1.0 software versions.Note!

Buildstation 5.3 requires Windows NT 4.0 (Service Pack 3 or higher).

Functional Changes

This section identifies the major feature and function changes between:• Buildstation 5.1 and Buildstation 5.3 software

• Buildstation 5.2 and Buildstation 5.3 software

• Viper si2™ • SLA 500• SLA 350 • SLA 5000• SLA 3500 • SLA 7000

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Please refer to Buildstation 5.3 Control Software User’s Guide Addendum for detailed information.

Changes Between Buildstation 5.1 and Buildstation 5.3 Software• Maximum Fill Speed: Poor surface quality and other build defects can occur when fill

speeds exceed the capability of the scanning mirrors. Fill speeds can no longer exceed the Maximum Hatch Ceiling value displayed on the software screen.

• Viper si2 SLA system: The Buildstation software supports the Viper si2 SLA system. The Viper si2 SLA system uses the BFF file format, which contains all the part build information.

• Post Hatch Delay: The Post Hatch Delay parameter, introduced in the 3D Lightyear 1.2 software, is supported in the Buildstation software.

• Motion Control Dialog Box: The Motion Control dialog has been updated to ensure the vat level reading is more comprehensible and to add functionality to the Viper si2 SLA system.

• Edit Menu Removed: The Edit menu was removed from the software interface.

• And the Changes Between Buildstation 5.2 and Buildstation 5.3 Software, below.

Changes Between Buildstation 5.2 and Buildstation 5.3 Software• Laser Safety Shutter Behavior: The laser safety shutter is now closed by default

when the system is not conducting a build and opens when the system is building. This is the opposite of the previous default open shutter position.

• Preferred Blade Gap: The Preferred Blade Gap value has been added to the3D Lightyear 1.3 software.

• Best Surface Finish: The hatching and filling technique known as Smart BestSurface Finish has been added to the 3D Lightyear 1.3 software, thus providing greater user flexibility and functionality. See the Buildstation 5.3 Control Software User’s Guide Addendum for detailed information.

• You no longer have to keep separate projects on the Viper si2 SLA system for normal resolution and high resolution modes in order to overcome incorrect maximum draw speeds.

• Customize Dialog Box exclusively for Viper si2 SLA system: Default Draw Speed Ceilings for Normal Resolution and High Resolution modes can be set in the Customize dialog box for the Viper si2 SLA system only.

• Performance Characteristics Dialog Box for Viper si2 SLA system:Normal Resolution and High Resolution laser characteristics display in the Performance Characteristics dialog box for the Viper si2 SLA system only.

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• Project Tree BFF Display: The Browse button has been removed from the project tree BFF display. In addition, the BFF display area is no longer editable.

• Laser Hours Display: The laser hours now display in the Status Bar at the bottom of the build screen.

• Customize Dialog Box: Two enhancements have been made in the Customize dialog box for all systems. The descriptions in the On New Jobs and Advanced Build Options sections of the dialog box change to describe the current status of the option.

• The Restart Build Button Renamed: The Restart Build button on the Build toolbar has been renamed to Continue Build.

Resolved Issues

• Supports for SLC files are no longer eliminated from the build file.

• The Preferred Blade Gap value reported from the BFF file has been expanded and now displays four digits.

Outstanding Issues

• Overly descriptive and possibly confusing error messages exist in the Buildstation software. For example, if a build is stopped while drawing a layer, the resulting messages are “Error status of 1 in main loop” and “DSP aborted.”

• On some geometries, you may observe the laser jumping to the rest position during part building.

• In some cases, a Viper system will not prompt to add resin when needed. Eventually a message stating “Limit encountered during leveling. Leveling attempt aborted” may be displayed, but the build will not abort after clicking OK.

• The Current Status area of the Motion Control dialog does not update from a previous action, which can cause confusion.

• A “Layer Thickness Out of Range” error message is displayed when you click past the “Need to Add More Resin” message and continue a build. The build then stops.

• Adjust Resin Volume takes a long time to finish on Viper systems. Seems to take 2 1/2 to 3 minutes to tell you if you need to Add Resin or Remove Resin when you click Adjust Resin Volume, or when you start a build. As a result, wait until you see the laser begin drawing to indicate the build has started.

• On Viper systems only, the Go To Start button is unavailable in the Motion Control dialog when the elevator has not yet been moved to the Home location. To move the

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elevator to the start position, click the Elevator Home button on the main screen of the software and then click Go To Start. This is only true on Viper systems.

• Desktop Buildstation software may hang when a build preview is stopped on an SLA 7000 system. You will need to abort the Buildstation software and restart it.

• In some cases, if the Duplicate all Build Job Parameters option is disabled, the new build will still inherit build information from the current Build Job Project.

• The Post Hatch Delay parameter does not count down the delay time correctly for multiple parts in a single BFF file.

• If the copies are made in Buildstation software, the Post Hatch Delay time seems to work fine, but if the copies are made in Lightyear software, the Post Hatch Delay time is incorrect or ignored.

• In the Field Service dialog of the SLA 3500 and Viper si2 SLA systems, there is a selection called “Sensor 4" which is for the calibration plate. Also, on Viper systems the High Resolution sensors list as Sensor 5 and Sensor 6, where Sensor 5 should beSensor 1 HR and Sensor 6 should be Sensor 2 HR.

• An “Incorrect Function” error message is displayed when launching Buildstation software with no network connection and “Enable Network Broadcasting” enabled.

• The Buildstation project tree has a file name length limitation of 47 characters.

• Two situations occur if the chamber door is opened during a Vat Unload or Vat Load process. If the elevator was still in motion, you must click the Stop button to enable the other control buttons on the dialog. In addition, if the elevator had finished moving but the vat had not finished moving to the bottom of its travel, an incorrect status message of “Vat Load Completed” or “Vat Unload Completed” is displayed.

• When the machine is building, opening multiple build windows and previewing other large builds causes the laser power to drop to a very low power (seen dropping from 825 mW to 30 mW).

• Build stops without an error message can occur when an invalid resin file is used. For example, Dp=0 and Ec=0.

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Installing Buildstation 5.3 Software from the CD-ROM

Note!The default directory where most files are located for the Buildstation 5.1 software is C:\Winsla5. The default directory where most files are located for the Buildstation 5.2 software is C:\Winsla\bin. If you installed the Buildstation 5.1 or 5.2 software in a directory other than these default directories, you should perform the backing up operations on the directory structure you used.

1. Back up the params.dat file from the default directory listed above, any *.GEO and *.CAL files, and procyon.mdb and license.dat. Place them in a folder that is not in the directory structure listed above such as C:\Backup.

Warning!You must back up these files before continuing, or you run the risk of eliminating files that are critical to your machine’s calibration and performance.

Note!Failure to back up the procyon.mdb file will eliminate the custom resin files, and builds in the job tree will no longer launch after the software upgrade. There are two ways to alleviate this situation if maintaining old resin and build files is a concern. One is to write down all the shrink factors, etc. associated with any of the BFFs you may wish to build again from the project tree, and then re-enter these factors after you have installed the new software. The other is to create the directory structure you are going to use for the Buildstation 5.3 software installation (for example, C:\Winsla53\bin). Then copy the backed up procyon.mdb into the bin directory prior to software installation (This will merge the two procyon.mdb files upon installation, giving you access to the previous builds and custom resin files, etc. with the new procyon.mdb.)

Important!3D Systems recommends that you delete any older versions of the Buildstation software before installing the new version. This will avoid any licensing conflicts and problems with incompatible file formats. Do not uninstall the older versions of the software.

2. Delete the entire installation directory structure using eitherWindows NT Explorer or File Manager.

Note!If you normally use a virus protection program on you SLA system controller, turn it off, or override its monitoring of the system before installing Buildstation 5.3 software. After completing the installation, you should restart the virus protection program. However, we are concerned that anti-virus software may interfere with normal build operation.

3. Insert the CD into the CD-ROM drive of the controller on your SLA system.

4. Click the Windows Start button in the lower left corner of the Windows Task bar.

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5. Click the Run command.

6. Inside the Open text box, type the command D:\Bldsta53_Install\setup.exe where D is the letter designation for your CD-ROM drive. Click OK.

7. When the Welcome dialog appears, click Next.

8. When the Choose Destination Location dialog appears, notice that C:\Winsla appears as the default destination folder. You can use the Browse button to change the location of the Buildstation 5.3 software installation if desired. When ready, accept the location and continue the installation by clicking Next.

9. In the Select Components dialog box, select the machine type on which you are installing the software and click Next.

10. When the Select Program Folder dialog appears, click Next to place an icon for the Buildstation software on your Start>Programs menu to aid in launching the program. You can change the name of the icon before accepting if desired.

11. When the Start Copying Files dialog appears, click Next to copy the files to the hard drive of the controller and install the software.

12. Click OK to the prompt that appears regarding installing a file into Windows.

13. When the Setup Complete dialog appears, click Finish.• Proceed to Obtaining and Installing Your Buildstation 5.3 Software

License.

Downloading Buildstation 5.3 Software from the Web

Note!The default directory where most files are located for the Buildstation 5.1 software is C:\Winsla5. The default directory where most files are located for the Buildstation 5.2 software is C:\Winsla\bin. If you installed the Buildstation 5.1 or 5.2 software in a directory other than these default directories, you should perform the backing up operations on the directory structure you used.

1. Back up the params.dat file from the default directory listed above, any *.GEO and *.CAL files, and procyon.mdb and license.dat. Place them in a folder that is not in the directory structure listed above such as C:\Backup.

Warning!You must back up these files before continuing, or you run the risk of eliminating files that are critical to your machine’s calibration and performance.

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Note!Failure to back up the procyon.mdb file will eliminate the custom resin files, and builds in the job tree will no longer launch after the software upgrade. There are two ways to alleviate this situation if maintaining old resin and build files is a concern. One is to write down all the shrink factors, etc. associated with any of the BFFs you may wish to build again from the project tree, and then re-enter these factors after you have installed the new software. The other is to create the directory structure you are going to use for the Buildstation 5.3 software installation (for example, C:\Winsla53\bin). Then copy the backed up procyon.mdb into the bin directory prior to software installation (This will merge the two procyon.mdb files upon installation, giving you access to the previous builds and custom resin files, etc. with the new procyon.mdb.)

Important!3D Systems recommends that you delete any older versions of the Buildstation software before installing the new version. This will avoid any licensing conflicts and problems with incompatible file formats. Do not uninstall the older versions of the software.

2. Delete the entire installation directory structure using eitherWindows NT Explorer or File Manager.

Note!If you normally use a virus protection program on you SLA system controller, turn it off, or override its monitoring of the system before installing Buildstation 5.3 software. After completing the installation, you should restart the virus protection program. However, we are concerned that anti-virus software may interfere with normal build operation.

3. Go to the 3D Systems web site at www.3DSystems.com and navigate to 3-D Toolbox, Software Download.

4. To download Buildstation 5.3 Software, right click with your mouse (Windows users) on the file name Buildstation 5.3 Install and choose the “Save this program to disk” option.

5. Save the file to a temporary directory.

6. From Windows NT Explorer, double click on the file C:\temp\Bldsta53_Install.exe to decompress the files.

7. Decompress the files into the same temporary directory.

8. From Windows NT Explorer, double click on the folder C:\temp\Bldsta53. Double click on Setup.exe. to start the Install Wizard. Follow the prompts to automatically install the software into the correct directory.

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Preserving Your Calibration Files

These steps are very important in preserving your machine-specific calibration data. 1. Copy the params.dat file that you previously backed up into the

C:\Winsla\Bin folder.

2. Copy all the *.CAL and *.GEO files into the C:\Winsla\Config folder.

3. Copy the procyon.mdb file to the C:\Winsla\Bin folder.

Your software is now installed and you are ready to obtain and install your license file.Note!

When rebooting after installing Buildstation software, a prompt may appear regarding “no default calibration file.” Simply go into the Setup menu and select Choose Geometric Calibration File, then browse to the new geo file location.

Obtaining and Installing Your Buildstation 5.3 Software License

Warning!Do not attempt to launch the Buildstation 5.3 software until you have installed the correct license file. Obtaining a license is a multi-step process. Before starting, make sure you have successfully completed the steps to install the software.

1. Open a Command Prompt (DOS Window).

2. Using the DOS Change Directory command, navigate to the bin directory where you installed Buildstation 5.3 software. If you accepted the default installation directory, you would type the command cd C:\Winsla\bin and press <Enter>.

3. From the bin directory, type the command lmutil lmhostid and press <Enter>. This command queries your system and returns the unique serial number (HOSTID) from your network card.

4. Record the HOSTID code. Later you will install the license file on this SLA system controller. License files are controller specific, so if you are installing Buildstation 5.3 software on multiple SLA system controllers, take steps now to identify this controller with its unique host identification code.

5. Repeat steps 1-4 for each SLA system controller upon which the Buildstation 5.3 software will be installed.

6. Go to the 3D Systems web site at www.3DSystems.com and navigate to the Technical Support | Software | Licensing page. In the first

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screen of the licensing page, type in the Authorization Code that was included in the software package and click Next. The Authorization Code is case sensitive and must be entered in all capital letters.

7. In the second screen, type in the HOSTID code you obtained from the system controller. The HOSTID is case sensitive and must be entered in lower case letters without hyphens or spaces.

8. The license generator will return the text of the license file. Copy and paste it into a text file using Notepad (NOT Wordpad) and save it as license.dat or you may download and rename the file.

9. Repeat steps 6-8 for each SLA system controller for which you need a license. Remember that each system controller requires a unique license, so make sure you have a way of distinguishing between them if you obtain multiple licenses.

10. Copy the appropriate license.dat file to the bin folder of each controller. If you used different names to designate separate files for multiple controllers, remember to rename each to license.dat when you install them on the correct controllers.

Setting the Default License File 1. Launch the Buildstation 5.3 software. The first time you launch the

software, the FlexLM License Manager will likely appear.

2. When prompted, choose the Select License File button and click Next.

3. Use the Browse button to navigate to and select the license.dat file you just installed and click Next.

4. Finally, select the Save Setting check box and click Finish.

The splash screen for the 3D Buildstation 5.3 software will appear as the program opens.Note!

If problems are encountered during this installation, or if the HOSTID query yields the resultant ffffffff, ensure that the computer is properly communicating with the network, then call the Technical Support Call Center at (800) 793-3669 in the U.S., or contact your regional Customer Service Office.

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©2002 by 3D Systems. All rights reserved. Specifications subject to change without notice. The 3D logo and SLA are registered trademarks of 3D Systems. Lightyear, Buildstation, and si2 are trademarks of 3D Systems. All other product names or services are registered trademarks or trademarks of their respective companies.

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Buildstation 5.4 SLA System Control Software Release Notes and Installation InstructionsP/N 22135-N13-00

Buildstation™ 5.4 SLA® Machine Control SoftwareRelease Notes

OverviewThe changes contained in the Buildstation 5.4 software are primarily directed at providingcompatibility with the corresponding release of 3D Lightyear™ 1.4 software.

Included in this document is information regarding:

Compatibility with previous versions Changes in functionality since the Buildstation 5.3 software release Issues that have been resolved in this version Issues that are still outstanding in this version Installation and licensing Instructions

System Support and Compatibility With Previous VersionsBuildstation 5.4 software supports the Viper, SLA® 500, SLA 350/3500, SLA 5000, and SLA7000 systems. It does not support SLA 190 or SLA 250 systems.

3D Systems recommends that you use the corresponding release of 3D Lightyear software,version 1.4, to create BFF files for SLA systems running the Buildstation 5.4 software.However, the format of the BFF files has not changed between versions 5.3 and 5.4 of theBuildstation software. Therefore, a BFF file created with versions 1.3 or 1.4 of 3D Lightyearsoftware will successfully build on SLA systems running Buildstation 5.4 software.

Buildstation 5.4 software requires Windows NT4 O/S with Service Pack 3 or later, runningon the system controller. Buildstation 5.4 software will not run on earlier versions of theWindows O/S, and has not been certified to run on Windows 2000 Professional or WindowsXP Professional.

Feature-Function ChangesThere are no major feature-function changes in this new release.

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Buildstation 5.4 SLA System Control Software Release Notes and Installation InstructionsPN 22135-N13-00

Resolved Issues The Add Resin prompt no longer interferes with Delayed Builds. The Adjust Resin Volume process no longer takes an inordinate amount of

time to complete on Viper SLA systems. Jumping to the rest position from a profiler on a Viper SLA system no longer cures

resin. The installation errors that occurred if a prior version was moved or deleted have

been resolved. The installation program now backs up critical files before installing a new version

and re-installs them for use with the updated version. The installation program now installs resin files for 3D Systems Accura® SL

materials. Issues with the Remote function have been resolved. Issues with supporting some SLA 500 system configurations have been resolved.

Outstanding Issues Under certain circumstances on a Viper SLA system, adding and building a

Normal-Res platform immediately following a High-Res platform can cause anerratic build exhibiting longer-than-normal build time and overexposed supports.Clear the job tree, or keep High-Res and Normal-Res builds in separate job trees.

Starting a build on a Viper SLA system with the resin well below the lower metal tabon the vat and with the vat near the top limit has resulted in the system failing toprompt for added resin and eventually encountering a leveling error during the buildthat does not respond to an abort command. Always check the resin level before abuild and if it is below the lower metal tab, add resin so that the level is between thetabs, but not close to the upper tab. Following this procedure resolves multiplebuild start and leveling issues on a Viper system.

A Delayed Build on a Viper SLA system can take a very long time during theChecking Resin operation with no indication that the system is doing anything.Depending on how far the system is from “level,” the process can take five minutesor more. Continue to monitor the system until the Delayed Build windowappears.

If the system loses its network connection and Network Broadcasting isenabled, the system repeatedly displays the message “Incorrect Function.” Checkand reset the network connection.

Various errors can occur if the operating system’s Screen Saver function isenabled. Instead of using Screen Saver, power the monitor off duringunattended periods.

There have been several cases where the Buildstation clock is off by exactly one ortwo hours even though the operating system’s clock is correct. The workaround isto calculate Delayed Builds based on the apparent time as displayed in theBuildstation software.

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Systems with a Coherent 328 laser can have difficulty with the restart delay routinesfollowing a Continue Build command. Manually turn the laser on using theField Service functions, and then restart the build.

In certain cases, creating numerous multiple copies of a part in 3D Lightyearsoftware using a PHD style can take longer to build than when those copies arecreated in the Buildstation software.

The message area in the Motion Control dialog is not cleared properly when anew motion is initiated after stopping a previous motion.

There are significant issues with the accuracy of the Build Time Estimator(BTE). For High-Res builds on a Viper SLA system, the BTE does not take intoaccount the fact that applying Best Surface Finish significantly increasesbuild time. Also, the BTE does not properly account for the post-hatch delay in PHDstyles. Other factors as well can significantly affect the accuracy of the BTE.

There are intermittent issues with the Autodrain function on SLA 350 and SLA500 systems.

If the system is directed to use an invalid resin file (e.g., a file with Dp=0 and Ec=0),the build will stop without displaying an error message.

An application error can occur if you stop a build preview before completion. (Thishas been observed when previewing on the SLA 7000 system, but could occur onother system types as well.)

Builds with numerous short vectors can cause the laser to frequently jump to therest position, thus increasing build times.

Ignoring the message “Need to Add More Resin” at the start of a build (particularlyon the Viper system) may cause the system to eventually reach a point where itcannot level and issue the confusing message “Layer Thickness Out of Range.”The true condition is that the system doesn’t have enough resin to continue.Adding resin will allow the build to continue.

Opening multiple build windows (which should not be done to preview anotherbuild) while the system is building can cause the system’s Max Laser Power todrop considerably. This has been observed on the SLA 7000 system with large BFFfiles (which take a long time to preview), but could happen on any system. Previewbuilds on a desktop version of the Buildstation software.

The Square Layout option does not follow a square pattern in every situation. Forexample, for three copies the layout is square, which is one above two. However,when adding a fourth copy the system creates a one-above-three layout, and whena fifth copy is added, the system correctly creates a two-above-three layout, and soforth.

Selecting a job in the build tree that has no associated BFF file (i.e., it has beendeleted or moved using Windows Explorer) can lead to application errors. Onesuch situation is when you highlight a job with a non-existent BFF file, then pressDefaults.

The system does not beep to signal the user to stop adding or removing resin if thedoor interlock is defeated.

The system displays the non-descriptive error message “Database write error” if afile is added to the project tree with a file name greater than 47 characters.

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Under certain circumstances, a build can start without completing the levelingoperation. Two known circumstances are:

o When beginning a build with the vat at the upper limit and No Initselected, the system issues the message “Limit reached during leveling –leveling aborted.” Clicking OK clears the message, but the build continueswithout completing the leveling operation.

o If you open a door during the check resin or leveling operation at the startof a build, the system issues the message “door opened during leveling –leveling aborted.” Just as in the scenario above, clearing the messagecontinues the build without performing the leveling operation.

Pressing Stop Build when the system is drawing the first layer can hang up thesystem. Only stop a build during a period when the system is not drawing.

Opening a door when a Vat Unload is in progress can lead to loss of vatcontrol and/or the system to issue incorrect and misleading status messages.

The system does not check the BFF file for completeness before it begins the build.The system will start building, then issue an error message when it reaches a badend-of-file.

The Restart Build icon is enabled after a build is finished. If you click thisicon following a completed build, the system resets the platform and draws the lastlayer again.

Installation and Licensing InstructionsNOTE:

If you normally use a virus protection program on your Buildstationsoftware controller, turn it off, or override its monitoring of thesystem before installing the Buildstation 5.4 software. Virus

protection should always be run manually between builds. Runningvirus protection continuously can cause build failures. Also, add

virus protection updates between builds.

Important!

During the installation of Buildstation 5.4 software, the system automatically creates abackup of the latest cal, geo, calibration.ini, license.dat, params.dat and procyon.mbd filesbefore writing any new files to the hard drive.

Installing the Software1. If you are installing from a CD, insert the CD into the CD-ROM drive on your

SLA system controller and proceed to step 2. If you are installing the softwarefrom a zip archive, unzip the installation files to a temporary directory.

2. Using Windows Explorer, locate the drive and directory that contains theinstallation files. This would be the CD-ROM drive if loading via CD-ROM, orthe temporary directory to which you unzipped the files in step one. Double-click the setup.exe file to launch the automatic installation program.

3. When the Welcome dialog appears, click “Next.”

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4. Read the licensing agreement in the Software License Agreement dialog andselect “Yes” to accept the terms of the agreement.

5. Review the Readme file in the Information dialog box and click “Next.”

6. When the Choose Destination Location dialog appears, choose Browse todisplay the Choose Folder dialog. Type in a valid folder name, or use theBrowse button to select a folder. If you type in a non-existent folder name, thedialog will ask if you want to create the folder. When ready, accept the locationand continue the installation by clicking “Next” to bring up the SelectComponents dialog.

7. From the list of machine types, select the one that matches your system andclick “Next.”

8. When the Select Program Folder dialog appears, click “Next” to place theBuildstation software launch icon on your “Start>Programs” menu. Click thisprogram icon whenever you wish to launch the Buildstation software.

9. When the “Setup Complete” dialog appears, click the checkbox if you wish toview the readme file, then click “Finish.”

Obtaining and Installing Your Buildstation 5.4 Software LicenseTo use the software, you must obtain a valid software license for each SLA system onwhich you intend to run the software. You obtain the license files from the 3D Systemswebsite.

Before visiting the website to obtain your license files, have your License AuthorizationCode (LAC), which was included in the customer letter mailed to all eligible customers, andthe HostIDs of the SLA systems for which you wish to obtain license files. The HostID(sometimes referred to as the physical address of the Ethernet card, or the MAC address)can be determined as follows:

1. Open a “Command Prompt” (DOS) window.2. Use the DOS Change Directory command and navigate to the \bin directory where

the Buildstation 5.4 software is installed. If you accepted the default installationdirectory, type the command “C:” and press <Enter>, then “cd c:\ProgramFiles\3D Systems\WinSLA54\bin” (or the appropriate path), and press <Enter>.

3. From the \bin directory, type the command lmutil lmhostid and press <Enter>. Thiscommand queries your system and returns a unique serial number (HOSTID) fromyour network card.

4. Record the HOSTID code.NOTE:

You will be required to install the resulting license file on this SLAsystem. License files are SLA system-specific; so if you are

installing Buildstation 5.4 software on multiple machines, take stepsnow to identify this machine with its unique host identification code.

5. Repeat Steps 1 - 4 for each machine.6. Go to the 3D Systems web site at www.3dsystems.com and navigate to the

software licensing page. In the first screen of the licensing page, type in the

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License Authorization Code provided to you in the customer letter and click Next.The Authorization Code is case sensitive and must be entered in all capital letters.

7. In the second screen, type in the HOSTID you obtained from the computer. TheHOSTID is case sensitive and must be entered in lower case letters withouthyphens or spaces.

8. The license generator will return the text of the license file. You can either Copyand Paste the displayed license text from your browser into a text file usingNotepad (NOT Word or Wordpad) and save it as license.dat, or you can follow theSave-License-To-File instructions found on the web page to download the file,naming it license.dat.

9. Repeat steps 6-8 for each machine for which you need a license. Remember thateach machine requires a unique license, so make sure you have a way ofdistinguishing between them if you obtain multiple licenses.

10. Copy the appropriate license.dat file to the \bin folder of each machine.

**************************************

© 2003 by 3D Systems, Inc. All rights reserved. Specifications are subject to change without notice.The 3D logo, Accura, and SLA are registered trademarks, and Buildstation and Lightyear aretrademarks of 3D Systems, Inc. All other product names or services are registered trademarks ortrademarks of their respective companies.

Documents

Buildstation 5.0 Release Notes - 3D Systems