J5 Pre-Heater Clogging

Heat Transfer | Controls Logic| Parameters | Materials Science Chemical Compatibility | Operations

October 2024 – July 2025

System Engineering

Project Scope and Background

Spontaneous polymerization of printing resin in the pre-heater renders the machine inoperable.
Affecting ~1500 machines.
Expensive replacement part and extensive technical service visit.
Operational savings goal: ~$120,000 yearly.

Research and Root Cause Analysis

I led a Cross-Functional Root Cause Investigation effort, involving mechanical design, system engineering, software, chemical compatibility, materials science and metallurgic research.

Printing Materials Root Cause was identified as a specific chemical component in UV-curable printing resin that had contributed to the failure.

System-level Root Cause was identified as unoptimized temperature control logic, contributing to premature aging of the unprinted resin in the system, and contributing to unwanted polymerization.

Mechanical level Root Cause was identified as compromised pre-heater resin path design, accelerating the polymerization process.

Chemical compatibility and metallurgic Root Cause was identified as below-standard anodized coating in critical locations.

Implementation & Outcomes

As it happens sometimes, the scope of this project was significantly bigger than expected, and the impact on the Products and engineering approach was profound.

On the Products level, we’ve implemented 4 major changes:

Mechanical redesign to the pre-heater’s resin path.
Introduction of advanced temperature control logics, implemented on the printer’s software in 3 phases.
Revised anodization requirements and test methods.
Introduction of improved resin compounds across most of the lineup.

The impact on the Engineering Approach was significant as well.

My team’s initial scoping was that this project will include a medium-level mechanical change, and a software patch. But as my investigation work progressed, I’ve found increasing amount of areas in need of rethink, redesign and deeper understanding.

With this in mind, I assembled a Cross-Functional Team, comprised of engineers from Software, Chemistry and Product departments, with me leading Mechanical and System Engineering aspects.

After Action Review process concluded with recommendations such as the importance of Brainstorming sessions, inclusion of all aspects of product development from an early stage, and more.

the implementation of the solutions and design improvements was a big project on its own, requiring significant operational effort on products with global supply chains and wide costumer install base.

J5 Pre-Heater Clogging

Heat Transfer | Controls Logic| Parameters | Materials Science Chemical Compatibility | Operations

System Engineering

Project Scope and Background

Spontaneous polymerization of printing resin in the pre-heater renders the machine inoperable.

Affecting ~1500 machines.

Expensive replacement part and extensive technical service visit.

Operational savings goal: ~$120,000 yearly.

Research and Root Cause Analysis

I led a Cross-Functional Root Cause Investigation effort, involving mechanical design, system engineering, software, chemical compatibility, materials science and metallurgic research.

Printing Materials Root Cause was identified as a specific chemical component in UV-curable printing resin that had contributed to the failure.

System-level Root Cause was identified as unoptimized temperature control logic, contributing to premature aging of the unprinted resin in the system, and contributing to unwanted polymerization.

Mechanical level Root Cause was identified as compromised pre-heater resin path design, accelerating the polymerization process.

Chemical compatibility and metallurgic Root Cause was identified as below-standard anodized coating in critical locations.

Implementation & Outcomes

As it happens sometimes, the scope of this project was significantly bigger than expected, and the impact on the Products and engineering approach was profound.

On the Products level, we’ve implemented 4 major changes:

Mechanical redesign to the pre-heater’s resin path.

Introduction of advanced temperature control logics, implemented on the printer’s software in 3 phases.

Revised anodization requirements and test methods.

Introduction of improved resin compounds across most of the lineup.

The impact on the Engineering Approach was significant as well.

My team’s initial scoping was that this project will include a medium-level mechanical change, and a software patch. But as my investigation work progressed, I’ve found increasing amount of areas in need of rethink, redesign and deeper understanding.

With this in mind, I assembled a Cross-Functional Team, comprised of engineers from Software, Chemistry and Product departments, with me leading Mechanical and System Engineering aspects.

After Action Review process concluded with recommendations such as the importance of Brainstorming sessions, inclusion of all aspects of product development from an early stage, and more.

the implementation of the solutions and design improvements was a big project on its own, requiring significant operational effort on products with global supply chains and wide costumer install base.

This was my first time leading a Cross-Functional System Engineering project, and for its success I received “Excellence Recognition” award.

Location

Contact

J5 Pre-Heater Clogging

Heat Transfer | Controls Logic| Parameters | Materials Science Chemical Compatibility | Operations

System Engineering

Project Scope and Background

Spontaneous polymerization of printing resin in the pre-heater renders the machine inoperable.

Affecting ~1500 machines.

Expensive replacement part and extensive technical service visit.

Operational savings goal: ~$120,000 yearly.

Research and Root Cause Analysis

I led a Cross-Functional Root Cause Investigation effort, involving mechanical design, system engineering, software, chemical compatibility, materials science and metallurgic research.

Printing Materials Root Cause was identified as a specific chemical component in UV-curable printing resin that had contributed to the failure.

System-level Root Cause was identified as unoptimized temperature control logic, contributing to premature aging of the unprinted resin in the system, and contributing to unwanted polymerization.

Mechanical level Root Cause was identified as compromised pre-heater resin path design, accelerating the polymerization process.

Chemical compatibility and metallurgic Root Cause was identified as below-standard anodized coating in critical locations.

Implementation & Outcomes

As it happens sometimes, the scope of this project was significantly bigger than expected, and the impact on the Products and engineering approach was profound.

On the Products level, we’ve implemented 4 major changes:

Mechanical redesign to the pre-heater’s resin path.

Introduction of advanced temperature control logics, implemented on the printer’s software in 3 phases.

Revised anodization requirements and test methods.

Introduction of improved resin compounds across most of the lineup.

The impact on the Engineering Approach was significant as well.

My team’s initial scoping was that this project will include a medium-level mechanical change, and a software patch. But as my investigation work progressed, I’ve found increasing amount of areas in need of rethink, redesign and deeper understanding.

With this in mind, I assembled a Cross-Functional Team, comprised of engineers from Software, Chemistry and Product departments, with me leading Mechanical and System Engineering aspects.

After Action Review process concluded with recommendations such as the importance of Brainstorming sessions, inclusion of all aspects of product development from an early stage, and more.

the implementation of the solutions and design improvements was a big project on its own, requiring significant operational effort on products with global supply chains and wide costumer install base.

This was my first time leading a Cross-Functional System Engineering project, and for its success I received “Excellence Recognition” award.

Injection Molding Design

New Product Introduction

Location

Contact