SINTER-2 USER GUIDE

SINTER-2 USER
GUIDE
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Markforged

480 Pleasant St
Watertown MA 02472
USA

https://support.markforged.com
support@markforged.com

For the latest PDF version of this document, visit our

support website.

Copyright © 2019-20 Markforged, Inc. All rights reserved.

Changes are periodically made to the information herein

which will be incorporated in revised editions of this
publication.

Markforged may make changes or improvements to

the product(s) described in this publication at any time
and without notice.

Version 1.1 / October 2020

SINTER-2 USER GUIDE

TABLE OF CONTENTS

SAFETY NOTES 4
CONNECTING YOUR FURNACE 5
NETWORK REQUIREMENTS 7
POWERING THE FURNACE ON/OFF 9
SETTING UP AND LOADING PARTS 10
SETTING GAS SUPPLY REGULATORS 11
SETTING INERT/MIX REGULATORS
SETTING RESERVE REGULATOR
DOOR FUNCTION AND OPERATION 14
STARTING A SINTER RUN 17
SMALL PART EXPRESS RUN 23
RAPID COOLING 25
REMOVING THE RAFT FROM A SINTERED PART 26
REPLACING THE GAS SUPPLY 27
INERT GAS USAGE
MIX GAS USAGE
REPLACING GAS SUPPLY FILTERS 31
FREQUENCY OF FILTER REPLACEMENT
FILTER REPLACEMENT PROCEDURE
REPLACING THE EXHAUST FILTERS 33
TROUBLESHOOTING A LEAK 38
STATIC PRESSURE CHECK
CLEARING AN EXHAUST CLOG 44
GAS USE MANAGEMENT 47

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SAFETY NOTES
Note: Consult the Safety Sheet included with your device for a comprehensive list of safety notes,
along with an explanation of the safety icons used in this manual.

REDUCING BURN RISKS

● During a sinter run, leave all doors closed
● Do not touch the surface of the Sinter-2 during a run
● Note that newly sintered parts are quite hot. Handle with care
● Never reach into the Sinter-2 to remove a newly sintered part without appropriate PPE

POWER DISCONNECT ACCESS

Take care to set up your Sinter-2 so that the disconnect and power switch are accessible at all times.

POWDER STATE
Never handle a partially sintered part, as it may be in a metal powder state. If a sinter run fails before
completing, always rerun the sinter process to completion before removing the part. If a second run is not
possible, contact Markforged Support. Metal powder should only be handled by trained personnel. See Safety
Sheet for further information.

ALWAYS FOLLOW SAFETY INSTRUCTIONS

Failing to use the Sinter-2 in the manner specified by the manufacturer may lead to unsafe operating conditions.
Follow all safety instructions posted on the unit and in the written documentation.

MIX GAS COMPOSITION

Always use mix gas of composition and purity as specified in the Facilities Guide. Using a higher
concentration of hydrogen can result in increased flammability risk.

DOOR LOCK INDICATOR LIGHT

The indicator light below the furnace door lights up to indicate that the door is locked. The door locks
automatically during a sinter run, and during certain onboard utilities, and will not unlock until the furnace tube
has cooled. In case of a potential powder state or power loss, the door remains locked, and will not unlock until
the powder state is cleared by a recovery run.

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USER GUIDE
CONNECTING YOUR FURNACE
BEFORE YOU GET STARTED
If you turned on your Sinter-2 before adding your furnace to your Eiger account, you must power cycle the unit
before it will be connected to your account. After shutting down the furnace, always wait at least 30
seconds before restoring power.

Note: The Sinter-2 does not utilize Wi-Fi; it requires an Ethernet connection.

CONNECT VIA ETHERNET (LAN)

1. Plug your Ethernet cable into the Ethernet port at the rear of the Sinter-2.
Note: Make sure that your LAN (Local Area Network) uses DHCP.
2. Once your Sinter-2 starts up, you should see an Ethernet symbol icon on the dashboard. If so, select it. If
not, access the network management utility (Menu > Settings >Network Manager).

OBTAIN YOUR FURNACE’S MAC ADDRESS

Your Sinter-2 cannot display its IP address, but it can display its MAC address for Ethernet .
1. Select the menu icon.

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2. Select Settings > System Info.

3. Select the Network button at the bottom of the screen to display your MAC address.

DISABLE ETHERNET
1. Select the Ethernet icon from the dashboard to open the Network Manager.
2. Select Offline, then Done.

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NETWORK REQUIREMENTS
For assistance with setting up your network, contact your internal IT team. Note that the Sinter-2 requires an
Ethernet connection for network access, and does not support Wi-Fi.

The following network requirements apply to all Markforged devices, not only the Sinter-2 furnace.

DHCP
Markforged devices support both DHCP and static IP configurations. For more information, see the Advanced
Networking Features article on the support site.

For proper operation, devices must be able to make outbound connections to services at the following
hostnames on the given ports (no inbound connections are needed). Most of these services are cloud-based
and geographically distributed, meaning that the underlying IP address ranges are fairly broad, and can change
over time, while the hostnames remain the same. This flexibility allows Eiger to maintain a higher level of
availability and performance, and this mechanism is common for many cloud-based applications you already
use and trust.

Devices will need to access the following hostnames on given ports (see table on next page).

DEVICE TIME SYNCHRONIZATION

Markforged products require accurate system time for securing HTTPS connections to Eiger and other
services; the SSL certificates used to ensure the authenticity of these services have time-limited validity, and
the printer’s time must fall within this window.

Currently, NTP -- Network Time Protocol, on UDP port 123 -- is the only supported mechanism for time
synchronization, and Markforged printers will attempt to connect to four different servers within the global public
NTP server pool, determined by querying hostnames ending in “.pool.ntp.org”.

Markforged printers also support customer-specified NTP servers. When a printer receives NTP server IP
addresses via DHCP (using DHCP option 042), these addresses will also be used for time synchronization
(connecting to UDP port 123).

BROWSER
Markforged products require the use of Google Chrome. WebSockets must be enabled.

If you are unable to connect to your furnace due to network issues, you will still be able to sinter offline. Please
contact Markforged Support for assistance if you are unable to connect to your furnace.

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HOSTNAME PORT PROTOCOL REQUIRED? REASON

s3.amazonaws.com, 443 TCP yes Downloading .MFP part files
mfeiger-production. produced by Eiger (printers
s3.amazonaws.com only)
cdn.eiger.io 443 TCP yes device operation
www.eiger.io 443 TCP yes Connecting to Eiger --
required for viewing printer
status, queuing print jobs,
keeping printer software up
to date, etc.
*.pool.ntp.org 123 UDP yes Time synchronization via
NTP is required for furnace
to connect securely to
Eiger. See note above about
NTP requirements and
alternatives.
ipv4.connman.net 80 TCP no Status check of furnace’s
network connection
-- primarily used for
troubleshooting
data.logentries.com 443 TCP no Remote logging of device
events and errors
data.logentries.com 10000 TCP no legacy logging (version older
than 9/14/2018)

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POWERING THE FURNACE ON/OFF

The Sinter-2 power switch is located on the lower left door on the front of the unit. Rotate the switch 90°
clockwise to the ON position to energize the Sinter-2 (see image).

Note the following safety concerns:

● When the unit is powered on, the lower left door cannot be opened.
● Gas will continue to flow through the system even when the power is turned off.
● Turning off the gas flow while the unit is hot may cause system damage.

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SETTING UP AND LOADING PARTS

Note: Only chemically debound (i.e. washed) “brown” parts can be run in the Sinter-2; see the Wash-1
User Guide for further information. Parts of different material must be sintered separately.

Part placement on the setter is important and should take into account part shrinkage and geometry. The
following guidelines will help ensure that your parts are loaded properly.

Parts can be loaded into the Sinter-2 in either the single- or double-layer configuration.

Only one of the two included setters may be used at a time. The double-layer setter tray allows for a larger
overall volume; note that parts on the upper layer must fit entirely within the height of the furnace tube.

Parts should be placed on the setters in the same orientation in which they were printed.

The part must rest on the same bottom surface in the Sinter-2 as in the Metal X printer, with the same vertical
orientation. The bottom of the printed part has a raft that will ensure that your parts are stable and in the correct
shape as they shrink in the furnace. The raft also keeps all of the support structures together.

(Raftless printing is also available; see the Support website for details.)

A part shrinks toward its center of mass, not its geometric center.

Make sure to lay out parts so that they will not come in contact during the sintering process. Never place one
part inside another in the furnace — e.g. never place a small solid part inside a ring-shaped part.
Note: Parts that touch during the sintering process may bond together, resulting in unrecoverable
failed parts.

Parts must be placed entirely within the confines of the setter trays.

A part that extends beyond the limits of the setter tray will droop downward, potentially warping the part. This
can irreparably damage the part. Always place parts entirely within the limits of the setter plate. Note that Eiger
will allow you to print parts with rafts wider than the setter plate. These parts can be sintered, but the raft must
first be trimmed.

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SETTING GAS SUPPLY REGULATORS

The Sinter-2 gas supply regulators must be carefully set to ensure proper functioning of the device. The built-
in Regulator Setting Utility makes this task easier, providing precise and immediate feedback about gas
pressure settings. When a notification banner appears at the bottom of the screen, you must set the gas
regulators before proceeding with Sinter-2 operation.

The utility will guide you through the process of setting the gas supply regulators. Each regulator has a target
operating range as indicated below. Note that the Sinter-2 cannot initiate a run unless the gas supply pressure
is within this target range; you must run the Regulator Setting utility in order to proceed. At each step of the
process, carefully read and follow the onscreen instructions to guarantee correct functioning.

SETTING INERT/MIX REGULATORS

Important note: When setting the regulators, always increase the setting slowly to avoid overshooting the
target range. Once gas is flowing, the pressure setting can’t be decreased, so if you go past the maximum
pressure, the utility will prompt you to try again.
1. Select the banner at the bottom of the screen.

2. The current regulator pressure readings will display onscreen. If either reading is out of spec, the
appropriate button will be enabled onscreen, indicated by a blue background, but either procedure can be
selected. Select either Set Inert Gas Pressure or Set Mix Gas Pressure.

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3. Follow the onscreen instructions and turn the regulator knob to lower the pressure setting below the
specified value, then select Next.

4. Follow the onscreen instructions and slowly increase the regulator pressure until it falls into the specified
range. Press Next.

5. The Sinter-2 will now verify the pressure setting. If it completes successfully, select Next; otherwise,
restart the process.

6. If necessary, repeat steps 2-5 for the other gas input.

7. When both regulators have been set correctly, select Done to exit the utility.

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SETTING RESERVE REGULATOR

There is no onscreen utility to set the reserve regulator. It should be manually set to 100psi when the system is
installed. It should only be necessary to carry out this procedure if the regulator setting is accidentally altered, or
if you are instructed to do so by Markforged Support.

If the reserve regulator drifts more than +/- 10psi from its 100psi target, follow these steps to reset the
regulator:
1. Run the Depressurize Gases utility (Utilities > Pressure Systems) and follow the onscreen instructions
to fully vent the inert side. It may be necessary to rerun the utility more than once before the system fully
depressurizes. When all three gauges zero out, press Done.
2. Close the inert shutoff at the top of the supply panel by turning it perpendicular to the pipe.
3. Decrease the reserve cylinder regulator setting, turning the knob counterclockwise until it feels loose. Do
not overturn the knob.
4. Open the reserve cylinder valve.
5. Slowly increase the reserve regulator setting until it reads 100psi.
6. Open the CLC (primary inert supply) valve.
7. Open the inert shutoff.

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DOOR FUNCTION AND OPERATION

DOOR OVERVIEW
The Sinter-2 door is designed to ensure safe operation of the furnace:
● Ensures that the radiation shield is inserted before commencing sintering run
● Will not close unless all six screws are fully torqued
● Will not unlock and open during a sintering run
● Automatically unlocks only when tube is fully cooled after a sintering run
● Remains locked when in powder state, until a recovery run is executed
● The indicator light below the door illuminates when door is locked

Note: The door will remain locked even when power is shut off.

IMPORTANT: If the latch handle is CLOSED when the furnace is powered OFF, the furnace must be
powered ON in order to open the latch handle.

The door has six screws that must all be tightened in order to close the latch handle. You will not be able to
close the latch handle unless all six screws are tightened:

The latch handle is open in the up position and closed in the down position:

Above: Open (Left) vs. Closed (Right)

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DOOR TORQUE PROCEDURE

In order to avoid leaks, the door must be properly torqued. This procedure is outlined in the Close Furnace step
of the Start Sinter utility.

Always use a star pattern when torquing screws. The numbers in the image below indicate the order in which
screws should be torqued.

1. Use the supplied torque wrench to fully torque each screw in the above pattern until the wrench clicks.
2. Close the door latch handle, moving it to the down position. You won’t be able to start a sinter run unless
the handle is in the closed position.

LOCK FUNCTIONS
The door lock is a safety feature that prevents users from opening the door during a sinter run or in powder
state, reducing the risk of coming into contact with high-temperature elements or metal powder.

In order to start a sinter run, the door must be properly torqued, and the latch handle must be in the closed
(down) position. This is highlighted in the Lock Furnace step of the Start Sinter utility.

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At the end of a sinter run, the door latch will become unlocked once the furnace has reached a safe
temperature. At this point, the user can open the latch handle.

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STARTING A SINTER RUN

SAFETY FIRST
● Always wear gloves when removing parts from the furnace after a sinter run
● Stay away from live electricity. Make sure that all sheet metal panels are securely attached while the unit is
powered on
● Observe all hot surface warnings. Never place items on top of the furnace. Never place combustible ma-
terials on or against the furnace

ONLINE VS OFFLINE SINTERING

The key difference between online and offline operation is with respect to monitoring. You can monitor the
progress of an online sinter run in Eiger, and will be notified via email when a run is interrupted or completes
successfully. When executing an offline sinter run, no such notification can be sent regardless of the outcome
of the run, and Markforged will be unable to provide automatic software updates or remote monitoring during
troubleshooting.

NOTE ON SINTERING DIFFERENT MATERIALS

Parts printed using different material must be sintered separately. No changes need to be made to the furnace
between runs of different materials.

PREFLIGHT CHECKS
See the Gas Supply Replacement section for details.
● Check gas supply
■ Mix, Inert reserve, and CLC cylinder valves are open?
■ CLC sufficiently full to complete run?
■ CLC pressure builder circuit valve open?
■ Sufficient mix gas present to complete run?
■ All gas lines securely connected?
■ Supply shutoffs open?

● Confirm brown part mass loss

■ Threshold mass loss achieved, or steady-state mass loss?
● Avoid leaks
■ Exhaust filter assemblies secure?
■ Inlet door securely closed?

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START A SINTER RUN

1. On the Sinter-2 touchscreen, select Start Sinter.

2. Confirm that your intended parts are fully washed and dried (i.e. brown parts). This step is important
because attempting to sinter green parts that are not fully debound will damage your furnace. Once you
confirm that the parts are fully washed and dried, select Next. Note: You can track the wash/dry
status of a green or brown part using the Wash Jobs page in Eiger. To access this page,
navigate to the main Eiger screen, then select Wash Jobs from the sidebar.

3. Select the material to be sintered. Be sure to select the right material: running the wrong schedule can
result in parts with undesirable attributes and/or furnace damage.

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4. Confirm that the inert gas supply is sufficient to complete the sinter run. If you are not using a CLC, you
must acknowledge the onscreen notification before proceeding.

5. Confirm that the inert reserve cylinder valve is open.

6. Confirm that the mix gas cylinder valves are open.

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7. Arrange your brown parts on the setter, making sure that none of the parts are touching or overhanging
the edges of the tray. Carefully place the loaded setter into the furnace tube, following placement
guidelines in the Set Up and Load Parts section. Ensure that the setter is fully level.

8. Slide the radiation shield into the tube until it hits the hardstop.
Note: Running the Sinter-2 without the radiation shield in place will destroy the door packing and
interrupt the run, potentially leaving a partially sintered part. Under normal circumstances, the
Sinter-2 will be prevented from kicking off a run if the radiation shield is not inserted.

9. Close the door, then follow this procedure to secure the door: (1) Moving in a star pattern from the top
left bolt (#1 in the image below), use the torque driver to tighten each bolt until it is flush with the door
surface. (2) Fully tighten all six bolts following the same star pattern.

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10. Lock the door after tightening all six bolts.

11. Ensure that the furnace’s wheel locks are deployed in the locked position.

12. Ensure that nothing is touching or leaning against the furnace.

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13. Press Start Furnace to begin a series of pre-sinter safety routines.

14. The Sinter-2 will carry out a precheck routine to ensure that the gas supply system is fully ready. You can
safely cancel the run at this point by pressing the Abort button onscreen. When the precheck is
complete, the sinter run will begin automatically -- no additional operator input is necessary. Some fan
noise will be audible during the Rapid Cooling check (see Rapid Cooling below).

If you are operating the Sinter-2 with an Internet connection (strongly recommended), you will be notified
when the run completes or is interrupted. If the Static Pressure Check fails, follow the steps in the Leak
Troubleshooting support article to determine the cause of the leak.

Note: The two most common locations of Sinter-2 leaks are the furnace door and the
exhaust filter fittings/canisters.

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SMALL PART EXPRESS RUN

The new Express Run feature allows you to sinter very small batches of 17-4 PH parts in up to 40% less time
than a standard sinter run. Express Runs are subject to the following limitations:
● Express Run works on Sinter-2 only -- the Sinter-1 does not support this feature
● Express Run only works with 17-4 PH stainless steel parts
● Express Runs can only be performed with a total run weight of 250 grams or less -- note that this
refers to the fully washed and dried brown part mass

If you select Express Run at runtime with more than 250g of parts in the furnace, you will experience quality
issues including part failure, surface finish damage, material property degradation, and furnace clogs.

Before the run, weigh your parts carefully with a scale that meets the Markforged requirements. (See the
Facilities Guide.) You can run any combination of small parts, so long as the total weight of the brown parts is
250g or less.

Express Runs will take around 17 hours. However, run estimates can vary up to an hour—since Sinter-2
installations vary from site to site, final run time will vary. In particular, customers running 50Hz power will
experience a longer cooling time, which will contribute to longer run times.

NOTE ON COST-EFFECTIVENESS
As the Express Run is limited to less than 250 grams total part mass, independent of gas and electricity
costs, it is generally cheaper in isolation but less cost-effective per gram of sintered part mass. As a result, we
recommend that you use the Express Run option only if you need a small (< 250 gram) part sintered quickly.

When possible, it is most cost-effective to fill a standard furnace run with more total mass rather than run
multiple individual Express Runs. For more information regarding gas consumption expectations for Standard vs.
Express runs, refer to the Gas Use Management support article.

ENABLE THE EXPRESS RUN

Ensure that your furnace’s firmware is updated to the most recent version. When you start a sinter run, select
17-4 SS as your part material, then select Small Part Express Run:

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Confirm your selection:

You will receive the usual update message when the run completes.

Note: Because the Sinter-2 does not monitor your brown parts, it is physically possible to kick off
an Express Run with more than 250 grams of parts on the setter. However, this will lead to part
degradation and run failure. If you choose the Express Run in error, select Go Back and begin a regular
run instead.

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RAPID COOLING
The Sinter-2 features a rapid cooling system that keeps overall sinter run times low compared to a passive
(ambient) cooling system.

The system produces blower and fan noise throughout the sinter run, which is no cause for alarm. Two levels of
noise can be detected during operation: the blower shuts off shortly before cooling is complete, while quieter
fans continue operation until the end of the run.

Immediately after shutoff, it is normal to see a temperature bump as the active cooling system disengages.

Note that rapid cooling system will continue to run until the furnace is cool even in the event of a canceled sinter
run. The door will remain locked until the furnace is cool.

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REMOVING THE RAFT FROM A SINTERED PART

Supplies:
● Vise
● Hammer

RAFT REMOVAL
1. Place the part upside down in a vise such that the top face of the raft rests on top of the vise jaws. Do not
squeeze the part itself in the vise.

2. Cup your hand below the part or lay down something soft to catch the part when it separates.
3. Use a hammer to tap the bottom face of the raft -- gently at first, then more forcefully if necessary. Take
care not to drop the part onto the floor.

TROUBLESHOOTING RAFT REMOVAL

If the raft and part are fused directly together, metal to metal, and the part geometry itself is not at fault,
please take the following troubleshooting steps to investigate your Metal X printer function before contacting
Markforged Support.
1. Run the XY Offset utility on your Metal X printer. For more information, see Adjusting Release Nozzle XY
Offset in the Metal X Printer User Guide.
2. Run the Extrusion Flow Check for release material on your Metal X printer. For more information, see
Extrusion Flow Check for Release Material in the Extrusion Flow Check section of the Metal X
Printer User Guide.
3. Download the device logs for your Metal X printer:
● Online printer: download logs from Eiger by selecting Devices from the sidebar, selecting the printer you
used for the stuck part, and pressing Download Logs near the top of the page.
● Offline printer: download logs by inserting a FAT32-formatted USB drive into the printer and navigating to
Menu > Storage > Save Logs on the touchscreen.

4. Contact Support. Attach the device logs to the support ticket and, if possible, share the part in question
by navigating to its Part View page on Eiger and clicking the Get Support button.

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REPLACING THE GAS SUPPLY

The Sinter-2 draws on three gas supply sources:
● one (1) medium or high pressure cryogenic liquid container (CLC) of inert gas, OR a 6-cylinder multipack
of inert gas (see CLC vs Multipack support article)
● two (2) high pressure mix gas cylinders
● one (1) reserve high pressure inert gas cylinder

This section gives expected consumables lifetimes, replacement procedures, and operator best practices for
the Sinter-2 gas supply.

CLC OVERVIEW
The Sinter-2 furnace, gas panel, and gas supply, including the cryogenic liquid container (known in the USA,
though not worldwide, as a dewar), should only be operated by trained personnel.

The following brief overview of CLC functionality does not substitute for proper gas-safety training.

CLCs are designed to store, in liquid form, substances that boil below room temperature. Its inner and outer
tanks are separated by insulation in a vacuum, which slows heat transmission from the environment to the inner
tank full of cryogenic liquid (in the case of the Sinter-2, pure liquid argon).

As the cryogenic liquid boils, pressure builds in the tank; a relief valve periodically lets off an insignificant amount
of excess gas to relieve the pressure. Do not be alarmed by this loud hissing; this behavior is normal. Liquid
and gas access ports allow users to draw off the cryogenic substance in either form, and a service port allows
refilling.

To maintain a minimum pressure inside the tank, the CLC will incorporate a pressure-building circuit. Opening
the pressure-building valve draws liquid from the bottom of the CLC into a pressure-building coil. The coil
passes through the insulating vacuum, which is warmed by the outside air; this causes the liquid in the circuit to
vaporize more quickly. This additional gas then feeds back into the supply.

A CLC will also incorporate a burst/rupture disk as a failsafe.

As mentioned elsewhere in this document, we do not consider the pressure gauge on your CLC a reliable guide
to remaining inert gas supply.

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GAS SUPPLY PANEL ILLUSTRATIONS

4 3 2 1

Mix Relief Valve

Post-filter
D Inert Shutoff Mix Shutoff Moisture Sensor Mix Regulator D

CLC Relief Valve

C C

B Regulated Inert B
Relief Valve

CLC Regulator Inert Reserve Regulator Mix Cylinder Change

Inert Reserve Over Valve
CLC Pressure Sensor Pressure Sensor Mix Cylinder Pressure Sensor Pre-filter Moisture Sensor

A A
Markforged
GAS SUPPLY REV

MODULE LAYOUT D
4 3 2 1

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INERT GAS USAGE

Assuming the furnace is used once a week and the inert cryogenic liquid container does not continue to purge
inert gas during downtime, a filled 230-liter CLC contains enough inert gas for up to 5 runs depending on local
conditions. At the beginning of each sinter run, a reminder will flash onscreen to check the liquid fill level of your
inert CLC, to confirm that it contains enough to complete the run. Be sure to monitor
● The number of runs since CLC replacement
● Whether or not the Sinter-2 has switched over to draw on the reserve inert gas cylinder

The reserve inert cylinder does not contain enough gas for a sinter run on its own. If the Sinter-2 switches over
to draw on the reserve cylinder in the middle of a run, the sintered parts will likely be compromised; allow the run
to complete, then immediately replace both the CLC and the reserve cylinder.

Warning: Connecting a high-pressure reserve or mix gas cylinder or improperly regulated cylinder
multipack to the CLC whip on the supply panel can cause a rapid release of inert gas, posing an
asphyxiation risk. Always use proper facility ventilation and evacuate the area in case of error. Refer to
the Facilities Guide for more information.

MIX GAS USAGE

A pair of high pressure mix gas supply cylinders can last a maximum of 3 runs. The cylinders should be
swapped out individually, as soon as they are spent. You need not wait to change both cylinders at once.

When one mix gas cylinder draws down to approximately 250psi, the Sinter-2 will automatically begin drawing on
the second cylinder. When this occurs, wait until the sinter run ends, then swap out the spent cylinder following
the procedure below.

If you do not swap out the used cylinder right away, the Sinter-2 will continue to draw on the second cylinder
until it also reaches the ~250psi threshold. At that point, the Sinter-2 will begin to draw on both mix gas
cylinders together, as long as they generate sufficient pressure to continue the run. However, the very bottom of
the mix gas in a cylinder may contain impurities, leading to failed parts.

Moreover, if the Sinter-2 runs out of mix gas in the middle of a run, it will generate a Firmware Error message and
terminate the run. Therefore, it is important to swap out mix gas cylinders as they become spent. Note that it is
possible to safely swap out a spent mix gas cylinder during a sinter run.

Always take appropriate safety measures when handling gas cylinders and cryogenic liquid containers (CLCs).

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MIX GAS REPLACEMENT PROCEDURE

The following text does not substitute for proper gas-safety training.

When not being moved, gas cylinders must be securely mounted to the storage rack with a strap or chain.
Cylinders must always be safely capped when not in use.
1. Close gas cylinder valve(s).
2. Disconnect spent gas cylinder(s) from gas panel and replace protective cylinder caps.
3. Safely remove the empty cylinders from the gas supply rack and transport them to their designated
storage area.
4. Safely transport the replacement cylinder(s) to the gas supply rack and secure in place.
5. Connect the replacement gas cylinder(s) to the gas supply panel.
6. Open the valve(s) on the gas cylinder(s). We recommend opening each valve fully, then tightening a half-
turn to reduce pressure on the outermost thread.

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REPLACING GAS SUPPLY FILTERS

FREQUENCY OF FILTER REPLACEMENT
Over time, gas supply filters become increasingly saturated. Clogged supply filters will not cause sinter runs
to fail, but the resulting increased moisture in the gas mixture can lead to reduced part strength. An onboard
counter will notify you when the supply filters need to be replaced. Note that impurities in your gas supply may
lead to contaminated parts, necessitating more frequent filter replacement.

FILTER REPLACEMENT PROCEDURE

Note: Due to the constrained nature of the fittings, the filters can be somewhat difficult to thread.
Always change both supply filters at once.
1. Begin by closing both mix gas cylinder valves. Then run the Depressurize Gas utility to fully purge any
gas on the mix side of the system. When complete, return to the main menu.
2. Turn the mix gas regulator counterclockwise to zero it out. Do not overturn.
3. Select the menu icon from the dashboard.
4. Select Gas and Materials > Supply Filters to begin the filter-replacement utility. Running the utility will
reset the furnace’s internal counter; after a fixed number of runs you will receive an onscreen notification
to replace the filters again.
5. Remove the cover from the gas supply panel.
6. Verify that the mix gas shutoff is open (parallel to the pipe).
Note: Failure to complete steps 1-2 and reduce mix gas pressure before completing the
following steps may lead to O-ring damage.
7. Unscrew the thumbscrews at the top of each filter, hanging the loose flex tube on the hook mounted
above the filters. Then unscrew the bottom thumbscrews and carefully lift the filters off the bottom
mounts.
Note: Gas will begin to flow when you unscrew the top thumbscrews. This behavior is to be
expected.
8. On the touchscreen, press Verify Removed to confirm that the used filters have been removed from the
system.
9. Unscrew both caps on the first filter to reveal the foil seals.
10. With the gas flow arrow on the side of the filter pointing UP, align the foil seal on the bottom of the first
filter with the penetrator on one of the lower fittings.

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11. While holding the first filter against the penetrator, bring the thumbscrew that floats on the lower fitting up
to the filter, then finger-tighten the filter onto the lower fitting.

12. Repeat steps 9-11 with the second filter and screw it in finger-tight.
13. Press the upper filter fitting down against the top foil seals of both filters, then finger-tighten the top
connections at the same time. Ensure that the upper fitting fits securely into its hook.
Note: If you fully tighten one top connection before tightening the other, you may have difficulty
creating a seal in the second fitting.

14. On the touchscreen, press Verify Installed to confirm the filter replacement.
15. Run the mix gas Regulator Setting Utility.
16. Replace the gas panel cover.

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REPLACING THE EXHAUST FILTERS

The exhaust filters of the Sinter-2 furnace capture byproducts from the sintering process. A single filter should
last approximately three (3) runs. The Sinter-2 switches automatically between filters as needed.

The system will remind you to replace the spent filter via a yellow notification bar on the touchscreen. The filter
must be replaced when indicated.

Every time you replace an exhaust filter, you should also remove the filter canister and clean the canister and
filter housing cap with a lint-free cloth, per instructions below.

Do not use third-party filters with your Sinter-2 furnace. Visually identical but materially distinct exhaust
filters are available from third-party sellers. However, non-Markforged-approved filters will not fully capture the
waste binding material, leading to failed sinter runs and potentially damaging the furnace.

A used filter will take on a yellowish color as it is coated with wax with some amount of black carbonization
along the top edge, as seen in the picture below. Consult your local waste management facility for safe disposal
guidelines.

Supplies
● Replacement filter
● Nitrile gloves
● Lint-free cloth
● Pipe cleaners

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ROUTINE MAINTENANCE
We recommend cleaning the filter housing cap, inlet fitting, and inlet tube every time you swap out the exhaust
filter, using a lint-free cloth and pipe cleaners.

Furthermore, we presently recommend breaking down and cleaning the exhaust assembly approximately every
30 sinter runs.

EXHAUST FILTER REPLACEMENT

1. Select the Menu button in the upper right of the touchscreen.
2. Select Gas and Materials > Exhaust Filter to begin the filter-replacement utility. Running the utility will
reset the furnace’s internal sinter-run counter for that filter; after a fixed number of runs you will receive an
onscreen notification to replace the filters again.

3. In this example, filter 1 is being replaced. Open the exhaust access panel on the door side of the Sinter-2.

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4. Remove the exhaust filter canister from the furnace by rotating the T-handle counterclockwise. The
canister will be easily removable once it is fully loosened from the cap.

5. Remove the used exhaust filter from the canister and safely dispose of it. Some liquid wax may remain at
the bottom of the cylinder. Soak up with a lint-free cloth and dispose of with the filter.

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6. Use the provided pipe cleaners and a lint-free cloth, remove any wax from the bore and face of the
exhaust housing inlet, inspecting the gasket from below to confirm a clean surface for the seal. Make
sure to work the pipe cleaner several inches into the inlet bore.
Doing so every time you replace the exhaust filter should prevent clogs from building up in the inlet.

7. Wipe down the inner surface of the canister with the lint-free cloth.

8. Select Verify Removed on the touchscreen.

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9. Place the new filter in the canister.

10. Hold the exhaust filter canister up against the seal of the cap and tighten the T-handle, rotating it
clockwise until the canister is securely fitted in place. Do not rotate the canister to tighten; doing so will
damage the exhaust canister seal.
Note: Overtightening can damage the canister seal. Make a tight seal without using excessive
force.
Note: The exhaust filter canister is a common site for system leaks -- take care to mount the
canister well seated on the gasket and tightly securely against the cap.
11. Select Verify Installed on the touchscreen and close the exhaust panel door.

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TROUBLESHOOTING A LEAK
The Sinter-2 system includes the gas supply, piping, tube chamber, and exhaust filtration and ventilation.
Onboard utilities and testing can be used to determine whether the Sinter-2 has a leak and, if so, isolate each
compartment in turn to determine its root cause.

Minor operator error is the most common cause of leaks. When a leak is detected, first investigate and secure
any components you might recently have interacted with: inlet door, exhaust filter canister, etc. The Sinter-2
control panel is tested as a module by the manufacturer and is unlikely to be a source of leaks.

This leak troubleshooting procedure therefore works from the “outside in,” beginning with consumables and
operator interaction and only then proceeding to internal components. For the final steps, you should contact
your Reseller, who will carry out additional diagnostics.

Note: SPC == “Run Utilities > Pressure Systems > Static Pressure Check routine.”

Note: The combustible leak detector will return false positives when Snoop is present.

STATIC PRESSURE CHECK

Note: The Static Pressure Check will fail if the furnace has not fully cooled.
1. Select Utilities > Pressure Systems > Static Pressure Check on the touchscreen.

2. The system will proceed with a series of checks to confirm proper functioning. If the utility completes
successfully without detecting a leak, press Done; otherwise, proceed with leak troubleshooting.

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INITIAL LEAK TROUBLESHOOTING WORKFLOW

1. SPC. If the check fails, proceed to next step.
2. Lift the door handle to disengage the latch so that you can access the door screws. Tighten each door
screw with the included 4 mm hex torque wrench until the wrench clicks. Lower the door handle to engage
the latch. SPC.

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3. Inspect the canister seal and gasket: Open the right side panel door, then remove the canister and
inspect the gasket; it should be evenly seated within the canister bracket, clean and clear of wax. If there
is debris present, use a lint-free wipe to clean the gasket. Securely reinstall the exhaust filter canister,
ensuring that it is centered on the gasket. If necessary, repeat this step for the other canister. SPC.

Above: Good (left) vs bad (right) filter canister gaskets

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4. Disengage the door latch and unscrew the door screws to open the door. Grease the O-ring on the end
cap face. Look at the inside of the door at the ring of grease; dry spots on the door may indicate matching
dry spots on the O-ring and a likely place for a leak.

Use a star pattern to tighten the door screws with the included torque wrench until the wrench clicks.
Re-lock the door. SPC.
5. Open the door about 20 degrees. Remove the upper sheet metal panel around the door. First loosen but
don’t remove the 2 screws (circled in yellow) along the bottom of the top panel and the 3 screws in the row
below those so the lower panel is no longer securing the upper panel. Remove the 7 screws (circled in red)
along the sides and top of the upper panel with a 3mm hex driver. Lean the upper panel out, lift up and
slightly to the right to clear the bottom lip and then slide the upper panel over the door to the left. SPC.

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Note: The Sinter-2 contains high voltage and other hazards. Do not remove any panels or protective
guards without appropriate technical training and experience necessary to minimize the risks to
yourself and others. If you do not feel comfortable accessing service areas of your Markforged
product, please contact your Reseller.

Note: Never begin a sinter run without all sheet metal and guards in place.
6. Disconnect the exhaust tube from the end cap (13/16” wrench to hold fitting in place, 7/8” to back off the
nut) and cap the exhaust with the SS-600-P Swagelok plug provided in your accessory kit -- follow
standard Swagelok fitting instructions. SPC.

7. If SPC does not fail in the Stabilize or Leak Check stages, the leak is presumably in the exhaust pathway.
If SPC fails in the Stabilize or Leak Check stages, the leak is likely in either the retort or the supply system.
NOTE: The SPC will fail the Depressurize portion of the SPC with the exhaust plugged such that
gas cannot escape the retort.

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8. If SPC fails in the Stabilize or Leak Check stages, tighten the gas lines at the manifold block above the
exhaust filter canisters, and where they enter the end cap.

9. With the right side sheet metal panel removed, remove the door by unscrewing and removing the door
hinge screw with a 3mm hex driver. While holding the door, slide the door off the hinge block. Tighten
each end cap screw 1/4 turn to ensure that the door packing is properly sealed.

10. Note: If your Reseller is present, run Utilities > Gas Flow Controls > Mix Gas Flow Check and use the
combustible gas leak detector to determine whether H2 is present. This will help the Reseller determine
the approximate physical location of the leak. Note: the leak detector will return false positives when
Snoop is present.
11. Note: Your Reseller also has the option of swapping the mix and inert connections at the rear of the
furnace and running the Static Pressure Check using mix gas. This will give the Reseller more time to use
the combustible leak detector and is less likely to produce false positives for leaking hydrogen. This step
should only be performed by the Reseller, never by a user. After this step, it is imperative that the Reseller
restore the mix and inert lines to their original configuration.

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CLEARING AN EXHAUST CLOG

SAFETY FIRST
If a sinter run is aborted due to a clog and the furnace displays a POWDER STATE warning, you cannot open
the main doors while troubleshooting the clog. Partially sintered metal material is potentially very hazardous; for
health and safety reasons, you must always complete a full recovery run before removing any parts from the
furnace.
Note: The parts will not be usable; the purpose of the recovery run is to ensure operator safety.

Note: The door will remain locked while items are in powder state. Do not attempt to force open the
door.

Once the parts have been completely sintered and cooled, the furnace will be safe to open. Note that clogs
which occur at the very beginning or end of a sinter run will not result in powder state.

ROUTINE MAINTENANCE
At present, we recommend routinely breaking down and cleaning the exhaust assembly approximately every 30
sinter runs.

CLEARING AN EXHAUST CLOG

Always wear nitrile gloves when handling the exhaust filters.
1. Turn off the flow of gas by closing the mix and inert gas shutoffs at the gas supply panel. Then turn off
power to the furnace by rotating the switch on the front panel.
2. Open the lower right sheet metal panel to access the exhaust filter canisters.
3. Remove the exhaust filter canisters by unscrewing the tee handle of each filter, and safely dispose of the
clogged filters.

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4. For ease of access, remove the lower exhaust panel by removing the 12 screws using a 3mm hex driver.

5. Remove the tubes and fittings connecting the main tube to the exhaust filters by loosening the fittings
using a 7/8” wrench as shown in the image below. Then disconnect the exhaust flex line from the end cap.
Please refer to the Swagelok Installer’s Pocket Guide for proper handling of Swagelok fittings.

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6. Once you have removed these components, check the exposed tubing and channel, labeled in the
photos below. Any buildup on these components can be removed from the inner cavity surfaces with a
pipe cleaner.

7. Use a lint-free cloth to clear out any wax buildup in each exhaust filter canister inlet.
8. Reattach the exhaust tubing assembly to the exhaust end cap -- referring to the Swagelok fitting
reinstallation instructions in the Pocket Guide -- then install the replacement exhaust filter and canister.
(Note that improperly tightened Swagelok fittings are a common cause of gas leaks.)

9. Check the wax tray (located beneath the exhaust filters) for significant wax buildup. If any solid wax is
found in the tray, contact Markforged Support for further instructions on cleaning the exhaust system.
10. Power up the Sinter-2 and restore mix and inert gas flow.
11. Run the following utilities to make sure gas is flowing and no leaks are present. The exhaust assembly is
the most common site for gas leaks, so double check that all components are securely reinstalled:

● Purge Valve Check (confirms system can depressurize; failure may indicate full or partial clog)
● Gas Flow Check (will fail quickly with a high-pressure warning if clog remains)
● Static Pressure Check (confirm no leaks from reassembled components)

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GAS USE MANAGEMENT

The number of possible sinter runs you can expect before replacing your gas cylinders depends on the furnace
type, material being sintered, and sinter run frequency. Refer to the table below to learn more.

Note: All numbers have the potential to differ slightly from your experience due to environmental
operating conditions. Regional differences can affect gas offerings. For more information on
approved gas setups and specifications, see the Metal X System Facilities Guide.

Notes:
1. Runs possible for a material schedule assumes that you are only running that schedule. Introducing other
material schedules can change your runs possible.
2. Numbers are only valid if you are running the approved gas setups specified in the Gas Supply
Requirements section of the Metal X System Facilities Guide.
3. Run total numbers do not include gas used during installation, any failed/incomplete runs you may
experience, or any utilities you may run between part runs.
4. The inert reserve cylinder (not listed in the table above) will need to be changed any time it is used.
Typically, this will be when the primary inert cylinder has run low.
5. Annealing includes the gas used for the sintering process as well.

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