Session 5: “Printing Solutions: Bringing Designs to Life”
Architect:
Syed Shayaan Haider - Markhor3D
Learning Objectives
In this session, students will:
- Observe 3D printed parts and note their features.
- Witness the process if 3D printing firsthand.
- Understand how to prepare a 3D design for printing using a slicer (Cura).
- Learn to check models for size, dimensions, overhangs, and wall thickness.
- Familiarize themselves with key slicer settings like supports and print quality.
- Witness the transition from digital models to physical objects through the 3D printing process.
Teaching Aids
Visual Aids:
- 3D Prints and toys for the students to observe.
- [Google Image Search “Cura slicer interface”]
- [Google Image Search “unsupported overhangs”]
- [Google Image Search “3D printing wall thickness”]
Required Equipment:
- Computers or tablets with Cura software installed.
- M3D Enabler 3D printer set up and ready to be used (basic sample file loaded too).
- Projector and screen for demonstrations.
Structure and Lesson Plan
Introduction & Show and Tell (10 minutes)
Teacher will showcase some ready made 3D prints. Ask students to notice its features:
- Layer Lines.
- Top and Bottom Most Surfaces.
- Surface Quality.
- Weight and Strength.
- Is it hollow or filled?
- Details.
It is encouraged that you start an 3D print of a simple model (preferably the M3D cube so) the students can witness the process firsthand.
Encouragement:
“We’ve designed amazing replacement parts in TinkerCad. Today, we’ll learn how to take the next step by preparing our models for printing, making sure they’re the right size and ready to print perfectly.”
Real-World Example Discussion:
- Ask students if they’ve ever on paper printed something that didn’t turn out as expected. Example, text was too small, colors were off, orientation of print was flipped. Similarly while making 3D objects especially 3D printing we face some issues such as incorrect sizing, surface finish qualities and cost. Explain that using a slicer helps avoid such issues.
In 3D printing, an overhang is like a part of your design that sticks out without anything underneath to hold it up. Imagine you’re building a tower with blocks. If you make the top block hang out over the edge, with nothing under it, it might fall down. In 3D printing, the printer starts at the bottom and builds up layer by layer. If there’s nothing under a part (like the block sticking out), the printer can’t print it properly, and it might get messy or fall apart. That’s why we add supports—like extra blocks underneath—to help hold up the overhang while it prints. [Google Image Search “unsupported overhangs”]
In simple terms: if a part of your design sticks out too much, the printer needs some
extra help (supports) to print it! [Google Image Search “supported overhangs”]
Sample Questions:
- “What do you think would happen if the model dimensions are off?”
- “Why do you think overhangs are a challenge in 3D printing?” [Chat-Gpt Search “why are overhangs tricky in 3D printing?”]
- In the context of 3D printing, cost means how much something takes in terms of money, time, or materials. For example:
- Money: How much you have to pay for the filament (the plastic the printer uses), or for the electricity to run the printer.
- Time: How long it takes to print your design. Some designs take a few minutes, while others can take hours!
- Materials: How much filament your design needs. Bigger or more detailed designs use more filament, which means they cost more to make.
- So, when we talk about the cost of 3D printing, we’re thinking about all these things together: money, time, and materials.
- “How can the design of the object impact Cost?” [Chat-Gpt Search “How do desgns effect the cost in 3D printing?”]
Demonstration of Cura Slicer (15-20 minutes)
Step-by-Step Cura Overview:
1. Import the Design:
- Open Cura and import the TinkerCad design file (.STL) that students have worked on.
- Recall how to export .stl file from Tinkercad [Included in TinkerCad Manual].
- Import .stl file to Cura using keyboard shortcut “ctrl+o” [Included in Cura Manual].
2. Adjusting Size and Dimensions:
Measure Twice Print Once
- Action: Explain how to verify the design’s size and scale it if necessary.
- Discuss why dimensions matter for both fitting replacement parts and for print quality.
- “If your puzzle piece is too big or small, it won’t fit. Let’s double-check the dimensions!”
- Prompt: Guide students to ensure their models match the measurements they took earlier in the project.
3. Supports and Overhangs:
- Action: Point out areas of the design that might have unsupported overhangs.
- Show how Cura can generate supports automatically or allow manual adjustment.
- Discuss why we add supports (to avoid sagging or failing prints).
- Example: “This toy wheel has a tricky overhang here. If we don’t add supports, the print will collapse.”
- [Google Image Search “3D printing supports overhangs Cura”]
- Red Color Highlights the area that cannot be printed without support.
- Effect of Printing without Supporsts:
- Red Color Highlights the area that cannot be printed without support.
4. Wall Thickness:
The thicker you make the walls of your object, the stronger and better it will be. But it will also use more material and take more time, which costs more.
- Action: Demonstrate how to adjust the wall thickness in Cura settings.
- Explain that wall thickness helps define the strength and durability of the printed object.
- “If the walls of your game token are too thin, it could break easily. Let’s make sure it’s strong enough!”
- Prompt: Show students how to experiment with different thicknesses depending on the type of object they’re printing.
- [Google Image Search “Cura wall thickness setting”]
5. Preview and Slicing the Model:
- Action: After checking all the settings, hit ‘Slice’ in Cura and show the estimated print time and layers preview.
- Ask students what they notice about the layers and how the model will be built up during printing.
Guided Practice (20 minutes)
Hands-On Activity:
1. Loading Models in Cura:
- Prompt: Have students load their own designs into Cura on their computers and follow along with each setting adjustment (size, supports, wall thickness).
2. Check for Printability:
- Guide students in previewing their models and making adjustments where necessary, ensuring dimensions are correct, overhangs are supported, and walls are thick enough.
Encouragement:
“Great job! You’re one step away from seeing your design come to life. Let’s make sure everything is perfect before we hit print.”
Allow students to explore Cura independently, adjusting settings for their designs based on what they’ve learned. Encourage them to ask questions if they need help refining their models.
Reflection and Follow-up (5 minutes)
Recap:
- Summarize the key settings in Cura: size and dimensions, supports, and wall thickness.
- Emphasize the importance of previewing models before printing to avoid errors.
Encouragement:
“We’re almost at the finish line! Once the printing process is complete, you’ll have a physical version of your design.”
Homework:
Ask students to finalize their Cura settings at home and be ready to print their designs next class. Remind them to check for overhangs and wall thickness.
Glossary
I. Slicer: Software that converts 3D models into layers for 3D printing.
II. Overhangs: Parts of a model that extend outward without support, requiring additional material to avoid collapse during printing.
III. Wall Thickness: The thickness of a model’s outer walls, impacting its strength and durability.
Teacher’s Resources:
- Guide to Cura (link to separate document).
- Getting started with M3D Enabler (link to separate document).
For suggestions, improvements, and corrections feel free to reach out at shayaanhaider@gmail.com