Session 3: “Prototyping: First Iteration Prints”
Architect:
Syed Shayaan Haider - Markhor3D
Session Overview
In this session, Grade 7 students prepare their initial 3D models for printing. They focus on optimizing their designs for printability by ensuring models are fully constrained and refined with advanced features like pattern tools. Students will also adjust slicing settings—such as support structures and layer height—to suit their models before printing prototypes. This hands-on session allows students to evaluate form and basic function, guiding improvements for future iterations.
Placeholder for example of pattern features in OnShape: [Google Image Search “OnShape pattern feature examples”]
Learning Objectives
By the end of the session, students will be able to:
- Optimize 3D Models for Printability: Refine models by applying constraints and using pattern features to add repeated, efficient details.
- Apply Design Adjustments: Ensure that designs are fully defined and structured for optimal support, wall thickness, and material usage.
- Adjust Slicer Settings: Import STL files into slicing software and fine-tune settings such as layer height, support structures, and infill density.
- Evaluate Prototypes: Print and review initial prototypes to assess form and function, noting areas for improvement.
Teaching Aids
Visual Aids:
- Placeholder: [Google Image Search “OnShape pattern feature examples”] – to show examples of designs using pattern features.
- Placeholder: [Google Image Search “slicer settings 3D printing”] – to illustrate key slicer settings (layer height, supports, infill).
- Placeholder: [Google Image Search “3D printed prototype evaluation”] – examples of prototype evaluations.
Required Equipment:
- Computers or Tablets:
One per student or group, with OnShape access and completed design files. - Slicing Software (e.g., Cura):
Installed and configured on available computers. - 3D Printer:
Ready to print prototypes. - Interactive Whiteboard or Projector:
For live demonstrations of design adjustments and slicer setup. - Measuring Tools:
Rulers or digital calipers for checking dimensions. - Notebooks and Pens:
For recording observations and settings. - Assistants or Volunteers:
Additional support for guiding design and slicer adjustments.
Structure and Lesson Plan (Total Time: 60 minutes)
1. Introduction and Recap (5 minutes)
- Welcome:
- “Good morning, everyone! Today, we’re moving from design to prototyping by preparing your models for 3D printing.”
- Recap:
- “Last session, you refined your digital models in OnShape using advanced sketching tools, constraints, and pattern features. Today, we’ll use those refined models to create prototypes and learn to adjust slicer settings for optimal prints.”
2. Final Design Adjustments (25 minutes)
- Review Design for Printability:
- “Examine your model to ensure it is fully constrained and closed. Check that all parts are connected, and the design includes efficient details like patterned arrays of holes or repeated features.”
- Incorporate Pattern Features:
- “Use the pattern tool to create repeated elements, such as a series of ventilation holes or decorative borders, while keeping the model light and strong.”
- Example: “A desk organizer might use a circular pattern to evenly distribute holes for storage compartments.”
- Ensure DFAM Principles:
- “Make sure your design minimizes unnecessary material. For instance, rather than using 100% infill, incorporate ribs or trusses to provide strength without excess weight.”
- Demonstration:
- Show a live example of a model (e.g., a pen holder) that has been refined using constraints and pattern features.
- Hands-On Activity:
- “Take 25 minutes to review and adjust your model in OnShape. Focus on tightening constraints, adding pattern features where needed, and ensuring your model is optimized for printing.”
Examples of Things You Can Make Using the Pattern Feature:
-
Ventilation Grids:
Use a circular or linear pattern to create evenly spaced holes on a box or enclosure. This is perfect for designing a ventilation grid that helps with airflow in devices like electronic cases or storage containers. -
Decorative Borders:
Create a repeated border or frame around an object, such as a decorative edge on a desk organizer or a phone case. You can use the pattern tool to replicate a simple shape (like a small triangle or circle) along the edge. -
Connector Arrays:
Design a grid of pegs or holes for a modular system. For example, a modular furniture piece might need evenly spaced connectors to attach different parts together securely. -
Keychain Patterns:
Use a circular pattern to evenly distribute design elements, such as initials or small logos, around the perimeter of a keychain. This gives a professional, balanced look. -
Textured Surfaces:
Apply a linear pattern of small, repeated features (like bumps or grooves) on the surface of an object, such as a phone stand or pen holder, to improve grip and aesthetics.
3. Slicer Adjustment and Setup (25 minutes)
- Importing and Setting Up the Model:
- “Once your design is ready, export it as an STL file using OnShape’s parts menu and right-click export method.”
- Placeholder: [Google Image Search “OnShape parts menu export”]
- Adjust Slicer Settings:
- Layer Height: “Set a layer height of 0.1–0.2 mm for better detail.”
- Infill Density: “Choose a moderate infill density (around 20–30%) and consider how your design’s internal structure (with ribs or trusses) can help support it.”
- Supports: “Enable supports where necessary, especially for overhanging features.”
- Print Orientation: “Make sure the model is oriented for optimal strength and minimal overhangs.”
- Placeholder: [Google Image Search “Cura slicer settings 3D printing”]
- Preview and Adjust:
- “Use the Preview function in your slicing software to check that your model is sliced correctly. Look at how the model is built layer by layer.”
- Hands-On Activity:
- “Spend 25 minutes importing your STL file into the slicer, adjusting these settings, and ensuring that your model looks ready to print.”
4. Conclusion and Next Steps (5 minutes)
- Session Summary:
- “Today, you refined your models using advanced OnShape techniques and set up your designs in the slicer for 3D printing. You learned to optimize your design for strength and efficiency and adjusted key slicer settings for a successful print.”
- Preview Next Session:
- “In our next session, we’ll move on to post-processing, where you’ll finish your prototypes by cleaning up supports and improving the surface finish.”
- Closing Encouragement:
- “Great work today! Your careful design adjustments and slicer setup will help ensure that your printed models are both functional and strong. Keep up the excellent work!”
Glossary
- DFAM (Design for Additive Manufacturing): Guidelines to design 3D models that print successfully and efficiently.
- Pattern Feature: A tool that replicates design elements in a linear or circular arrangement.
- Constraints: Rules that keep elements in a sketch fixed in relation to each other (parallel, perpendicular, equal, etc.).
- Extrusion/ Revolve: Methods used previously to turn 2D sketches into 3D models.
- Infill Density: The internal fill of a model that balances strength and material usage.
- Supports: Structures that help hold up overhanging parts during printing.
- Layer Height: The thickness of each layer in a 3D print.
- Slicer: Software that converts 3D models into layers (G-code) for 3D printing.
- STL File: A file format that contains the geometry of a 3D model for printing.
For suggestions, improvements, and corrections, feel free to reach out at shayaanhaider@gmail.com