This 3-day course is designed to bridge the gap between a digital concept and a physical object. You will move from learning the constraints of 3D geometry to mastering the "slicing" software that tells a printer exactly how to lay down melted plastic or resin.

Day 1: Design for Additive Manufacturing (DfAM)

Day one is about 3D modeling with a "printing mindset." Unlike traditional modeling, you must design with gravity and material properties in mind.

• Parametric vs. Direct Modeling: Choosing the right tool (e.g., Fusion 360 or Tinkercad) for the job.

• The Golden Rules of DfAM:

  • The 45° Rule: Designing angles that don't require "supports."

  • Wall Thickness: Ensuring parts are structurally sound but not wasteful.

  • Tolerances for Fit: Learning that a $10\text{ mm}$ peg will not fit in a $10\text{ mm}$ hole; you need "clearance."

• Creating Manifold Geometry: Ensuring your 3D models are "watertight" so the printer doesn't get confused by "holes" in the mesh.

Day 2: Slicing Software & Printer Mechanics

Day two focuses on the "translator"—the Slicer. This software converts your 3D model (STL/OBJ) into G-code (the movement instructions for the printer).

• Anatomy of a 3D Printer: Understanding the Extruder, the Hot-end, the Build Plate, and the Stepper Motors.

• Slicing Parameters:

  • Layer Height: Choosing between speed (thick layers) and detail (thin layers).

  • Infill Patterns: Designing the internal "honeycomb" to balance strength and weight.

  • Shells/Perimeters: Defining the thickness of the outer "skin."

• Support Structures & Rafts: Learning when to use "Tree Supports" and how to ensure the part sticks to the bed using "Brims" or "Rafts."

Day 3: Material Science & Post-Processing

The final day is about hitting "Print" and refining the result. You will learn that the job isn't finished when the machine stops moving.

• Material Selection:

  • PLA: Easy to print, biodegradable, but low heat resistance.

  • PETG: The "all-rounder" (strong and heat resistant).

  • ABS/ASA: Tough, but requires an enclosure due to fumes and warping.

  • TPU: Flexible, rubber-like material.

• Troubleshooting the "First Layer": Leveling the bed and solving common issues like "Stringing," "Ghosting," or "Elephant's Foot."

• Post-Processing Techniques:

  • Support removal and sanding.

  • Chemical smoothing (e.g., Acetone vapor for ABS).

  • Painting and assembly (gluing multi-part prints).