The recoater motor assembly powers the re coater roller in Fuse 1 generation printers. During the printing process, the recoater roller picks up powder from either side of the upper print enclosure, then deposits it as a layer. A malfunctioning recoater motor assembly may prevent the recoater roller from properly distributing powder in the print enclosure and lead to print failures.
Use this guide to replace the recoater motor assembly on Fuse 1 generation printers.
Required Supplies:
Formlabs:
Third-party:
Estimated time: 45–60 minutes
Danger:
Read and follow all safety instructions and warnings in the operator manual. Replacement with incorrect parts can lead to burns, shock, fire, or explosion. Dispose of all parts in accordance with local regulations.
Warning:
Do not perform this procedure if the printer was printing less than six hours prior. Failure to do so may result in serious burns. Allow the print enclosure to cool to room temperature before touching or inspecting any Fuse 1 components.
Preparing the workspace
Overview: Prepare the printer and a dust-free workspace for replacing the recoater motor assembly.
Notice:
Fuse 1 generation printers contain sensitive electronic components. Ground yourself before touching any electronics in the printer by using a grounding strap or touching a grounded piece of metal.
Step 1: Prepare the workspace
Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust.
Step 2: Unplug the printer
Disconnect the power cable before continuing with maintenance. Do not perform maintenance on the printer while it is connected to power. Wait five minutes after disconnecting the printer from power before proceeding.
Danger:
Performing maintenance on the printer while it is plugged in increases the risk of electric shock. Never remove the back panel of the printer while the printer is plugged in. Never reconnect the printer to power while the back panel is uninstalled.
Step 3: Remove the Wi-Fi antenna
Unscrew and remove the Wi-Fi antenna, if it is connected.
Removing the rear panels
Overview: Remove the rear panels to access the interior of the printer.
The six black lower rear panel screws are circled in red. The four chrome lower rear panel grounding screws are circled in blue.
Using a 2.5 mm hex driver, remove the six black panel screws and the four chrome panel grounding screws securing the lower rear panel to the printer. Set the screws aside, taking care to separate the black and chrome screws for later reinstallation.
Pull the lower rear panel straight back and away from the printer. Lay it down on a flat, clean surface.
Locate the ring clamp attached to the exhaust duct in the center of the printer.
Using a 6.5 mm flathead screwdriver, loosen the ring clamp screw. Do not remove the screw. Pull the exhaust duct away from the exhaust pipe.
Open the filter cabinet door on the printer. Locate the exhaust inlet on the right side of the cabinet.
Using a 2.0 mm hex driver, remove the four screws attaching the exhaust inlet to the filter cabinet. Set the screws aside.
The two black upper rear panel screws are circled in red. The two chrome upper rear panel grounding screws are circled in blue.
Using a 2.5 mm hex driver, remove the two black panel screws and two chrome panel grounding screws securing the upper rear panel to the printer. Set the screws aside, taking care to separate the black and chrome screws for later reinstallation.
Step 8: Remove the upper rear panel screws
Using a 2.5 mm hex driver, remove the eight screws securing the upper rear panel to the printer:
Set the screws aside.
Step 9: Remove the upper rear panel
Pull the upper rear panel straight back and away from the printer. Lay it down on a flat, clean surface.
Removing the recoater motor assembly
Overview: Remove the recoater motor assembly from the printer.
Step 1: Locate the recoater motor assembly
Facing the rear of the printer, the recoater motor assembly is located on the motor mounting bracket on the hopper-side of the printer.
Step 2: Disconnect the encoder cable
Disconnect the encoder cable labeled CO69 by pressing the plastic tab and gently pulling the connector away from the housing. Do not pull on the wires.
Step 3: Disconnect the motor cable
Disconnect the motor cable labeled CO64 by grabbing the white connector and gently pulling it away from the housing. Do not pull on the wires.
Step 4: Remove the recoater motor assembly screws
Using a 3.0 mm hex driver, remove the four screws securing the recoater motor assembly to the motor mounting bracket. Set the screws aside.
Step 5: Remove the recoater motor assembly
Pull the recoater motor assembly straight back and away from the printer. Set the motor assembly aside for disposal with electronic waste.
Installing the replacement recoater motor assembly
Overview: After removing the recoater motor assembly from the printer, install the replacement recoater motor assembly.
Step 1: Align the replacement recoater motor assembly
Align the replacement recoater motor assembly with the motor mounting bracket so that the motor and encoder cable connectors face down. Ensure the recoater motor assembly screw holes are aligned with the corresponding holes in the motor mounting bracket.
Step 2: Rotate the recoater shaft
Rotate the recoater shaft until it engages with the replacement recoater motor assembly.
Thread the four 10.0 mm screws into the screw holes on the motor mounting bracket. Using a 3.0 mm hex driver, tighten the screws until finger tight.
Step 4: Reconnect the motor assembly cables
Motor cable C064
Encoder cable C069
Reconnect the motor cable and the encoder cable into their white connectors on the recoater motor assembly. The cables will only fit in the connector in the correct orientation. Be careful not to bend the pins in the connectors. Do not pull on the wires.
Reinstalling the rear panels
Overview: After installing the replacement recoater motor assembly, reinstall and secure the rear panels.
Step 1: Align the upper rear panel with the printer
Lift the upper rear panel and align it with the four screw holes on the top of the printer.
Step 2: Secure the upper rear panel top screws
Thread the four 6.0 mm screws into each of the screw holes on the top of the printer. Using a 2.5 mm hex driver, tighten the screws until finger tight. You may need to adjust the exhaust duct to correctly position the upper rear panel.
Step 3: Secure the buffer side panel screws
Thread the two 6 mm screws into the screw holes on the buffer side and the two 6 mm screws into the screw holes on the hopper side. Using a 2.5 mm hex driver, tighten the screws until snug.
Step 4: Secure the hopper side panel screws
Thread the two 6mm screws into the holes on the hopper side. Using a 2.5 mm hex driver, tighten the screws until snug.
Step 5: Secure the upper rear panel grounding screws
The two black upper rear panel screws are circled in red. The two chrome upper rear panel grounding screws are circled in blue.
Thread the panel screws into the indicated screw holes on the upper rear panel. Refer to the image for the correct locations of the black and chrome screws. Using a 2.5 mm hex driver, screw in the two black panel screws and two chrome grounding screws securing the upper rear panel to the printer.
Notice:
The placement of the chrome screws is critical to the printer's electrical grounding. Incorrect placement may lead to printer damage.
Step 6: Slide the exhaust duct into position
Slide the end of the exhaust duct with the ring clamp back onto the exhaust pipe. Ensure the exhaust duct presses against the insulation panel.
Step 7: Tighten the exhaust duct ring clamp
Using a 6.5 mm flathead screwdriver, tighten the ring clamp until finger tight.
Step 8: Secure the exhaust inlet screws
Open the filter cabinet door on the printer. Thread the four 8.0 mm screws into the screw holes. Using a 2.0 mm hex driver, screw in the four exhaust duct screws until finger tight.
Step 9: Check the exhaust duct seal
To ensure there is no gap between the exhaust duct’s mounting plate and the filter cabinet housing, shine a flashlight or other light source around the exhaust inlet inside the filter cabinet. If any light is visible behind the filter cabinet, the duct is not properly sealed. If necessary, use a 2.0 mm hex driver to tighten the exhaust duct screws. Close the filter cabinet door when finished.
Step 10: Secure the lower rear panel grounding screws
The six black lower rear panel screws are circled in red. The four chrome lower rear panel grounding screws are circled in blue.
Thread the panel screws into the indicated screw holes on the lower rear panel. Refer to the image for the correct locations of the black and chrome screws. Using a 2.5 mm hex driver, screw in the six black panel screws and four chrome panel grounding screws securing the lower rear panel to the printer.
Notice:
The placement of the chrome screws is critical to the printer's electrical grounding. Incorrect placement may lead to printer damage.
Step 11: Reinstall the Wi-Fi antenna (optional)
Screw the Wi-Fi antenna onto the jack on the back of the unit.
Finalizing the repair
Overview: After installing the replacement recoater motor assembly, power on the printer and perform final checks.
Step 1: Power on the printer
Connect the power cable to the printer and the power supply. The printer initializes.
Step 2: Test the repair
Start a print. Monitor the printer to ensure that the recoater roller moves normally and distributes powder normally. Contact Formlabs Support or your certified service provider to share the results of the procedure.
