Replacing the Form Studio 1 LevelSense, camera, and resin tank RFID assembly

On Form Studio 1 printers, the resin level sensor (known as LevelSense), camera, and resin tank RFID sensor are part of the same assembly. The LevelSense system measures the amount of resin in the resin tank, triggering resin dispensing from the cartridge as needed. The camera facilitates timelapse recordings, print photography, and the monitoring of potential part defects. The resin tank RFID sensor is used to identify the resin type and confirm the tank's presence in the printer. If any one of these components malfunction, it may prevent the printer from functioning properly.

Use this guide to replace the LevelSense, camera, and resin tank RFID assembly.

Estimated time: 10–20 minutes

Overview: Prepare the machine and a dust-free workspace for replacing the LevelSense, camera, and resin tank RFID assembly.

Step 1: Wear gloves and prepare your workspace

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

Step 2: Remove the build platform

Remove the build platform first to avoid dripping resin onto the optical surfaces.

Step 3: Remove the resin cartridge

Remove the resin cartridge and close the vent cap to prevent resin from dripping off of the bite valve and into the printer.

Step 4: Remove and store the resin tank

Remove the resin tank and cover it with its lid. Set the tank aside on a clean, flat surface.

Step 5: Power down and 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.

Overview: Remove the back panel and top halo panel to access the LevelSense, camera, and resin tank RFID assembly.

Step 2: Remove the top halo panel and back panel

The halo panel encircles the top of the printer. Open the printer cover. Unclip the halo panel from the left and right sides of the printer by pulling up on the front edges. Lift the halo panel up and away from the printer and set it aside. Remove the back panel and set it aside.

Overview: With the panels removed, unplug and uninstall the LevelSense, camera, and resin tank RFID assembly.

Step 1: Unplug the cables from the assembly

Locate the LevelSense, camera, and resin tank RFID assembly, positioned on the right side of the printer (when viewed from the back). Open the cable clip at the top of the assembly and free the ribbon cable it secures.

Unplug the three cables from the assembly. Take note of the orientation of the ribbon cables in their connectors.

• For the ribbon cables: The ribbon cables are secured in their connectors with a latch. Lift the latch away from the assembly to free the cable. Once the latches are in the upright unlocked position, the cables can be easily removed.
• For the JST connector: Gently squeeze the plastic tab to unplug the cable. Do not pull on the individual wires.

Step 2: Uninstall the LevelSense, camera, and resin tank RFID assembly

The LevelSense, camera, and resin tank RFID assembly is secured to the printer with two screws. Using the 2.5 mm hex key, loosen and remove the screws and set them aside. Note that the top screw has a washer; set that aside as well.

Pull on the back of the assembly while pushing it from inside the printer cavity to unmount it. Set the LevelSense, camera, and resin tank RFID assembly aside for disposal with electronic waste.

Overview: After uninstalling the original LevelSense, camera, and resin tank RFID assembly, mount and secure the replacement component.

Step 2: Mount the replacement assembly

Align the LevelSense, camera, and resin tank RFID assembly with the cutout in the tower shell. Press it forward and down until it clicks into place. 

Step 3: Secure the replacement assembly

Place the washer on one of the two LevelSense, camera, and resin tank RFID assembly retention screws. Thread that screw into the upper screw hole in the assembly. Thread the remaining screw (without a washer) into the lower screw hole. Using the 2.5 mm hex key, tighten until snug.

Route the long ribbon cable extending towards you through the cable clip on the top of the assembly. Close the cable clip to secure the cable in place.

Overview: After replacing the LevelSense, camera, and resin tank RFID assembly, reinstall the printer panels.

Overview: After installing the new LevelSense, camera, and resin tank RFID assembly, power on the printer and perform final checks.

Step 1: Power on the printer

Close the printer cover and connect the power cable to the printer and the power supply. Turn on the switch at the back of the printer. The printer will turn on and initialize.

Step 2: Calibrate the resin level sensor

Calibrate the resin level sensor using the on-screen tool:

1. On the printer touchscreen, tap Settings > Tools > Calibration > Resin Level Sensor. The Calibrate resin level sensor screen appears. Tap Start to continue to the next screen.
2. Open the printer cover. Place the resin level sensor calibration card in the spot indicated on the touchscreen.
   • The resin level sensor calibration card is located in the tool caddy, which is stored on the left side of the printer.
3. Tap Next to continue.
4. Read the confirmation screen and tap Calibrate.
5. Wait for the calibration process to complete. Do not move or adjust the printer while it is calibrating the resin level sensor.
6. The printer displays Calibration successful when the calibration is complete. Tap Close.
7. Remove the resin sensor calibration card, place it back in the tool caddy, and stow it in the slot on the left side of the printer.

Step 3: Check the resin tank RFID sensor

Insert a resin tank and verify that the printer correctly identifies it.

Step 4: Check the camera

Open PreForm and select your printer on the Job Setup screen. Click Camera Snapshot in the right-hand panel and check that an image appears.