Step 1: Prepare the workspace

Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust.

Step 2: Empty the hopper

Empty the hopper to below the level of the powder sensor you are replacing. The powder sensors are visible from inside the hopper. Scoop powder into a clean container for reuse. You can also use the Empty Hopper function on the printer:

1. Insert an empty build chamber.
2. Tap Settings > Calibration > Empty Hopper on the printer’s touchscreen.
3. Follow the on-screen prompt on the Empty Hopper screen to transfer the powder from the hopper to the build chamber. This process may take up to an hour.

Step 3: 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.

Step 1: Begin removing the hopper-side panel screws

Using a 2.5 mm hex driver, loosen and remove the two black (circled in red) and one chrome (circled in blue) 8.0 mm M4 button head screws from the back-left of the printer. Take note of the locations of these screws, as the placement of the chrome screws is critical to the printer's electrical grounding. Set the screws aside.

Step 2: Continue removing the hopper-side panel screws

Move to the hopper side of the printer. Using a 2.5 mm hex driver, loosen and remove the 10 M4 countersunk screws holding the hopper-side panel to the printer. Remove the top-most 6.0 mm countersunk screws last to make removing the panel easier. Set the screws aside.

• Three 16.0 mm screws, circled in green
• Three 12.0 mm screws, circled in blue
• Four 6.0 mm screws, circled in red

Step 3: Tilt the hopper-side panel

Allow the panel to tilt away from the printer, allowing access to the interlock switch cables. Do not remove the panel at this time.

Step 4: Disconnect the interlock switch and remove the hopper-side panel

Locate the black and red cables leading to the interlock switch on the inner left-hand side of the panel. Disconnect the cable labeled C033.

Separate the hopper-side panel from the printer, taking care to ensure that none of the cables are caught or tangled. Set the panel down on a flat, clean surface.

Step 5: Remove the inner door handle

Using a 2.0 mm hex driver, loosen and remove the four 10.0 mm M3 black countersunk screws holding the inner door handle to the printer. Remove the door handle and set it and the screws aside.

Step 6: Remove the hopper shell

Lift the hopper shell upwards then pull it away from the printer. Set the hopper shell and lid aside

Step 2: Disconnect the powder sensor

Disconnect the cable from the powder sensor you are replacing. Grip the plastic connector and pull straight down (for the upper sensor) or up (for the lower sensor) to unplug it. Do not pull on the wires themselves.

Step 2: Secure the powder sensor

Thread one mounting screw into both of the screw holes in the sensor housing. Using a 2.5 mm hex driver, tighten until snug.

Step 3: Connect the sensor cable

Plug the sensor cable into the new powder sensor. The connector only fits into the sensor in the correct orientation.

Step 1: Mount the hopper shell

Align the hopper shell with the hopper, then slide it down into place.

Step 2: Mount and secure the inner door handle

Align the four screw holes in the inner door handle with the corresponding screw holes on the front edge of the hopper side of the printer. Thread one 10.0 mm M3 black countersunk screw into each of the four screw holes, then use a 2.0 mm hex driver to tighten until snug.

Step 3: Reconnect the interlock switch cable

Align the bottom of the hopper-side panel to the bottom of the printer and allow it to lean against you. Reconnect the interlock switch cable, labeled C033, to its receptacle. If necessary, tuck the interlock cable slack into the side of the printer’s frame.

Step 4: Begin securing the hopper-side panel

Thread one M4 countersunk screw into each of the 10 screw holes in the hopper-side panel. Using a 2.5 mm hex driver, tighten until snug. For greatest convenience and ease of installation, thread and tighten in the following order:

1. Four 6.0 mm screws below the hopper, circled in red
2. Three 16.0 mm screws below the filter door, circled in green
3. Three 12.0 mm screws above the filter door, circled in blue

Step 5: Continue securing the hopper-side panel

Thread the two black 8.0 mm M4 button head screws into the screw holes circled in red in the image here. Thread the chrome 8.0 mm M4 button head screw into the screw hole circle in blue here. Using a 2.5 mm hex driver, tighten until snug.