WHITE PAPER

Replacing the Form 4 cover damper

Form 4 generation printers have a damper attached to the Z-tower that softens the closing action of the cover. A damaged cover damper may cause the cover to be difficult to open and close or to close faster than expected.

Use this guide to remove and replace the cover damper on a Form 4 generation printer.

Required Supplies:

Formlabs:

Cover damper
Cover damper bracket
Cover damper bracket screws (4x)
2.5 mm hex driver (included in the Form 4 tool caddy)

Third-party:

Nitrile gloves

Estimated time: 10 minutes

Preparing the workspace

Overview: Prepare the printer and a dust-free workspace for replacing the cover damper.

Step 1: Remove the build platform

Remove the build platform first to avoid dripping resin onto the Light Processing Unit (LPU).

Step 2: 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 3: Remove and store the resin tank and mixer

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

NOTICE:

Wear gloves and hold the resin tank by the tank grips on either side to avoid contamination or damage to the underside of the tank.

Step 4: Prepare the workspace

Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust. Prepare additional space for storing the back panel of the printer during maintenance.

Step 5: Clean the printer

WARNING:

Resin may cause skin irritation or an allergic skin reaction. Wear gloves when handling liquid resin or resin-coated surfaces. Wash skin with plenty of soap and water.

Open the printer cover and clean any resin pooled on and around the LPU with paper towels. Dampen the paper towels with isopropyl alcohol if necessary to fully remove the resin.

DANGER:

Fire hazard. IPA is flammable. Keep containers closed, and keep out of the reach of children.

Step 6: 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.

Removing the back panel

Overview: Remove the back panel to access the cover damper.

NOTICE:

Formlabs 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: Remove the back panel screws

Use a 2.5 mm hex driver to remove the eight screws securing the back panel to the printer. Set the screws aside.

Step 2: Remove the back panel

Remove the back panel by sliding it down and away from the back of the printer. Set the back panel aside.

Removing the cover damper

Overview: After preparing the printer and workspace, remove the cover damper.

Step 1: Open the printer cover

Open the printer cover to more easily access the cover damper.

Step 2: Locate the cover damper

The cover damper on the Form 4 generation printer is located on the right side of the Z-tower, as seen when facing the back of the printer. It is a small piston secured behind a rectangular bracket.

Step 3: Remove the cover damper

The cover damper sits in a bracket, which is secured to the Z-tower with four screws. Use a 2.5 mm hex driver to loosen and remove the screws. Remove the cover damper, bracket, and screws and set them aside.

Installing the replacement cover damper

Overview: Mount and secure the replacement printer cover damper.

Step 1: Insert the cover damper into its bracket

Orient the replacement cover damper with the piston section facing up. Slide the cover damper into the cover damper bracket.

Step 2: Mount and secure the cover damper

Place the rounded portion of the cover damper bracket into the slot in the side of the Z-tower. Align the four screw holes in the replacement cover damper bracket with the corresponding holes in the printer’s Z-tower. Thread one cover damper bracket screw into each of the four screw holes. Use a 2.5 mm hex driver to tighten until snug.

Reinstalling the back panel

Overview: After replacing the cover damper, reinstall and secure the back panel.

Step 1: Close the printer cover

Close the printer cover before reinstalling the back panel.

Step 2: Mount the back panel

Slide the top edge of the back panel under the cover bracket. Ensure that the eight screw holes in the back panel align with the corresponding holes in the printer and the back panel sits flush with the sides of the cover.

Step 3: Secure the back panel

Thread one back panel screw into each of the eight screw holes in the back panel. Use a 2.5 mm hex driver to tighten until snug.

Finalizing the repair

Overview: After installing the new cover damper, 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 cover

Open and close the cover several times. Check that it moves smoothly and the printer properly detects when the cover is open or closed. Contact Formlabs Support or your authorized reseller to share the results of the procedure.