Cassette Care
Overview
The printer cassette sits on the printer deck and holds liquid resin during printing. The transparent window in the center creates the dead zone that unlocks the speed and quality of the Digital Light Synthesis™ process. During printing, light from the light engine in the body of the printer shines through the window and cures liquid resin to build parts.
The window is not a simple piece of glass, but a highly-engineered, complex optical membrane. Treat it as delicately as your own eye.
Improper maintenance or damage to the window will reduce print quality and may result in failed prints and production delays.
Product Options
Cassettes are available per printer type.
This document focuses on the standard cassettes that ship with the printer.
Printer | Standard Cassette |
|---|---|
M1/M2 | C2 |
M3/M3 Max | D1 |
L1 | C2 |
Refer to additional cassette documents for information about non-standard cassettes.
Cassette Features
Comparison Table
Printer | Weight | Dimensions | Resin Capacity |
|---|---|---|---|
M1 | 2 kg 4.4 lbs | 254 x 191 x 76 mm 10 x 7.5 x 3 in | 800 mL |
M2 | 2.8 kg 6.2 lbs | 298 x 254 x 83 mm 11.75 x 10 x 3.25 in | 1600 mL |
M3 | 3.4 kg 7.5 lbs | 332 x 256 x 89 mm 13.1 x 10.1 x 3.5 in | 1700 mL |
M3 Max | 6.4 kg 14 lbs | 415 x 360 x 118 mm 16.4 x 14.2 x 4.7 in | 3200 mL |
L1 | 20.4 kg 5.0 lbs | 604 mm x 440 mm x 86.7 mm 23.8” x 17.3” x 3.4” | 3700 mL |
Main Features
The different printer cassettes share several features that are important to keep in mind for the cleaning process.
Metal frame
Window
Seal
Handles
Underside Features
All cassettes have mounting features.
M2 cassette - Kinematic pin mounts
M3 cassette - Pull studs
L1 cassette - Schunks
L1 cassette - Mounting features
Never spray solvent onto the underside of the cassette.
For more detailed information about the cassette features, go to the relevant printer course:
M2 & M3 Cassette Lids
The cassette lid is a UV-resistant cover that enables resin to be stored in a cassette outside of a printer. The lid keeps light, dust and debris from getting to the resin stored in the cassette, keeping the resin safe for reuse. The lid is especially helpful for oral health customers that use one-part resins.
For more information about cassette lids, go to M1/M2 Printer or M3/M3 Max Printer.
Transport
Wear Clean Gloves
Always handle all cassettes with clean gloves to avoid contaminating.
Do not handle the underside of the cassette. This will minimize cleaning and maintenance on the underside.
M Series Cassettes
When carrying M Series cassettes, use both hands and hold the cassette frame using the
- Outside lip on an M1 cassette
- Handles on an M2 cassette
- Handles on an M3/M3 Max cassette
L1 Cassette
The L1 cassette weighs ~45 lbs* and should be moved with the L1 Cassette Cart whenever possible.
* Legacy B1 cassettes weigh ~60 lbs
Cassette Hotel
When moving the cassette into one of the L1 Cassette Hotel drawers, it will be necessary to have 2 people manually lift the unit and gently place it in the intended space.
See L1 Cassette Hotel for full instructions.
Storage
How long can resin be left in cassette?
One-part resins
- Cassette (without lid) left in the printer, with the door closed, can be left for up to 1 day then stirred before use.
- Cassette covered with a cassette lid or aluminum foil can be stored on a bench or enclosed storage for up to 1 day.
- Cassette must be stored on an opaque surface as light can penetrate through bottom of cassette and cure the resin.
- Resin must be stirred with a spatula before use.
Two-part resins
- Do not store two-part resins in the cassette.
- Due to the pot life of two-part resins, expired resin will partially cure and possibly damage the cassette.
- Dispense these resins just before printing to ensure maximum print quality.
M Series Cassette
When not in use, the cassette should be stored in the printer with the door closed or on a stable surface with the lid on to prevent the accumulation of dust or other contaminants.
For longer term storage, Carbon recommends storing the cassette in the original packaging.
L1 Cassette
Storage between prints
The L1 cassette should be stored in the printer with the door closed to prevent the accumulation of dust or other contaminants.
Storage in Production Rotation
When waiting for rotation in production, the L1 cassette should be stored in the L1 Cassette Hotel.
Never stand cassette on its side as it can easily fall over and shatter.
For longer term storage, Carbon recommends storing the cassette in the original case.
Cassette Cleaning
Proper cassette cleaning is critical to ensure print success. If improperly cleaned, print quality can be adversely affected.
When to clean cassette after printing?
- One-part resins: within 24 hours.
- Two-part resins: within the resin’s pot life (or first thing in the morning after an overnight print.)
Guidelines
To protect your cassette's window from damage, it is important to use only the right tools for the job.
Never use an instrument to scrape resin from the cassette window.
Valid Tools and Consumables
Yes! Blue shop towels are safe to use when cleaning your cassette, but ONLY with solvent (IPA or Acetone), never dry.
Yes! Silicone spatulas, soft and flexible, are safe to use on the window when in good condition.
Cracked, stiff, or broken spatulas should be discarded.
Yes! Kimwipes are safe to use when cleaning your cassette, but ONLY with solvent (IPA or Acetone), never dry.
Yes! Pre-soaked IPA or acetone wipes are safe to use on your cassette window.
Not Valid Tools
No blades or scrapers! Never use a sharp object of any kind on the window.
No putty knives! Even a dull edge can damage the window.
No cracked, stiff or broken spatulas!
- If exposed, the rigid interior of the spatula can damage the window.
- Cracked, stiff, or broken spatulas should be discarded.
- Avoid using Acetone to clean spatulas, as this will lead to cracking.
Do not scrape the window with fingernails! Even they can damage the window.
- Avoid scrubbing, forcefully pushing or scratching the cassette, even with a gloved finger.
No Solvent on Underside
Never spray solvent onto the underside of the cassette.
Before Cleaning
- If applicable, remove cured resin stuck to the window (see below).
- Put on clean gloves.
Remove Cured Resin from Window
In some cases, cured resin may stick to the window. This can happen in the event of an adhesion failure. The cured resin must be removed from the window before the cassette can be used for printing.
Contact Carbon Support if these methods are not successful.
Cleaning
M1/M2/M3 Cassette Cleaning
L1 Cassette Cleaning
The inside of the cassette can be cleaned while installed in printer Or in the cassette cart (where also inspected)
After Cleaning
Cleaning the Window Seam
This video demonstrates the window seam cleaning technique on an M2 cassette. But the same technique applies to all cassettes.
Cassette Inspection
After cleaning, inspect the cassette for any irregularities that may affect print quality.
Cassette inspection is critical to ensure the window is in proper condition for printing, to maintain print quality and avoid permanent damage to the cassette.
When to inspect the cassette
- Upon receipt
- After cleaning cassette
- Before dispensing resin
What Cassette Inspection Looks For
M Series Cassette Inspection
Applies to M1, M2, M3 and M3 Max cassettes.
L1 Cassette Inspection
L1 Cassette Damage Evaluation Handout
Please consult this document if you notice any irregularities on your L1 cassette.
Check Window Between Prints
Debris Detection
Debris in the resin pool can jeopardize printing by damaging cassettes and causing print failures or defects. Even small fragments (less than 1 mm) of cured resin or external debris can pose issues.
Detecting and removing these fragments improves print outcomes and reduces the overall cost of Carbon printers by safeguarding cassette health and longevity.
Resin that is free of debris in the cassette can be reused for multiple prints under the following conditions:
- One-part resins: within 24 hours.
- After 24 hrs, filter resin back into bottle and dispense with a clean cassette.
How to check for debris varies depending on the printer type (or workflow) you are using.
- M3 and M3 Max printers automatically detect debris (software v1.42 and higher)
- L1 printers using the Gen 2 Aligner Model Solution workflow automatically detect debris (software v1.44 and higher).
- L1 printers (remaining workflows) and M1, M2 printers require manual detection of debris
Carbon expects to enable debris detection for more L1 printers in a future software release.
Because this feature relies on Force Feedback, it will not be made available on M1 or M2 printers.
Automatic Debris Detection
M3, M3 Max, L1* Automatic Debris Detection
M3 and M3 Max printers will abort a print and alert the user if solid debris is detected in the resin at the start of a print.
When Debris is Detected
- Filter or replace resin before continuing. Reference reclaiming resin instructions. Remember that most debris will be too small to easily spot visually in the resin.
- Select Debris Removed to restart printing
- The project that was previously disrupted will still be at the top of the print queue.
- An override option is available in the unlikely event that no debris can be located/removed, and the print continues to abort. Use this option with extreme caution.
*L1 printers using the Gen 2 Aligner Model Solution workflow automatically detect debris (software v1.44 and higher).
Manual Debris Detection
M1, M2, L1* Check Window Between Prints for Debris
Use the spatula to check for cured resin loose in the liquid, or stuck to the window, in between prints.
Check Spatula for damage
- It is important to periodically check your silicone spatula to make sure it hasn't stiffened or cracked with age.
- Do not use acetone to clean the spatula, which will lead to stiffening.
*L1 printers using the Gen 2 Aligner Model Solution workflow automatically detect debris (software v1.44 and higher).
Resin Level Detection
M3, M3 Max, L1*
M3 and M3 Max printers will abort a print and alert the user if there is too little resin in the cassette for the print, or if there is too much resin to proceed safely.
- Too little resin can lead to a failed print or a completed print with visible evidence of resin starvation.
- Too much resin in the cassette may overflow into the printer when the platform descends, damaging the printer.
When an inappropriate amount of resin is detected:
- Add or remove resin before continuing.
- The project that was previously disrupted will still be at the top of the print queue.
- Select Resin Corrected to restart printing
- The project that was previously disrupted will still be at the top of the print queue.
- An override option is available if needed Use this option with caution.
*L1 printers using the Gen 2 Aligner Model Solution workflow automatically detect resin level (software v1.45 and higher).
M1, M2, L1*
Visually review the cassette's resin level to ensure enough resin remains in the cassette for subsequent prints.
*L1 printers using the Gen 2 Aligner Model Solution workflow automatically detect resin level (software v1.45 and higher).
Cassette Maintenance
Maintenance Schedule
Frequency | Action | M1/M2 | M3 | L1 |
|---|---|---|---|---|
PER PRINT | X | X | X | |
PER SHIFT | Additional acetone cassette cleaning (see below) | X | X | X |
| X | X | X | |
| X | X | - | |
WEEKLY | Underside cassette cleaning - L1 | - | - | X |
MONTHLY | X | - | - | |
AS NEEDED | X | X | X | |
| X | X | X | |
| - | - | X |
Notes
Additional Acetone Cassette Cleaning
Cassettes require a thorough cleaning with acetone every 24 hours. If running multiple shifts per day, this additional cleaning can be done on the shift of your choice. This wipe down is recommended in addition to regular cleaning.
The cassette should be outside of the printer to enable access to all surfaces of the cassette. An M Series cassette can be on a workbench; the L1 cassette should be in the L1 Cassette Cart or on top of the L1 Cassette Hotel.
- Wipe down the cassette inside and outside with an acetone wipe or an acetone dampened towel.
- While wiping, do not dig into the seam between the window and the frame. Excessive force at the seam can break the seal between these features and damage your cassette.
- If the seam shows resin seepage and needs extra attention, follow the steps on Cleaning the Window Seam .
M2
L1
Clean Underside Mating Features
For proper installation of the cassette, features that mate with the printer must be clean and free of resin or debris.
Clean the mating features at the same time you clean the underside of the window.
To inspect and/or clean the mating features, the cassette must remain outside of the printer after cleaning the window underside.
Do not apply solvent directly to any features on the cassette underside.
- Inspect the mating features on the underside of the cassette for any resin or debris.
- If dirty, apply 99% IPA to a lint-free towel and clean each feature.
- Spot clean the underside frame as needed with the IPA damped wipe.
Note: The M1/M2 cassette also has kinematic pin mounts that mate with the printer. Maintaining these features requires a different process which occurs monthly.
Window Blemishes
The cassette window can have a range of different imperfections. Some of these will make the cassette unusable for production and necessitate replacing the cassette.
Read through the different imperfections below to understand the difference between manufacturing artifacts, surface contamination and window damage. Consult the examples below whenever you see an imperfection on your window.
In very rare cases, a manufacturing defect may arise that affects printed parts. If you can't find a match for your window blemish in Manufacturing Artifacts, Surface Contamination or Window Damage, reach out to Carbon Support to resolve the issue.
Manufacturing Artifacts
Manufacturing artifacts have no impact on printing. They are a normal result of the manufacturing process.
Ghost Ring
Description
- M1/M2 cassettes only
- Condition present beneath the window's top layer
- Only visible when looking at window from an angle. Not visible when looking straight at the window.
Cause Byproduct of manufacturing process.
Action None required. Keep printing.
Rippling
Description
- M3 and M3 Max cassettes only.
- Next-gen oxygen permeable optics for the M3/M3 Max printer have a top layer that expands when heated during printing, resulting in temporary rippling.
- Effect diminishes upon cooling and disappears under the vacuum of an installed cassette.
- Not window damage.
Cause Byproduct of manufacturing process.
Action None required. Keep printing.
Normal use of a rippling M3 cassette will not cause window damage, but improper care or excessive force in cleaning could cause a crease (see window damage for more information).
Semi-Circular Hologram
Description
- L1 cassettes only
- Condition present beneath the window's top layer
- Only visible when looking at window from an angle. Not visible when looking straight at the window.
Cause Byproduct of manufacturing process.
Action None required. Keep printing.
Watermark
Description
- Condition present beneath the window's top layer
- Only visible when looking at window from an angle. Not visible when looking straight at the window.
Cause Byproduct of manufacturing process.
Action None required. Keep printing.
Inclusions
Description
- Very small surface imperfections
- Does not cause distortion when viewing a sheet of printed text placed directly underneath window
Cause Byproduct of manufacturing process.
Action None required. Keep printing.
Surface Contamination
Surface contamination requires further cleaning of the window.
Streaks
Description Streaks indicate small amounts of leftover resin.
Cause Not fully cleaning the cassette window.
Action
- Continue cleaning the window with an acetone dampened blue towel or wipe until the streaks are gone.
Solvent Spots
Description Spots of dried solvent on the window.
Cause Use of too much solvent in the final wipe of the window during cleaning.
Action
- Follow proper cleaning procedures.
- Dampen a blue towel or wipe with acetone and wipe the window until spots are gone. Allow the acetone to evaporate slightly from the wipe if spots persist.
Haze
Description
- Haze on a window represents a build up of light dust.
- Generally appears on the underside of the window that is cleaned less frequently.
Cause
- General cassette usage.
- Persists with lack of proper maintenance.
Action
- Clean the underside of the window with an IPA dampened wipe, followed by an acetone dampened wipe.
- Reference weekly cassette maintenance for details.
- Follow the maintenance schedule closely.
Seeping Resin
Description Resin bubbles up out of the seam between the window and frame of the cassette.
Cause Improper cleaning of the cassette, particularly after the use of high viscosity resins.
Action
- Assess cleaning practices and adjust as needed going forward.
Ghosting
Description A hazy silhouette of a part printed frequently and repeatedly.
Cause Repeated exposure of light and heat in the same pattern on the window.
Action
- Standard window cleaning practices will not remove the hazy silhouette.
- Periodically rotating cassettes in production can mitigate the issue.
Window Damage
Window damage occurs as a result of mishandling and causes permanent damage to the window, making it unusable for printing.
Stop printing with a damaged cassette.
Avoid Window Damage Window damage is avoidable. Follow proper cleaning and maintenance procedures. See Avoid Window Damage below for additional recommendations.
Returning a Damaged Cassette If your cassette is damaged, remove it from production and return the cassette to Carbon for repair.
Print Defects
In addition to inspecting the cassette, reviewing printed parts is an essential part of production. Parts can provide evidence of a cassette window with surface contamination or window damage.
Window Damage
Crease
Description
- M3 and M3 Max cassettes only
- Top layer on an M3 cassette window is aggressively dragged at areas of rippling and folded to create a crease.
- Appears whiteish compared to the manufacturing artifact rippling.
Cause
- Tool damage
- Using a spatula incorrectly and/or aggressively on a rippling M3 cassette window
- Using an unapproved tool on a rippling M3 cassette window
- Reference Manufacturing Artifacts for information on rippling
Action
- Follow proper cleaning procedures, using only the correct tools.
- Remove inappropriate tools from production.
- Stop printing with cassette
Dent
Description Localized impression without penetration of top layer.
Cause
- Contamination
- Debris pressed into the window by the platform.
- Damaged platform pressed into window
- Tools used aggressively on the platform
- Platform dropped
Action
- Check window between prints for contamination.
- Remove damaged platforms from production.
- Check all other cassettes used with damaged platform.
- Stop printing with cassette
Puncture
Description
- Penetration into top window layer.
- Appears as a hole in top layer.
- Diagonal streaks often accompany a puncture
Cause
- Contamination
- Debris pressed into the window by the platform.
- Damaged platform pressed into window
- Tools used aggressively on the platform
- Platform dropped
- Tool damage
Action
- Check window between prints for contamination.
- Remove damaged platforms from production.
- Check all other cassettes used with damaged platform.
- Follow proper cleaning procedures, using only the correct tools.
- Stop printing with cassette
Scratch
Description
Linear damage in the top window layer.
Cause
- Tool damage
- Using a sharp tool or using a tool incorrectly.
- Often occurring at the edges of the window where cleaning was aggressive.
Action
- Follow proper cleaning procedures, using only the correct tools.
- Remove inappropriate tools from production.
- Stop printing with cassette
Gouge
Description
Elongated damage, often coupled with drag marks, resulting in tears in the top layer of the window
Cause
- Tool damage
- Using a sharp tool or using a tool incorrectly.
- Often occurring at the edges of the window where cleaning was aggressive.
Action
- Follow proper cleaning procedures, using only the correct tools.
- Remove inappropriate tools from production.
- Stop printing with cassette
Avoid Window Damage
Window damage is caused by improper cassette care and can be avoided by knowing the pitfalls.
Contamination
Debris pressed by platform into the window's top layer.
Source Debris as small as 1 mm may damage the window.
- Cured bits of resin, such as small supports.
- Other hard, foreign material.
Action
- Filter and reclaim resin if contamination is suspected
- Determine source of contamination and eliminate from production area
- Document contamination for ongoing prevention
Damaged Platform
Gouges or burrs protruding from platform surface or perimeter dents or punctures window's top layer.
Source
- Aggressive use of metal tools.
- Dropping platform on floor or other hard surface.
Action
- Check all cassettes for damage at the matching location
Tool Damage
Damage caused by inappropriate usage of tools on the window.
Source
- Wrong tool: any metal tool or blade
- Broken tool
- Such as a damaged spatula
- Aggressive tool usage
- Too much force
Action
- Use only approved tools.
- Replace damaged tools.
- Do not use Acetone to clean spatulas. Use a dry towel or IPA dampened towel to clean.
- Do not use force on windows.
- Review Cassette Cleaning Protocol and update processes as needed.
Returning Damaged Cassette
If you find window damage during cassette inspection, go to Returning a Damaged Cassette and follow the instructions for your region.
For details about cassette entitlements and return policies, see Cassette RMA Policies.
Resources
M Series Cassette Care Handout
Printable reference to use in the lab.
M Series Cassette Care for Dental Handout
Printable reference to use in the lab.