The recoater distributes powder in an even layer as it moves across the print bed. A damaged recoater roller can cause print failures due to debris or uneven recoating.
Use this guide to replace the recoater roller in a Fuse 1 generation printer.
Required supplies:
Formlabs:
Third-party:
Estimated time: 5–20 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.
Removing the quartz tube heater spatial filters (optional)
Overview: Prepare the printer for the repair and remove the quartz tube heater spatial filters to better access the recoater roller. The recoater roller can be removed without removing the quartz tube spatial filters, but there will be less space to work within the print enclosure.
Step 1: Prepare the workspace
Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust. Put on appropriate personal protective equipment for the powder in the printer, based on the safety data sheet for the powder.
Step 2: Open the print enclosure door
Open the print enclosure door using the touchscreen. If there is a build chamber inserted, unplug and remove it.
Use a 2.5 mm hex driver to remove the 8.0 mm M3 cap screw holding either quartz tube heater’s spatial filter to the frame.
Insert your finger into the slot on the spatial filter and pull it away from the printer to remove it from the print enclosure. Set the spatial filter aside.
Step 5: Unmount and remove the second spatial filter
Repeat steps 3–4 for the remaining filter.
Removing the original recoater roller
Overview: Unmount and remove the original recoater roller.
Step 1: Position the recoater roller for removal
On the touchscreen, navigate to Maintenance > Motor Moves. Touch and hold the appropriate directional toggle that will move the recoater out into the middle of the printer.
Caution:
Crush hazard. Keep your hands, clothing, and tools clear of the path of the recoater roller while it is moving.
Step 2: Remove the recoater roller retention bolts
Use a 7 mm wrench to remove the two hex bolts holding the roller to the recoater arm.
Step 3: Uninstall the recoater roller
Gently pick up the front of the recoater arm and tip it towards the back of the printer. If the roller does not drop off the arm, gently pull it downward and away from the arm. Remove the recoater roller and set it aside for disposal.
Tip:
If the bearing blocks seem stuck to the recoater arm, rethread both bolts slightly, then tap the head of each bolt with a mallet.
Installing the replacement recoater roller
Overview: Clean and install the replacement recoater roller.
Put on a new pair of nitrile gloves. Wet a nonabrasive cleaning cloth with ethanol or isopropyl alcohol. Thoroughly wipe down the roller, ensuring there is no remaining dust or residue.
Maneuver the recoater roller’s pinion gear into the back of the printer so that it is loosely aligned with the corresponding rack gear. Position the rear bearing block so that its two pins align with the corresponding holes in the bottom of the recoater arm.
While holding the rear roller mount in place, rethread the hex bolt by hand so it is still loose but does not allow the pins to drop out of the holes. Do not fully tighten the bolt.
Position the front bearing block so that its two pins align with the corresponding holes in the bottom of the recoater arm.
While holding the front bearing block in place, rethread the hex bolt by hand so it is slightly loose. Do not fully tighten the bolt.
Check that the rack and pinion gears are properly meshing. Move the loosely mounted recoater roller if needed.
Using a 7 mm wrench, tighten the rear hex bolt first, followed by the front hex bolt. Do not over-torque the bolts, as they may strip and become stuck.
Reinstalling the quartz tube heater spatial filters (optional)
Overview: If you previously removed the spatial filters, align and reinstall them.
Step 1: Align the spatial filter with the frame
Align the slots on the spatial filter with the rails on the lamp frame.
Step 2: Install the spatial filter
Push the spatial filter along the rails towards the back of the printer. Ensure that the alignment pins on the back of the front face of the spatial filter go into the corresponding holes in the lamp frame. The front of the spatial filter sits flush against the front of the lamp frame when it is properly installed.
Thread the 8.0 mm M3 cap screw into the screw hole in the front of the spatial filter. Tighten the screw with a 2.5 mm hex driver until finger tight.
Step 4: Install and secure the other spatial filter
Repeat steps 1–3 for the other filter.
Finalizing the repair
Overview: After installing the replacement recoater roller, start a print and perform final checks.
Step 1: Test the repair
Insert and connect a build chamber, close the print enclosure door, and start a print. Monitor the printer to ensure that the recoater roller moves smoothly and the print proceeds normally. Contact Formlabs Support or your certified service provider to share the results of the procedure.
