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MAKERSPACE MODULE: INTRO TO 3D PRINTING

This required introductory course covers the fundamentals of 3D printing and is necessary to gain access to the 3D printer in the makerspace. By the end of this module, you’ll understand the core concepts of 3D printing and be equipped with the knowledge to safely create your first print.

LEARNING OBJECTIVES:

WHAT IS 3D PRINTING?

  • 3D printing is the process of transforming digital design files into physical, three-dimensional objects using a specialized machine known as a 3D printer. This technology begins with a digital blueprint—typically a CAD (Computer-Aided Design) file—that serves as the model for the object. The printer reads this file and translates the design into precise instructions, guiding the machine in the construction of the object. 3D printing is used in a wide variety of fields including prototyping, manufacturing, healthcare, architecture, and even fashion, due to its ability to create complex shapes and custom designs quickly and efficiently.
  • 3D printing builds objects through a method known as additive manufacturing, which constructs items layer by layer from the bottom up. Unlike traditional manufacturing methods that often involve cutting or subtracting material from a larger block (subtractive manufacturing), additive manufacturing adds material only where it is needed. This layer-by-layer approach allows for intricate designs, reduced waste, and greater flexibility in production. Each layer is precisely fused or cured before the next is added, allowing the object to gradually take shape with high precision and minimal material loss.

FDM 3D PRINTER IN ACTION

THE HISTORY OF 3D PRINTING

1980s: The Birth of 3D Printing

1984 – Stereolithography (SLA) Invented:
Charles "Chuck" Hull invents SLA, the first 3D printing technology, using UV lasers to cure liquid resin layer by layer.

1986 – 3D Systems Founded:
Hull co-founds 3D Systems, marking the beginning of commercial 3D printing.

1990s: Commercialization & Core Technologies

1989 – Fused Deposition Modeling (FDM) Invented:
Scott Crump invents FDM, extruding thermoplastic filament layer by layer. He co-founds Stratasys, which becomes a major player in 3D printing.

Commercialization Begins:
3D printing begins moving from research labs to industrial use for rapid prototyping. Companies like 3D Systems and Stratasys bring machines to market.

2000s: Expansion & Breakthrough

Industrial Adoption Grows:
3D printing use spreads to aerospace, automotive, and healthcare for more than just prototyping.

New Materials:
Metals, ceramics, and composites broaden the scope of printable objects.

2008 - Medical Milestone:
The first 3D-printed prosthetic limb showcases custom, affordable healthcare applications.

Part of Industry 4.0:
3D printing integrates into smart, digital manufacturing systems.

2010: Democratization & the Maker Movement

Consumer & Desktop 3D Printing Booms:
Open-source projects like RepRap and platforms like Thingiverse democratize access to 3D printing.

Online 3D Printing Services Rise:
Services like Shapeways and i.materialise make it easy to upload and print designs.

Education & Hobbyist Use Expands:
Schools, makerspaces, and home users embrace 3D printing for STEM learning and creative projects.

2020s: Advanced Materials & Global Applications

Materials & New Frontiers:
Development of biocompatible, food-safe, and recycled materials, as well as concrete for printed homes.

New Applications Emerge:
3D printing now used in construction, fashion, bioprinting, and aerospace part manufacturing.

AI & Automation Integration:
Machine learning and automation optimize print quality, material use, and design workflows.

TYPES OF 3D PRINTERS

  • DLP (Digital Light Processing): Uses a digital projector to flash an entire layer of resin at once, curing it quickly with light for fast, high-detail prints. Learn more…
  • SLA (Stereolithography): Uses a laser to trace and cure each layer of resin individually, offering excellent detail and surface finish. Learn more…
  • FDM (Fused Deposition Modeling): Melts and extrudes plastic filament through a nozzle, building objects layer by layer—it’s the most common and budget-friendly type. Learn more…

THE BASIC ANATOMY OF AN FDM 3D PRINTER

Understanding key components of a 3D printer is essential for grasping how the printing process works. Each component plays a vital role in transforming digital designs into physical objects. The following section breaks down these critical elements and their functions.  Additionally, you can view and download a PDF of the parts labelled HERE.

power supply
Power Supply

Converts electrical power from the wall into usable voltage for the printer.

controller
Controller

Acts as the brain of the printer, managing movement, temperatures, and inputs.

print bed
Print Bed

The surface where the 3D object is built layer by layer.

extruder
Extruder

Feeds filament into the hotend for melting and printing.

hotend
Hotend

Heats and melts the filament so it can be precisely deposited.

endstop switches
Endstop Switches

Detect the limits of movement to help the printer calibrate its position.

bed leveling screws
Bed Leveling Screws

Allow manual adjustment of the print bed to ensure it's level.

USB port
USB & SD Ports

Enable loading print files from external storage devices.

3D printers generally have three primary axes of movement, named after the Cartesian coordinate system:
  1. **X-Axis** – Left to right (side-to-side) movement
    Usually moves the print head or the print bed depending on the printer design.
  2. **Y-Axis** – Front to back (forward and backward) movement
    Can be the bed or the head again, depending on the printer. In many designs, especially bedslingers like the Ender 3, the bed moves in the Y direction.
  3. **Z-Axis** – Up and down (vertical) movement
    Controls layer height and is responsible for moving the nozzle or the bed vertically.

3 MOST COMMON TYPES OF FILAMENT

1. PLA (Polylactic Acid)

  • Made from: Renewable resources like corn starch or sugarcane.
  • Environmental attributes:
    • Biodegradable under industrial composting conditions (but not quickly in home compost or nature).
    • Lower carbon footprint than petroleum-based plastics.
    • Non-toxic fumes when printing (safer for indoor environments).
    • Still requires proper disposal — can contribute to waste if not composted correctly.

2. ABS (Acrylonitrile Butadiene Styrene)

  • Made from: Petroleum-based synthetic polymers.
  • Environmental attributes:
    • Not biodegradable — persists in landfills and nature.
    • High emissions when printing — releases VOCs (volatile organic compounds) and potentially harmful fumes.
    • Highly durable — can be reused or recycled mechanically in specialized facilities, but recycling is uncommon.
    • Energy-intensive to produce compared to PLA.

3. PETG (Polyethylene Terephthalate Glycol-modified)

  • Made from: A variation of the same plastic used in water bottles (PET), modified for better 3D printing performance.
  • Environmental attributes:
    • Recyclable — easier to recycle than ABS, and some facilities accept PETG along with PET.
    • Not biodegradable, but less brittle waste compared to ABS.
    • Lower VOC emissions than ABS during printing, though still some.
    • Can be made with recycled content (rPETG filament options available).

HOW DOES 3D PRINTING WORK?

Step 1: Download or Design a 3D Model

Download:
  • Go to a 3D model repository like Thingiverse, Cults3D, or Printables.
  • Search for a model that suits your needs and download the file (usually in .STL or .OBJ format).
Design:
  • Use 3D modeling software like Tinkercad (beginner-friendly), Fusion 360, or Blender to create your own design from scratch.
  • Export your design as an .STL or .OBJ file.

Step 2: Slicing the Model

  • Open a slicer software like Orca, *used in the MakerSpace, PrusaSlicer or another slicer of your choice.
  • Import your .STL or .OBJ file.
  • Select your printer profile.
  • Modify parameters:
    1. Layer height (affects resolution)
    2. Perimeters and infill density (strength/weight)
    3. Supports (for overhangs)
    4. Choose material type (e.g. PLA, PETG)
  • Slice the model — this converts it into G-code, the instructions your printer will follow.
  • Save the G-code file to an SD card, USB, or send it directly to the printer (if network-enabled).

Step 3: Post Processing

  • Once printing is complete:
    1. Carefully remove the print from the bed (use a scraper if needed).
    2. Remove any support material (manually or with tools).
    3. Optional: sand, paint, glue, or chemically smooth the model to improve appearance or functionality..

Step 4: Printing

  • Prepare your 3D printer:
    1. Load the correct filament (e.g., PLA, PETG, ABS).
    2. Make sure the print bed is clean and leveled.
  • Insert the SD card/USB or access the print via your printer’s interface.
  • Start the print job.
  • Monitor the first few layers to ensure adhesion and detect early failures.

3D PRINT IN ACTION: FROM START TO FINISH

HOW LONG DOES IT TAKE?

Printing time can vary greatly. It ranges from a few hours for small objects to several days for larger or complex designs. Here’s what affects the time:

  • Size and Complexity: Bigger, more detailed objects naturally take longer to print.
  • Printing Settings: Adjust these for quality or speed, depending on your needs.
  • Material and Printer Type: Different materials and printers have varying speeds and capabilities.

UNDERSTANDING SAFETY GUIDELINES

HIGH TEMPERATURES
  • Printer nozzle and hotend can reach temperatures of well over 200 ° C.
  • Don't touch components during operation.
  • Use safety gloves for hot tasks such as nozzle changing or cleaning.
MOVING PARTS
  • Close printer doors whenever 3D printers are operational.
  • Moving parts in 3D printers keep moving even with doors open.
  • Use the printer's interface to stop or cancel the job.
VENTILATION
  • Close printer doors whenever 3D printers are operational.
  • Moving parts in 3D printers keep moving even with doors open.
  • Use the printer's interface to stop or cancel the job.
FIRE & ELECTRICAL SAFETY
  • Always monitor prints, especially when using flammable materials.
  • Keep a fire extinguisher nearby and check power connectio
PPE
  • Wear personal protective equipment.
    Protect against potential injuries.
  • Always wear safety goggles and gloves when dealing with components or post processing prints.
HOUSEKEEPING
  • Keep it tidy to avoid trip hazards and prevent accidents.
  • Dispose of waste materials properly.
  • Maintain a clutter free workspace.
Congratulations on completing the first steps of our 3D printing journey!

Let’s quickly sum up our 3D printing journey!

  1. First, we learned the basics.
  2. Then, we found out about printer parts and materials.
  3. Next, we understood the printing process step-by-step.
  4. Lastly, we talked about safety.

Now, you’re all set to dive into the next step toward creating your own 3D object!

KNOWLEDGE CHECK:

To ensure everyone uses the 3D printer safely and responsibly, completing this short quiz is mandatory before you’re able to book printer time.