3D Printing Guide for Teachers

copyright PrintLab

Hello from PrintLab

It’s an exciting time for teachers looking to

integrate 3D printing in the classroom and
it is our mission at PrintLab to make the
process as easy, enjoyable and valuable as
possible.
We hope you find the information in this
guide useful and if you require any advice
or support, please do not
hesitate to contact us at
hello@weareprintlab.com

Let’s inspire the next generation,

together.

www.weareprintlab.com

Contents
 4: 3D Printing Tips for the Classroom

030 Calculating Filament Costs

031 Classroom Tips for Costing
032 Managing Print Time
033 General Classroom Tips

5: Integrating 3D Printing into the Curriculum

034 3D Printing Braille

035 Make a 3D Contour Model
036 3D Population Graph
037 3D Printing Molecules
038 Design a 3D Printable Pen
039 Balloon Powered Dragster
040 Make an Egyptian Obelisk
041 Design your own Spinning Top
042 Design your own Whistle
043 3D Printing Solutions
 Enjoy the journey!
Su
p po
rt

1.
Introduction
In the first chapter of this guide you will be given an
overview of the 3D printing industry along with the 3D
printing process. The aim of this chapter is to provide you
with the essential background knowledge to enable you to
confidently talk about 3D printing to your students.
001 Introduction to 3D Printing
Introduction

3D printing is a manufacturing process where successive layers of material are laid

down on top of each other in an additive process. Although 3D printing is often spoken
of as a new technology, it has actually been around for over 30 years. Around 8 years
ago, patents around 3D printing began to expire and 3D printing opened up to mass
audiences. The landmark point for its commercial adoption came from the open source
RepRap project - a 3D printing initiative with the goal of creating low cost, self
replicating 3D printers. Being open source, all the files were freely available online and
in the following years we saw a large number of startups creating their own 3D
printers, inspired by the RepRap project. Let’s take a look at the steps required in the
typical 3D printing process:

1. 3D model file
It all begins with a digital 3D model of a design. There are hundreds of software programs
that enable you to design in 3D. Some free ones that are great for educators are SketchUp,
TinkerCad and Fusion 360.

2. Slicing
The 3D model file (typically an STL file) is then split up into very fine layers in a software
program called a “slicer”. The output from the slicer is a code, which tells the 3D printer how
to move and where to lay down material.

3. 3D Printing
Once the code is loaded to the 3D printer, it will begin the production process. One layer is
created at a time until the model is complete. This can take minutes or hours depending on
the size of the model.
 4. Post-processing
Depending on the type of 3D printer and the model file you print, there may be a
requirement for some post-processing. Examples include removing support material,
cleaning and sanding.

002 3D Printing Types

Introduction

There are various types of 3D printers that work using different technologies and
materials. However, all 3D printers have something in common - they all build up an
object layer by layer. Let’s take a look at 4 popular 3D printing methods:

1. FFF (Fused Filament Fabrication)

This is the most popular type of 3D printer for educators and they work by melting plastic
filament and depositing it onto a print bed, where it solidifies. Additional layers are printed
on top of each other until the model is complete. Types of plastic include PLA, ABS and
composites that combine plastic with wood, copper, bronze and several others.

2. SLA/DLP (Stereolithography/Digital Light Processing)

SLA/DLP machines utilise light sources to cure a liquid photopolymer. A print bed is
submerged in resin and the light is used to solidify certain areas. Once a layer has solidified
the print bed will move, allowing the light to cure the next layer.

3. SLS (Selective Laser Sintering)

Selective Laser Sintering works in a similar manner to SLA/DLP technologies but the light
source (laser) is used to fuse powdered material together. The most common material for
SLS printers is nylon.

4. Material Jetting
 Material jetting uses a similar technology to a standard inkjet printer. The difference being
that the material used is a liquid photopolymer that is cured by a UV light source once it hits
the print bed.

There are several other 3D printing technologies available but for the purpose of this
introductory guide, we’ll be focusing on FFF 3D printing.

003 Why 3D Printing?

Introduction

1. Less Waste
In traditional ‘subtractive’ manufacturing, a block of material is cut down to create an
object, which can result in up to 90% in waste material. Because 3D printing uses an
additive process, little or no material is wasted.

2. Customisation
Products such as pens, phone cases etc are created on assembly lines because it is cost
efficient to produce them in this way. With 3D printing, each design can be different
and there will be no additional tooling or assembly costs involved.

3. Complex Geometries
Subtractive manufacturing techniques have limitations in the geometry of products.
Machines simply cannot cut or mill certain patterns but with 3D printing, these
limitations don’t exist.

4. Efficient Prototyping
Imagine being able to design a concept and hold a prototype of this within a matter of
hours. 3D printing enables this at just a fraction of the cost of creating prototypes
through traditional methods.
004 3D Printing Limitations
Introduction

1. Speed of Large Production Runs

3D printing is a great tool to obtain prototypes and low quantities of products quickly
because there is no setup required. For large production runs, 3D printing is not a
viable option because of the speed of the actual printing process.

2. Cost of Large Production Runs

In traditional manufacturing, the cost of production decreases with the amount of
products being made. With 3D printing, this is not the case because cost is based on
material usage. Therefore large production runs can be very expensive.

3. Materials
More and more new materials are becoming available for 3D printers but there is still a
very long way to go before there are anywhere near the amount of options available
through traditional methods.

4. Accuracy
In some industries such as engineering and automotive, small components require
extreme precision. Although 3D printers can be precise right down to around 10
microns, subtractive methods can still achieve better precision.
005 Uses in Industry
Introduction

Now that you have some background knowledge of 3D printing, let’s take a look at how
3D printing is used in various industries.

Architecture
Typically, architects can spend days creating physical models to explain their designs to
clients. Using modern technology, they can use their existing CAD drawings to rapidly
create a 3D model and print it in 3D. Not only do they save time but complex
geometries that can’t be modelled by hand can be produced efficiently and at a low
cost.

Prosthetics
The amazing e-NABLE project use desktop 3D printers to create custom prosthetics for
children at a production cost as low as $50. Being such a low cost option benefits
children in particular because they grow out of their prosthetics quickly. Additionally,
3D printing allows children to choose custom options for their prosthetics such as
superhero designs!

Medical
One of the key benefits of 3D printing is the ability to customise objects at no extra
cost. The medical sector is taking advantage of this in various ways and one prominent
field is that of hearing aids. The process begins by taking a 3D scan of the patient’s ear,
which ensures an accurate 3D print can be made that has a perfect fit for that specific
patient.

Dental
Combined with 3D scanning technologies, dentists can now 3D print moulds, visual
aids, bridges, crowns, guards and more. 3D printing eliminates the need for manual
tasks, which saves weeks of time and similarly to hearing aids, each product is
accurately tailored to the patient. There are many 3D printers designed specifically for
dentists.
006
Introduction

Product Design
3D printing enables product and industrial designers to create prototypes within hours
as opposed to weeks through traditional methods. The cost to create a prototype can
be in excess of $10,000 when you consider the tooling required for processes like
injection moulding. With 3D printing, prototypes can be achieved at a fraction of the
cost.

Aerospace
3D printing for aerospace purposes allows complex geometries to be created with no
waste material and no tooling required. This results in innovative functional parts and
millions of dollars are saved. GE aviation have even started testing the largest jet
engine ever built. The engine is said to be more efficient, advanced and powerful due
to its 3D printed components.

Hobbyists
Desktop 3D printers can now be acquired for under USD$500, which has gained the
interest of many hobbyists. From 3D printing toy characters to functional items for the
home, we’re seeing anyone and everyone becoming part of the “maker movement”.
Many industry experts have predicted that in the next ten years, most households will
have a 3D printer.
007 3D Printing in the
Classroom
Introduction

The 3D printing industry is set to grow from $7.3 billion in 2016 to $21 billion in
2020, and 3D printing expenditure in education is set to grow from $200 million
in 2015 to $500 million by 2019. But what is the relevance of the macro scale
for you, as a teacher? These facts are important because they will have a direct
effect on the very students you teach. As you saw on the previous page, 3D
printing is making huge waves in so many different sectors. The innovative
technology is going to disrupt the design process and the supply chain that we
see today.

Because of this, it is essential that we prepare students for the challenges of

tomorrow. Over the next 5-10 years, we’ll begin to see further advances,
particularly with materials, software and printing speed. These advances will
bring on what has been described as the next “industrial revolution” and the
people heading up this revolution will be those who are currently in education.

In addition to preparing students for their future careers, 3D printing revolutionises

the way students engage in the classroom.
008
Introduction

The fact that 3D printing technology still needs developing actually plays to our
advantage - why? Because it empowers students to solve problems and truly learn the
ins and outs of how this exciting technology works. One of the biggest questions we
get asked is “what can I do with a 3D printer?” - and we usually answer this question
with, “what can’t you do with a 3D printer!”.

Many people seem to think that a 3D printer belongs in a D&T classroom, but what
they fail to recognise is that 3D printing is seeing massive success in all areas of
education. Take exploration of fossils in a History lesson for example, what better way
to teach this than to 3D print examples that students can examine, hold and
understand. Physics is another example, where students could print their own model
boats, some hollow and some solid, to experiment with what floats, what doesn’t and
why.

There is an enormous scope of opportunity with 3D printing and we are excited to

assist you in your journey.
009 3D Printing by Subject
Introduction

Maths
Models of equations and volumes can be 3D printed to assist students in
understanding maths for real life applications. Imagine printing a Fibonacci spiral that
students can observe and hold!
 History
Help students understand what it was like to live in various eras by 3D printing replica
artefacts and statues. There are hundreds freely available from websites such as
Thingiverse and YouMagine.

Geography
Understanding topography can be difficult by reading 2D maps, so why not recreate
them in 3D. The below
image shows a lesson
project where
students design and
Science 3D print a 1:50,000
scale contour model of
Mount Everest.

Explore density, mass,

projectiles and much more by allowing students to design objects like balloon powered
boats, rockets and rubber band powered cars. It’s a sure way to get them thoroughly
engaged in design and problem solving.

010
Introduction
 Design Technology
Combine traditional woodworking with 3D printing, offering a fresh and modern way
of designing. The above image shows a lesson where students make a workshop stool
with 3D printed connectors.

Engineering
Prototyping is a huge part of any engineering process. With 3D printing students can
bring their ideas to life and create several iterations of their designs to achieve the
best functional results.

Art
3D printing enables us to create complicated artistic forms that can’t be produced by
using traditional methods. This opens up new innovative opportunities for students to
explore.

Food Technology
Food moulds and cookie cutters are a great way to engage students, whilst teaching
them new design skills. We are also beginning to see a range of food specific printers
such as chocolate 3D printers!

2.
Getting 3D Printable Files
Now that you have some initial background knowledge, it’s time to look at how we actually obtain a 3D
printable file. There are several ways to do this and in this chapter we’ll take a look at downloading pre-
designed files, creating files in CAD software and 3D scanning physical objects.
Image Credit: IBN Khuldoon National School
11 Downloading Models
ng 3D
able Files
The easiest way to obtain a 3D printable file is to download pre-designed files. Simply head to one of the below
websites and there will be hundreds of free models available for download. The most common 3D printing file
type is known as an STL. Once downloaded you can open the STL’s in your 3D printer’s software where you will
select various parameters before ‘slicing’ the model and sending it to the 3D printer.

3DKer - www.3dker.com
3DKer is Shining3D’s online platform. It is a thriving community which gives users free access to thousands of 3D
printable models all over the world. The 3DKer team want to bring an extraordinary experience to the general
public.

Thingiverse - www.thingiverse.com
Thingiverse is a an online community for discovering, making, and sharing 3D printable things. As the world’s
largest 3D printing community, they believe that everyone should be encouraged to create and remix 3D things,
no matter their technical expertise or previous experience.

YouMagine - www.youmagine.com
YouMagine is an online community of 3D printing enthusiasts who wish to work together to share, remix and
make better 3D printed things. YouMagine facilitates this community, empowers and gives you the tools you
need in order to improve, invent & make.

MyMiniFactory - www.myminifactory.com
MyMiniFactory, which launched in 2013, is one of the world’s leading curated social platform for 3D printable
objects. On MyMiniFactory, you can find tens of thousands of 3D designs ready for you to download for free.
These will work with any desktop 3D printer, and they have tested every single one so that it is guaranteed to
print!

12 Downloading Tips
ng 3D
able Files
 With the amount of freely available models on the internet, you might struggle finding the model you want. In
addition, most of the sites allow anyone to upload designs so you want to make sure that they are 3D printable.
Here are some tips for finding the right model and making sure it is printable:

Check the Path Viewer in your Slicing Software

Most slicing software packages have a ‘path viewer’ or ‘layer viewer’ that allow you to drag a slider to see the
actual path the printer will take when printing. Be sure to check this prior to starting a 3D print to ensure
everything looks correct

Check out the Education Sections

Most of the websites listed on the previous page have a specific section for education. There are many teachers
around the world who are active in sharing their designs. You may also be able to contact the designer using
information provided on the website to ask for advice and tips!

Look at Popular Models and Read the Comments

Next to each available model you will see how many views and downloads each one has. Popular models are
likely to be well-designed and 3D printable. In addition many users leave comments on the designs - reading
these may help you learn about the best settings for that specific model.

Use the Search Function

the sites listed on the previous page have a search bar where you can type in keywords to find models.
you a lot of time if you know the type of model you want to print. You can even type in subject areas such as ‘Maths’ or

013 CAD Software

Getting 3D
Printable Files

CAD stands for Computer-Aided Design Software and refers to computer programs that
are intended for design purposes. They can either be 2D,
 3D or both and most 3D printable files are created with CAD software. CAD was
invented in the 1960’s and over the years it has replaced manual drafting methods
because of its speed, accuracy and ability to easily make amendments.

CAD is used in a whole range of industries such as architecture, engineering,

animation, medical and education etc. In recent years CAD software has become
extremely accessible and there are now many free programs available to download. In
addition to being free, there has been an increase in the availability of software
packages suitable for those with no experience.

Tinkercad We advise that you try out a range of the options listed on the next page. You
will most likely find one that you think is best suited for your students, but it is
also worth noting that different software packages are better for certain types
of models. For example there are some programs that excel in digital sculpting
and others that perform better at sketching and extruding surfaces. For this
reason we recommend keeping an open approach and encourage students to
experiment with various software options.

14 CAD Options for Schools

ng 3D
able Files

Tinkercad - www.tinkercad.com
Tinkercad is a simple, online 3D design and 3D printing app that can be used through a web browser. It is a great
tool for educators at the beginner/ intermediate level. Shapes are the basic building blocks of Tinkercad. A shape
can add or remove material and you can import your own or work with existing shapes. Shapes can then be
moved, rotated or adjusted freely in space. You can also group shapes together to create detailed objects as
complicated as you like.
 SketchUp - www.sketchup.com
SketchUp is another simple design software that differs from Tinkercad in various ways. Firstly it is an offline
software, meaning you can work directly from your desktop with no internet connection. In SketchUp you
start by drawing lines and shapes before pushing and pulling surfaces to turn them into 3D forms. You can
stretch, copy, rotate and paint to make anything you like. SketchUp is used by a wide range of people, from
complete beginners to architects and product designers.

Fusion 360 - www.autodesk.com/products/fusion-360/

overview
Fusion 360 is a cloud-based 3D CAD, CAM, and CAE platform for product development. It
combines industrial and mechanical design, simulation, collaboration and machining in a single
package. The tools in Fusion 360 enable fast and easy exploration of design ideas with an
integrated concept to production toolset. Fusion 360 is an advanced design software but the
amazing tools it provides makes it a top choice for educators.

Meshmixer - www.meshmixer.com
Meshmixer is state-of-the-art software for working with triangle meshes. If you need to clean up a 3D scan,
do some 3D printing, or design an object that fits something else, Meshmixer can help. Think of it as a sort
of “Swiss Army Knife” for 3D meshes. It excels above the other software packages mentioned on this page
when it comes to editing 3D scans.

onsiderations

of 3D design that need to be considered when creating

D printers have their limitations and it’s important to
sroom. Let’s take a look at some design considerations

1. Overhangs

FFF 3D printers require at least a partial surface or layer to print on top of, therefore problems may arise
when printing steep overhanging features. The larger the overhang angle, the poorer the surface
quality.
 2. Bridging

Bridging is essentially an overhang but the printer ‘bridges’ across two points. The larger the bridge, the
poorer the quality.

3. Support

To help with overhangs and bridging,

support material can be generated by
most slicers. This is temporary

Support
016
Getting 3D
Printable Files
3D Scanning structure that is peeled off
after printing but the surface
quality is usually
compromised.

3D scanning is the process of collecting 3D data of an object’s shape and appearance. A 3D scanner can turn
physical objects into digital 3D models!

3D scanning opens up a world of opportunities that include:

- Preservation of artefacts
- Ability to reverse engineer products
- Ability to recreate models in a wide range of materials
- Accurate inspection of objects (e.g. precise measurements of distances and surfaces)
- Designing customised products (e.g. prosthetics that fit a patient perfectly)

By introducing students to 3D scanning at such an early stage, you can easily obtain 3D files and further down the
line you can develop lessons around editing 3D scans for functional applications.

How 3D Scanning Works

There are various types of 3D scanners - some use laser technology, some take photos around an object - but in
this guide we’re going to look at Structured Light 3D Scanning. We believe that structured light 3D scanning is the
most suitable for the classroom because it is a completely safe light source, as opposed to laser technology that
can be harmful to the eyes.

1. Structured Light Scanners project a pattern onto an object. Built in

cameras measure the edges of the pattern and through triangulation
they can determine the angle and distance of the object from the 3D
scanner.

This results in something called a point

2. cloud. A point cloud is a set of 3D data points created by a 3D scanner. It
cannot be 3D printed because there are no surfaces, only tiny dots in a
3 dimensional space.

Models need to be watertight to be 3D printed. Most 3D scanning software packages can easily convert a point
cloud into a 3D printable STL file through the click of a button! The
software will essentially join up all the dots in the point cloud to
create a solid surface.
18 Scanning Considerations
ng 3D
able Files

It is important to understand that there are certain limitations with all lightbased scanners. The below diagram
shows different objects that may be difficult to scan:

omplex Internal Geometries Transparent/Translucent Objects

he projector and cameras must have a When the light and pattern from the
irect line of sight to the surface in order to projector hits a transparent or translucent
ecord data from it. Therefore models with object, it will pass through the surface.
omplex internal geometries or deep holes Therefore any data recorded by the
re difficult to scan. cameras will be inaccurate. A common way
to prepare models that are transparent/
translucent is to spray them with temporary
white paint or cover them in white powder.

Shiny Objects Very Dark/Black Objects When the light and

When the light and pattern from the pattern from the projector hits a very dark
projector hits a glossy surface, it will reflect - surface, it will be absorbed. The scanner is
this also causes inaccuracies. Similarly to unlikely to pick up much data from a black
transparent objects, shiny objects can be object. Again, they can be prepared with
prepared for 3D scanning by applying white white paint or powder.
paint or powder.

19 3D Scanning Applications
ng 3D
able Files
Museums
3D scanning is widely being used in museums. Perfectly identical, richly detailed, true-to-scale copies of an
ancient artefact or a sculpture also represent an opportunity, not only to preserve but to teach and allow those
interested to get hands-on without risking damage to a priceless item.

Medicine/Health
3D scanning enables the design and production of a prosthetic limb that is measured to a remarkable accuracy,
meaning maximum comfort, mobility and reduction in pain. Coupled with 3D printing, this process is a fraction of
the time and cost of traditionally used methods.

Engineering
Another area with huge potential for 3D scanning is engineering. The ability
to scan any object and then use CAD for modification makes both reverse
engineering and rapid prototyping an extremely streamlined process. Detailed
measurements can be performed and investigation in to mechanical properties
is simplified.

Science/Research
Researchers at Drexel University have recently begun 3D scanning and printing
dinosaur fossils and building their very own scaled-down robotic replicas. The
objective is to see how the dinosaurs bones interacted with one another to create
movement and respond to environmental stresses.
 020
Getting 3D
Printable Files

Architecture
The ability to scan and analyse buildings in high detail makes 3D scanning a hugely attractive proposition when
conducting architectural surveys. 3D scanning provides the user with extremely accurate measurements and the
ability to fully utilise, visualise and modify data with CAD.

Design
As we continue to design and develop more effective materials for a range of purposes, we commonly look to
mimic natural materials for their superior properties, be it plant structures or even fossils. What better way to
study these complex arrangements and create a new design than through scanning and studying in high
resolution.

Full Body Scanning

Major games developers have been creating gaming characters with 3D scanning
for some time, however as ease-of-use and affordability improves, more small-
medium game and app developers can use 3D scanning to give gamers a better
user experience.

Virtual Reality/Animation
Since no two human bodies are the exact same, what better subject to use when creating a unique 3D model.
There are numerous services opening up around the world that enable the user to be 3D scanned and take home
their very own 3D printed replica model of themselves.

21 3D Scanning in the Classroom

ng 3D
able Files
The Initial Value of 3D Scanning
Whilst students get to grips with CAD software, 3D scanning is an amazing way to easily obtain files for 3D
printing. A popular option for educators is to run a series of hands-on activities where students create models
out of clay or plasticine. These objects can then be placed onto a turntable 3D scanner that will give a 3D
printable output (STL file). The STL files can then be uploaded straight on to your 3D printer’s slicing software,
where you can explore a range of options before 3D printing your students’ creations.

There can be many lessons taught during this process, such as how obtaining a digital file of a design allows you
to explore a variety of manufacturing techniques with different materials. For example, you may wish to create
some versions in wood using CNC machinery and some models in plastic using a 3D printer.

022
Getting 3D
Printable Files

Progressing 3D Scanning in the Classroom

As explained on the previous page, 3D scanning is great for obtaining 3D printable files, but its value goes much
further than that. Once students become familiar with the 3D scanning process, you can introduce them to more
advanced techniques that involve modifying 3D scans.

Take a look at the below image, which shows a 3D printed pen. The pen was created by clay modelling the shell
before 3D scanning it. CAD software was then used to edit the model so an ink cartridge can slot into the middle
of the shell when 3D printed.
This exact same process of scan, edit, manufacture is widely being used in the product design industry. By
introducing students to this process at an early stage, they can relate to real-world applications - something that
is essential to prepare them for their future careers.

3.
Preparing Files for 3D
Printing
Having obtained an STL file, the next step is to upload it to your 3D printer’s slicing software. Within this
software you can change various parameters to your requirements. In this chapter we’ll look at some
considerations and tips to help you prepare models for 3D printing.
23 Model Orientation
ring Files for
inting

One of the most important things to do within slicing software is to optimise the
orientation of your model for 3D printing. Take a look at the below examples of a
sailing boat model.

Excessive Overhangs Poor Bed Adhesion Correct Orientation

If we placed the sailing overhang, the worse the relative amount of surface
boat model in this surface quality. area touching the print
position, the resulting In this scenario only a bed/raft.
print would be very poor fraction of the model is in For the sailing boat model,
quality. If you look at the contact with the print bed. this is the best orientation.
sails of the boat and The software can generate There are no areas with
imagine the printer a raft (base structure) for steep or large overhangs
creating this section, you this to be printed on but and there is a large flat
may realise that the this is unlikely to stop the surface touching the print
printer will essentially be print from coming off the bed. If you cannot avoid
printing in thin air. There is print bed when printing. overhangs by rotating the
no material under the sail Good bed adhesion is model, you should
to print on top of. critical to all 3D prints and orientate it to the position
Generally, the bigger the in order to achieve this, with the least overhangs.
angle and area of the there needs to be a Most slicing software have
a function called ‘Support’, which is discussed on the
next page.

024 Support
Material
Preparing Files for

3D Printing

Most slicing software packages can automatically

generate ‘support structure’. This is where the printer
will create a temporary structure of lines underneath
overhanging features, which is peeled off when the
print has finished. The temporary structure enables
FFF printers to print steep overhangs and bridges but
the surface quality when removed will not be
completely smooth. Some higher-end machines have 2
nozzles and allow you to print support in a soluble
material such as PVA that dissolves when the model is
submerged in water.

Most slicing
packages have
build support f
bed only
everywhere. I
The overhang angle here is Because this object has a only is selected
less than 50 degrees. This is steep overhang, support be created wh
generally acceptable and there material will be required. It arrows are belo
will be no compromise in may be possible to print this everywhere
surface quality, without support but the support will be
therefore support is not surface quality will be
required. affected.
 create
d
where
the
red
and
green
arrow
s are
show
n
below
.
Raft

025 Print Bed Adhesion

Preparing Files for 3D
Printing

When 3D printing, a common problem is that models sometimes detach from the print
bed due to the shrinkage effect of plastic. To help models stick to the print bed, slicing
software packages generally have the below functions:
 Brim

A brim is similar to a raft in that it helps around the model, giving it a larger
models stick to the print bed. However, surface area to stick to the print bed.
instead of being a thick base, brims are
usually a single flat layer that wraps

There is often some confusion in which bed adhesion method to use, if any. Our advice
is to try all options and see what works best for the models you are printing.

026 Resolution
Preparing Files for 3D
Printing
Resolution in 3D printing terms usually refers to the layer height. Generally, the
smaller the layer height, the better the surface quality. However using very small layer
heights can add a considerable amount of time to the printing process.
When printing in the classroom you must balance print quality with time.

Low Resolution
High resolution prints generally have printer and the physical design of your
layer heights between 0.02mm and model.
0.1mm. An important thing to note is Low resolution prints can have layer
that resolution is not the only factor that heights around 0.3mm. These types of
affects surface quality. Other factors that prints are especially good for the
affect surface quality include print speed, classroom if you have a large amount of
nozzle temperature, x/y accuracy of your students requiring 3D prints because the
 print time dramatically reduced. An important thing
027 Infill can be to mention is that when printing with
Another important setting to explore is infill. Infill refers to
Preparing Files for
3D Printing
the structure inside a model. Most 3D prints are not solid
because they have a grid-type pattern printed inside to save time and filament. You
can easily adjust the density of your models within slicing software. Below are some

Hollow

Models can be printed completely hollow with only an outer

shell. Many models can print hollow without it affecting
surface quality but models with large top surfaces may
struggle because the printer won’t have material/infill to print
on top of.

Regular

Most models are printed with infill lines around 4-6mm apart or around 20%
density.

Solid

Solid models aren’t very common in the classroom unless it is

a functional requirement. Printing solid objects uses much
The print speed and temperature you should choose are dependent on several factors
including material type, surface quality desired and time constraints.
Below are some general tips on making your selection.

Print Temperat
Speed ure

- Choosing fast print speeds will - For better surface quality you
affect surface quality so if you are want to opt for a low temperature but
looking to create smooth finishes, opt going too low will also give you
for a slow print speed. A slow print underextrusion. Experiment to find the
speed for printing PLA is generally right temperature for your printer and
around 30-50mm/s. material.

- If opting for a fast print speed, - When printing with fast print
be careful not to push the printer too speeds, temperature may need to be
much because this will cause increased in order to reduce
underextrusion. This will show up and underextrusion effects. Again
holes in your print and happens experimentation is the best way to
because the printer cannot extrude figure out the best settings for your
enough filament in time. printer and material.

029 Calibration
Preparing Files for

3D Printing

Calibration refers to the process of ensuring you have a level

print bed that is the correct distance away from the printer’s
nozzle. Although this is not to do with preparing your files, it
 is one of the most essential aspects of the printing process.
Some printers may have an ‘auto-levelling’ function, which
automatically performs this process. With other printers,
you may have to manually adjust screws to ensure the print
bed is in the correct position. Let’s take a look at 2 scenarios
to explain why calibration is so important.

1. In this scenario
the print bed is
completely
level. When
printing begins,
the nozzle
squashes
filament onto
the print bed. The squashing effect gives the model good adhesion to the bed,
which is critical for a successful print.

2. If the print bed

is not level,
several
problems can
occur. At
points where
the print bed is
too far away
from the
nozzle, the printer will essentially be printing in mid-air, leaving messy strands of
filament in the build area. If the print bed is too close to the nozzle, the nozzle will
scratch across the print bed and no filament will be extruded. This can also prevent
the extruder module from moving freely.
4.
3D Printing Tips for
the Classroom
In this chapter we’ll be giving you some essential tips for 3D printing in the
classroom. These include considerations such as time and cost management.
Image Credit: Makerversity DIY
030 Calculating Filament Costs
3D Printing Tips for
the Classroom

Most slicing software packages provide you with printing information such as the
amount of material the print will use. This means you can work out the approximate
cost of a print. The first thing to do is to calculate the cost of 1g of filament. You can do
this by following the below questions.

What is the weight of one of your filament reels in grams?

_________________________________________________

What is the cost of one of your filament reels?

_________________________________________________

The calculation to work out the cost of 1 gram of filament is:

cost of filament reel / weight of filament reel

e.g. If your filament costs $35 and the weight of filament is 750g, the cost
of 1g of filament = $0.05.

What is your cost of 1g of filament?

_________________________________________________

Now that you have your cost of 1g of filament, simply slice some models to find out the
grams of material each model will use. Then the material usage in grams by the cost of
1g of filament to work out the approximate cost of each model. By experimenting with
various model sizes and infill settings, you will be able to get a good indication of your
material costs in the classroom.
31 Classroom Tips for Costing
inting Tips for
assroom

1. Keep a Log
It can be very helpful to keep a simple log of the amount of filament being used over a
period of time. Take note of how the amount changes over time - is it increasing as
more students gain access to the 3D printers? This will help you when budgeting for
materials. In addition to the amount of filament, keep note of what specific type and
colour of filament is being used. You may find that certain colours are more popular
than others and you should therefore place your orders accordingly.

2. Set Design Criteria

Some students may be tempted to print their designs as big as possible! It’s always
good to set some design criteria, for example tell you students that their designs must
fit within the dimensions 50x50x50mm. This also gets them thinking about real-world
applications, where most designs have a set brief to follow.

3. Budget for Failed Prints

Although 3D printing has come a very long way in recent years, you will still come
across failed prints. This isn’t always to do with the hardware or materials - infact the
majority of the time it may be that designs haven’t been optimised for 3D printing. An
example of this is if a student creates a design that has holes in the model, resulting in
a failed print. When budgeting for materials, keep this in mind and include failed prints
in your log.

4. Group Work
In addition to individual projects, encourage students to work in groups. This again
relates to real-world applications because it is rare that architects or engineers will
work on projects alone. By working in groups it reduces the amount of printing, but
still engages each student in the design process.
032 Managing Print Time
3D Printing Tips for
the Classroom

Similarly to the costing exercise, you can also experiment with printing time. Try slicing
various sized models to see how the print time is affected. Below is an example where
we sliced the same model twice at different sizes. Model 1 has an estimated print time
of 11 minutes whereas model 2 has a print time of 5 hours! A good classroom tip to
remember is that it is not always essential for every student to have a large print for
themselves. Consider group work or competitions where students vote for which
design is 3D printed. Another good tip is to make use of the print bed and load as many
designs onto the bed as possible within your slicing software.

Model 1: 30x30x8mm - Print Time: 11

minutes

Model 2: 145x145x37mm - Print Time: 5

hours
33 General Classroom Tips
inting Tips for
assroom

Here are some final tips to keep in mind when 3D printing in the classroom:

1. Let students handle 3D printers

There’s no better way to learn about 3D printing than to get hands-on. This especially
applies to students! So make sure they have access to the printers - let them tinker and
fix technical problems themselves.

2. Work together with students

Don’t be afraid to admit to your students that you don’t know everything about 3D
printing. Work together with them in solving problems and keep your lessons open
ended. What we mean by this is that although lessons should have set criteria and
learning outcomes – there is a world of opportunity beyond this if you allow students
some freedom to explore.

3. Don’t isolate 3D printing

In modern day industry, it is rare that 3D printing is used as a tool on its own. It
compliments other forms of design and manufacturing, such as laser cutting, CNC
machining and 3D scanning, to enhance the outcome. Keep this in mind when planning
your lessons and integrate 3D printing with core curriculum topics.

4. Be flexible and open to change

Something just as important as having a plan, is the need to be flexible and open to
change. It is highly likely that the way you do things when you first begin your journey
will be completely different to a year down the line. This is all part of the development
process, so always try new techniques and keep an open mind.
5.
Integrating 3D
Printing into the
Curriculum
Whether you teach technology, computing, maths, science, history,
geography or any other subject, we can assure you that 3D printing
has a place in your classroom. In this chapter we’ll take a look at
some example 3D printing lessons that can be integrated into core
topics. The examples shown are from PrintLab Classroom - a creative
lesson plan portal for teachers.
You can learn more about PrintLab Classroom at:

https://classroom.weareprintlab.com/
 In this 1 hour lesson students collaboratively design and 3D print their school name in braille. The lesson

034
035 3D
Make
Printing
a 3D Contour
Braille Model
Integrating 3D
Printing into the Curriculum
involves context about the written language braille along with mathematical calculations, CAD design and
3D printing. Each student is assigned a different letter of their school name to design in Tinkercad software
and the braille blocks are 3D printed and placed together in a readable format.

English/Languages | Maths | Design Technology | Computing

Try this lesson for free here: https://bit.ly/2IZUhoO

In this lesson students collaboratively design and 3D print a 1:50,000 scale model of Mount Everest and its
surroundings. The lesson involves mathematical calculations along with CAD design tasks, mapping skills
and 3D printing. Each student is assigned a separate part of the model to design in SketchUp software,
 which is 3D printed and assembled so that students can fully understand the topography of the world’s

036 3D Population Graph

Integrating 3D
Printing into the Curriculum
highest mountain.

Geography | Maths | Design Technology | Computing

Watch the lesson video here: https://bit.ly/2IZTGDA

In this lesson students collaboratively design and 3D print bar charts showing the population growth of 10
countries from 1972 to 2017. The lesson is spread over 3 x 1 hour sessions and involves context about the
causes and effects of global population growth along with mathematical calculations, CAD design, 3D
printing and demographic research.
 Maths | Geography | History | Design Technology | Computing

037 3D Printing Molecules

Integrating 3D
Printing into the Curriculum

Watch the lesson video here: https://bit.ly/2qAIwOO

In this 3 lesson project, students learn how to design, edit and 3D print chemical structures using free
software. The project involves an introduction to atoms and molecules before students split up into teams.
Each team will be allocated a different molecule to research before 3D modelling and 3D printing the
chemical structure. By 3D printing and having a tangible object, students can better visualise and
understand the molecular world. In the final lesson of the project, each group will present their 3D printed
model along with their research.
 Chemistry | Biology | Physics | Computing

038 Design a 3D Printable Pen

Integrating 3D
Printing into the Curriculum

Watch the lesson video here: https://bit.ly/2JPidN1

In this lesson, students design and 3D print a functional pen. The lesson begins with a series of
mathematical calculations on linear sequences. The calculations help students determine the
measurements of the pen, which is designed in Tinkercad in the main part of the lesson. Finally, one of the
pens is 3D printed and once complete, a Bic biro cartridge slots into the centre to make it functional.
 Maths | Art & Design | Design Technology | Computing

039 Balloon Powered Dragster

Integrating 3D
Printing into the Curriculum

Watch the lesson video here: https://bit.ly/2H6c94P

In this project, students will begin by learning about forces, motion and Newton’s Third Law. Using this
knowledge, students will embark on a creative journey to design and 3D print their own functional, balloon
powered dragster! Their aim is to create a vehicle that can travel as far as possible in a straight line and in
the final lesson, they will compete against each other using their own unique dragsters.
 Physics | Maths | Design Technology | Computing

040 Make an Egyptian Obelisk

Integrating 3D
Printing into the Curriculum

Watch the lesson video here: https://bit.ly/2H1E95D

In this lesson, students design and 3D print a personalised Egyptian obelisk. The lesson begins with a
presentation and discussion session about hieroglyphics and obelisk monuments. Following the
presentation, students will be split up into teams and given a 3D printed obelisk model, prepared by the
teacher prior to the lesson. The mission for the teams is to decipher the hieroglyphic word and research its
meaning and relevance to Ancient Egypt. The lesson ends with students presenting their findings. In the
second lesson, students will use a tutorial video to design and 3D print their own personalised obelisk!

History | Religious Education | Art & Design | Design Technology

Watch the lesson video here: https://bit.ly/2EQ5plD

041 Design your own Spinning Top

Integrating 3D
Printing into the Curriculum
n this 2-part lesson, students design and 3D print their own unique spinning top. During the lesson they will
experiment with demonstration models and make design decisions on how they intend to improve the
design and aesthetics of the demonstration models. In the main part of the lesson, students will follow an
instructional video to design a spinning top. Using the skills learnt in the tutorial, they go on to design their
own unique spinning top, which will be used in the class competition in lesson 2!
Physics | Maths | Design Technology | Computing | Art & Design
Watch the lesson video here: https://bit.ly/2H1E95D
 In this 4 lesson project, students embark on a design journey to create their own functional 3D printed

042 Design your own Whistle

Integrating 3D
Printing into the Curriculum
whistle. Lesson 1 begins with a presentation and discussion about sound waves, frequency and amplitude.
The class will then go through a 3D modelling tutorial in Tinkercad to design and 3D print a whistle. The
design tutorial will give students the necessary CAD skills to create their own unique whistle designs in the
next part of the project. In lessons 2-3, students use research and sketching methods before they 3D model
and 3D print their own whistle. In the final lesson, students will test their whistles, analyse their designs
and consider any improvements.

Music | Physics | Maths | Design Technology | Computing

Watch the lesson video here: https://bit.ly/2EQbRZZ
 It has been our mission from day 1 to build a 3D printing ecosystem specifically for education and we are

043 3D Printing Solutions

Integrating 3D
Printing into the Curriculum
excited to support more teachers in their 3D printing journey! If you’re looking to introduce 3D printing into
the classroom, we have a range of 3D printing bundles that start as little as $835 (USD). Learn more about
our solutions at www.weareprintlab.com
Let’s inspire the next
generation, together
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