[DL54] Finalizing Designs and Preparing for Printing

M3D DesignLab DesignLab Grade 5
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Session 4: “Finalizing Designs and Preparing for Printing”

Architect:
Syed Shayaan Haider - Markhor3D

Session Overview

In this session, Grade 5 students will complete their functional object designs in TinkerCad, ensuring they are ready for 3D printing. They will learn how to identify and fix common design issues such as unconnected parts, overhangs, and thin walls. The session introduces DFAM (Design for Additive Manufacturing) principles, which help create models that print successfully and function well. Students will also learn how to export their final designs as STL files, preparing them for the next step in the printing process.

Learning Objectives

By the end of the session, Grade 5 students will:

  • Finalize Their Designs: Complete their functional object models in TinkerCad with accurate dimensions and proper connections.
  • Understand DFAM Principles: Learn the basics of Design for Additive Manufacturing to create print-ready models.
  • Identify Common Design Issues: Recognize and fix problems like unconnected parts, overhangs, and thin walls.
  • Prepare Models for Printing: Learn how to export their completed designs as STL files for 3D printing.

Teaching Aids

Visual Aids:

  • Demonstration Videos: Clips showing how to finalize designs, identify common issues, and export STL files.
  • Step-by-Step Guides: Simple screenshots or slides outlining each step of checking and exporting designs.
  • Example Models: Display models with common issues and their corrected versions to illustrate DFAM principles.
  • Infographics: Visual guides on DFAM principles and common design issues in 3D printing.

Required Equipment:

  • Computers or Tablets:
    • One per student or pair, with TinkerCad logged in and their designs ready to edit.
    • Internet access for accessing tutorials and reference materials.
  • Interactive Whiteboard or Projector:
    • For live demonstrations of finalizing designs and exporting STL files.
  • Printed Examples:
    • Physical examples of printed objects highlighting common issues and good designs.
  • Assistants or Volunteers:
    • Additional adults to help guide students through identifying and fixing design issues.
  • Notebooks and Pens:
    • For students to take notes on DFAM principles and their design adjustments.

Structure and Lesson Plan (Total Time: 60 minutes)

1. Introduction and Linking to Previous Sessions (10 minutes)

  • Greet the Students:
    • “Good morning, Grade 5! Today, we’re going to finalize your designs and get them ready for 3D printing.”
  • Recap Previous Sessions:
    • “Last time, you designed useful objects like phone holders and desk organizers. You used measurements and alignment tools to make sure everything was the right size and fit together perfectly.”
  • Present the Session Overview:
    • “Today, we’ll finish your designs, check for any problems that might stop them from printing correctly, learn about Design for Additive Manufacturing (DFAM), and export your models as STL files.”

2. Understanding DFAM Principles (15 minutes)

  • Explain DFAM:
    • “DFAM stands for Design for Additive Manufacturing. It means designing your models in a way that makes them easy to print and strong enough to use.”
  • Introduce Key DFAM Principles:
    • Connected Parts:
      • “Make sure all parts of your model are connected. Unconnected parts can fall apart or fail to print.”
    • Overhangs:
      • “An overhang is a part of your model that sticks out without support. Too many overhangs can cause printing problems.”
    • Thin Walls:
      • “Walls that are too thin might break easily. Make sure your walls are thick enough to be strong.”
    • Proper Supports:
      • “Some designs need extra support when printing. Think about where you might need to add supports to keep your model sturdy.”
  • Show Example Models:
    • “Here is a model with unconnected parts and overhangs. Let’s see how we can fix these issues to make it print successfully.”

3. Identifying and Fixing Common Design Issues (15 minutes)

  • Explain Common Issues:
    • Unconnected Parts:
      • “If parts of your model are not connected, they might not print correctly. Let’s make sure everything is linked together.”
    • Overhangs:
      • “Too many overhangs can cause your model to collapse or have rough edges. We can reduce overhangs by adding supports or redesigning those areas.”
    • Thin Walls:
      • “Walls need to be strong enough. Let’s check that all parts of your model have walls that are at least 2mm thick.”
  • Demonstrate Fixing Issues:
    • Step-by-Step Demonstration:
      1. Check Connections:
      • “Look at your model and make sure all parts are connected. If you see any gaps, use the box tool to bridge them.”
      1. Reduce Overhangs:
      • “Identify any overhangs and either add a support structure or change the angle to reduce the overhang.”
      1. Thicken Walls:
      • “Select thin walls and increase their thickness to make them stronger.”
  • Hands-On Practice:
    • “Now, go through your designs and check for unconnected parts, overhangs, and thin walls. Fix any issues you find using the tools in TinkerCad.”
  • Teacher and Assistant Support:
    • Walk around to help students identify and fix design issues.
    • Provide examples and tips for making models DFAM-friendly.

4. Drafting and Finalizing Designs (10 minutes)

  • Explain the Finalization Process:
    • “Once you’ve fixed any issues, make sure your design is exactly how you want it. Double-check all measurements and connections.”
  • Hands-On Activity:
    • “Take a few minutes to review your design. Make any final adjustments to ensure everything is connected, overhangs are minimized, and walls are thick enough.”
  • Teacher and Assistant Support:
    • Assist students in making final tweaks to their models.
    • Ensure all students have a complete and print-ready design.

5. Preparing and Exporting Models as STL Files (10 minutes)

  • Explain the Exporting Process:
    • “To print your model, you need to export it as an STL file. This file is what the 3D printer will use to create your object.”
  • Demonstrate Exporting to STL:
    • Step-by-Step Demonstration:
      1. Select Your Model:
      • “Click on your completed model to select it.”
      1. Export as STL:
      • “Click on the ‘Export’ button in the top-right corner of TinkerCad.”
      • “Choose ‘.STL’ from the list of file formats.”
      • “Save the STL file to your computer.”
  • Hands-On Practice:
    • “Now, export your own designs as STL files. Follow the steps to make sure your file is ready for printing.”
  • Teacher and Assistant Support:
    • Help students with exporting their files.
    • Ensure all students successfully save their STL files.

6. Sharing and Feedback (5 minutes)

  • Invite Students to Share:
    • “Would anyone like to show their final design and explain how they made it ready for printing?”
  • Provide Positive Feedback:
    • “Great job on your phone holder! It’s sturdy and the dimensions are perfect for holding a phone securely.”
    • “Your desk organizer looks very organized and well-measured. Excellent work on aligning the parts!”
  • Encourage Peer Feedback:
    • “Listen to your classmates’ designs and think about what you liked and any ideas you might use in your own projects.”

Glossary

  • DFAM (Design for Additive Manufacturing): Guidelines to design 3D models that print successfully and are functional.
  • Overhang: A part of the model that extends outward without support, which can cause printing issues.
  • Thin Walls: Walls that are too narrow and may break or not print correctly.
  • Connected Parts: Ensuring all parts of the model are linked together to maintain structure and functionality.
  • Extrusion: The process of adding height to a 2D sketch to create a 3D object.
  • STL File: A file format used for 3D printing that contains the model’s geometry.
  • Measurement Tool: A feature in TinkerCad that shows the exact size of your objects and helps you set precise dimensions.
  • Alignment Tool: A tool in TinkerCad that helps you position objects accurately relative to each other.
  • Scaling: Changing the size of an object while keeping its proportions the same.
  • Clearance: The small gap between parts of a model to ensure they fit and move correctly without sticking together.
  • Grid and Snap Settings: Settings in TinkerCad that control the size of the grid and how objects snap to it for precise placement.
  • Precision: The quality of being exact and accurate in measurements and design.
  • Closed Surface: A shape where all the lines connect to form a complete boundary without any gaps.
  • Pivot Point: The fixed point around which a part rotates or moves.
  • Rotational Motion: Movement in which an object rotates around an axis or pivot point.

For suggestions, improvements, and corrections, feel free to reach out at shayaanhaider@gmail.com