¶ Intended Use
The intended use of the Rapidia Conflux 1 furnace is to sinter metal powder green parts made using the Rapidia Conflux 1 printer. Only materials distributed by Rapidia Tech. Inc. are certified for sintering in the furnace.
Additional operations such as brazing, annealing, and precipitation hardening can be performed in the furnace; consult an expert at Rapidia before proceeding. Additional materials from various other additive manufacturing processes may be compatible with sintering in the furnace if the binders used can be effectively thermally debound; consult an expert at Rapidia before proceeding. Placing materials not suitable for use in the Rapidia furnace could result in adverse effects which could result in permanent damage to hardware components, electrical components, release of harmful chemicals, implosion of the retort and voiding of the warranty.
Argon is the only tested and approved process gas appropriate for use in the Rapidia furnace. 3% hydrogen in argon has been tested for compatibility but not performance. Use of hydrogen gas or higher percentages of hydrogen in forming gases could result in catastrophic failure in the form of an explosion, damage to retort, or adverse chemical reactions.
Rapidia does not take responsibility for any such incidents that result from sintering foreign or unapproved materials in the furnace.
See the following section for a detailed list.
¶ Approved Materials
All system components designed by Rapidia are compatible with the supplied media. The following materials are approved for sintering in the furnace:
- Rapidia 316L
- Rapidia 17-4 PH
- Rapidia Inconel 625
- Rapidia Support Material
Note that more materials may become available. For information see Materials.
¶ Requirements for Furnace Operation
The furnace should be set up with appropriate space in accordance with Section Installation Requirements to ensure adequate cooling, vapor exhaust and gas supply. The gas cylinder must be affixed in a way that satisfies local regulations.
Any tripping hazards behind the furnace must be covered to prevent accidental disconnect.
¶ Normal Operation
During normal operation, the furnace must be attached accordingly to facility power and argon gas supply set to the correct pressure. All sheet metal panel covers must be attached to the exterior of the furnace and secured in place.
¶ Maintenance
Before performing maintenance, ensure the furnace has fully cooled to prevent touching any hot surfaces.
During maintenance, the furnace should be powered off and disconnected from the facility power supply to prevent any unintentional electrocution.
¶ Safety Symbols
| Safety symbols used in this user manual. | |
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May cause serious health effects or damage ozone layer |
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Fire hazards |
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May cause or suspected if causing health effects |
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Gases under pressure |
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Explosion or reactivity hazards |
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Risk of electrical shock or electrocution |
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Risk of burns from hot surfaces |
¶ Safety Hazards
There are numerous safety hazards ranging in severity and probability as listed below. All operators of the furnace and anyone working in the facility should be well aware of these risks.
¶ Chemical
- The debinding and sintering processes carried out in the furnace produce hazardous substances. See SDS for details.
- These will be collected in the vacuum exhaust system and partially emitted through the exhaust line.
- You may be exposed to these hazardous substances:
- If there is a leak in the retort
- If the exhaust is not routed properly
- While performing maintenance of the exhaust system
- Exposure to metal powder or silica dust when performing maintenance on the retort and heating elements
- Exposure to metal powder when machining green parts
¶ Electrical
Electrocution risk from a live part
- Heat damage from arc if performing maintenance while the furnace is live
- Electric shock or burn from shorting the 12V backup battery
¶ Mechanical
- Pinching and crushing risk associated with moving parts of the furnace door
- Loaded spring
- Rotating handle
- Sliding door mechanism
- Dropping heavy components of the furnace on feet, legs, or other body parts
- Sintered parts
- Sheet metal panel covers during maintenance
- Battery
- Graphite shelves
- Foot injury from rolling the unit on supplied casters Finger injury from cooling fans
- Tripping hazards from uncovered lines and cables behind furnace
¶ Hot Surfaces
- Burn risk from removing sintered components and graphite shelves
- Fire risk of anything left in contact with hot surfaces
- Rear of furnace
- Placing hot graphite shelves down on combustible surfaces
- During rapid cooling, hot air is exhausted from the top of the furnace and temperatures of the vent box can exceed 100 °C. To avoid fire hazards there should be at least 460 mm (1.5’) clearance on top of the furnace. Keep any flammable materials clear.
¶ Flammability and Explosion
- During the debinding process carried out in the furnace, flammable substances are produced which can accumulate if:
- The exhaust system malfunctions
- The exhaust hose is not properly vented
- This can result in flammability and explosion hazards if an ignition source is present.
- Risk of explosion/implosion of retort
- Risks associated with the use and transport of compressed gas cylinders
¶ Personal Protective Equipment
- Always heed the safety hazards and warnings described in section: Safety Hazards.
- Ensure any persons servicing or operating the furnace are wearing the required protective equipment as noted in individual sections in this manual