3D Printing Design Course

Lesson 1 • Printer Hardware Components

Identifies mechanical, electrical, and motion-system components common across printer types. Connects hardware knowledge to troubleshooting and maintenance tasks.

Lesson 2 • Essential 3D Printing Terminology

Defines layer height, infill, supports, and other foundational terms used throughout the course. Ensures precise communication in design and production contexts.

Lesson 3 • Core Additive Manufacturing Processes

Compares FDM, SLA, SLS, and MSLA processes by mechanism and output quality. Enables informed technology selection for specific applications.

Lesson 4 • History and Evolution of Additive Manufacturing

Traces additive manufacturing from early stereolithography to modern multi-material systems. Provides context for understanding why specific technologies dominate today.

Lesson 1 • Introduction to CAD Software Interfaces

Orients students to parametric and direct-modeling environments used in 3D printing workflows. Builds navigation fluency before geometry creation begins.

Lesson 2 • Mesh Repair and Optimization

Diagnoses and fixes non-manifold geometry, inverted normals, and gaps before slicing. Ensures clean STL or 3MF files that slice without errors.

Lesson 3 • Parametric Modeling Techniques

Uses parameters and constraints to build models that update predictably when dimensions change. Supports iterative design cycles common in prototyping workflows.

Lesson 4 • Tolerances and Fit for Assemblies

Applies clearance and interference fit principles to multi-part printed assemblies. Produces functional joints, snap fits, and press fits on the first print.

Lesson 1 • Thermoplastic Filament Properties

Compares PLA, PETG, ABS, ASA, and nylon by strength, flexibility, and temperature resistance. Guides material selection based on end-use environment and load conditions.

Lesson 2 • Material Storage and Handling

Establishes moisture control, temperature storage, and contamination prevention practices for filaments and resins. Prevents print defects caused by degraded or contaminated materials.

Lesson 3 • High-Performance Engineering Filaments

Covers PC, PEEK, PEI, and carbon-fiber-reinforced materials for demanding structural applications. Addresses the specialised hardware and enclosure requirements these materials demand.

Lesson 4 • Photopolymer Resin Types

Distinguishes standard, ABS-like, flexible, castable, and dental resins by cure behaviour and application. Connects resin chemistry to post-cure requirements and safety protocols.

Lesson 1 • Temperature and Speed Optimisation

Tunes nozzle temperature, bed temperature, and print speed for consistent extrusion and adhesion. Prevents stringing, warping, and under-extrusion through systematic calibration.

Lesson 2 • Advanced Slicer Features

Applies modifier meshes, custom supports, and colour-change scripts to complex print jobs. Extends slicer capability beyond default settings for professional outputs.

Lesson 3 • Support Structure Strategies

Generates and customises supports to protect overhangs while minimizing removal effort. Reduces post-processing time and surface damage from poor support placement.

Lesson 4 • Layer, Shell, and Infill Configuration

Configures layer height, perimeter count, and infill to meet strength and surface quality targets. Connects each parameter to its mechanical and visual outcome.

Lesson 1 • Multi-Material and Dual-Extrusion Printing

Configures dual-extrusion systems for soluble supports and multi-colour or multi-material parts. Addresses purge tower setup, nozzle offset calibration, and material compatibility.

Lesson 2 • First-Layer Adhesion Techniques

Applies surface preparation, adhesion aids, and slicer settings to achieve reliable first-layer bonding. Prevents warping and delamination that cause mid-print failures.

Lesson 3 • Printer Calibration Fundamentals

Performs bed leveling, Z-offset setting, and extruder E-step calibration as a baseline routine. Accurate calibration is the prerequisite for all subsequent print quality work.

Lesson 4 • Print Quality Diagnostics

Identifies stringing, layer shifting, under-extrusion, and ghosting by visual inspection of failed prints. Links each defect to its root cause for targeted correction.

Lesson 1 • Washing and Curing Protocols

Executes IPA and dedicated wash-solution cleaning followed by UV post-cure to achieve full mechanical properties. Establishes safe solvent handling and waste disposal practices.

Lesson 2 • Resin Printer Maintenance

Schedules FEP replacement, LCD screen inspection, and resin vat cleaning to maintain print reliability. Preventive maintenance reduces costly failures and downtime.

Lesson 3 • Surface Finishing for Resin Parts

Applies sanding, priming, and painting techniques to achieve production-quality surface aesthetics on resin prints. Connects finishing steps to downstream application requirements.

Lesson 4 • Support Placement for Resin Prints

Designs and places supports to prevent suction cupping, delamination, and print failure on resin platforms. Balances support density against surface mark minimization.

Lesson 1 • Communicating Prototypes to Stakeholders

Presents prototypes with annotated renders, test data, and iteration summaries to non-technical audiences. Builds stakeholder confidence and accelerates design approval.

Lesson 2 • Design for Testability

Embeds measurement features, test points, and modular interfaces into prototype geometry. Enables quantitative validation without redesigning the entire part.

Lesson 3 • Prototyping Strategy and Planning

Defines prototype fidelity levels and selects the appropriate technology and material for each stage. Aligns prototyping effort with development phase and validation goals.

Lesson 4 • Functional Mechanism Printing

Prints gears, linkages, hinges, and snap-fit assemblies that perform mechanical functions directly off the printer. Validates kinematic designs before committing to production tooling.

Lesson 1 • Batch Printing and Plate Optimisation

Maximises build volume utilisation through nesting, orientation analysis, and multi-part plate strategies. Reduces per-part cost and machine time in production runs.

Lesson 2 • End-Use Part Design Considerations

Applies fatigue, creep, and anisotropy analysis to parts intended for sustained mechanical service. Bridges the gap between prototype geometry and production-grade part design.

Lesson 3 • Hybrid Manufacturing Integration

Combines 3D printing with CNC machining, casting, and injection moulding to leverage each process's strengths. Designs parts with intentional hybrid interfaces for optimal performance.

Lesson 4 • Intellectual Property and File Security

Addresses ownership of CAD files, licensing of digital designs, and protection of proprietary geometry. Prepares students to manage IP responsibly in commercial printing contexts.

Lesson 5 • Jigs, Fixtures, and Tooling Applications

Designs printed jigs, fixtures, and assembly aids that reduce manufacturing cycle time and error rates. Demonstrates immediate ROI of in-house 3D printing for production support.