Electrode Maintenance

Changing and Sharpening Electrodes

As electrodes wear, they will become dull and result in lower quality and less attractive welds. Sharpening or changing them out periodically is important to maintain weld consistency.

The Orion's electrodes are made of tungsten and are double ended, meaning that either end can be used for welding. The 1mm electrodes require the included collet with the small hole in the center. This collet is pre-installed in the stylus when shipped. The 1mm electrodes cannot be used with the other non-holed collet, and similarly the 0.5mm electrodes cannot be used in the holed collet. Inserting and tightening electrodes into the wrong collet can damage the stylus.

When swapping electrodes, use caution when touching any part internal to the stylus. With extensive use, the internal parts and especially the electrode WILL BE HOT. Allow them to cool before attempting to change electrodes. As an added safety precaution, it is recommended to enter a menu or put the Orion in Stop Mode. To change the electrode, first remove the stylus hull by gently pulling it from the stylus. Then loosen the collet cap by twisting it counter-clockwise. Grasp the electrode and push it into the collet to free it, then pull it out to remove it.

If changing electrode sizes, the collet must also be swapped out. To do this, remove the collet cap by continuing to twist it counter-clockwise. The collet should be loose and will remain in the stylus shaft. If it is not loose, gently tap it out with a screwdriver or other small tool. Replace the collet with the desired one. Replace the collet cap, but do not tighten yet. Insert the fresh electrode into the collet and lock it into place by hand tightening the collet cap in a clockwise direction. Finally, replace the stylus hull by pushing it snuggly back into place. See below for an exploded view of the stylus.

When sharpening electrodes, be sure to remove them from the stylus first. Use the included diamond wheel in a rotary tool to reshape the tips. Be sure to follow all safety instructions provided by the rotary tool manufacturer. When grinding down the tips, attempt to create a 15° angle to the tip as shown below. A sharp tip welds better in much the same way that a sharp pencil writes better.