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• 08:30am - 09:00am: Snacks, coffee and networking

• 09:00am - 10:30am: Module 1 - Introduction to 3D Printing
   

• 3D Printing Fundamentals (Presentation)

  • 3D printing refers to additive manufacturing (AM), a broad class of manufacturing methods, but all involve the sequential addition of materials, as opposed to subtractive manufacturing 

  • Introduction to the family of 3D printing technologies:

    • FDM - cover briefly as we will cover it in great detail later

    • Stereolithography 

    • Laser sintering

    • Multi Jet Fusion 

    • Niche AM including layered paper printers and house printers

 

• Deep dive into FDM -  the printer of the classroom and hobbyist

  • FDM Printer configurations

  • 3 axes and their control systems

  • Hot ends and extruders - how they function and their limitations 

  • Which materials can be printed and why

  • Run through of commonly used materials
     

• Slicing - how to convert the file into the language of the printer

  • Slicing converts a model into tool paths in 2D slices

  • Slicing considerations - precision and mechanical properties

  • Overhangs

  • Advanced slicing settings

 

• Models and data types

  • Meshes and why they are used

  • File types and model repositories

  • CAD created files

  • 3D scanners and their place in the classroom
     

• Keeping your printer primed

  • Common printer errors

  • Troubleshooting 101

  • Servicing schedule

 

10:30am - 11:00am: Morning tea and coffee

 

11:00am - 12:30pm: Module 2 - 3D prints in the classroom

 

• Summary of educational usefulness (Presentation)

• How printers stack up against competing technologies (laser cutters, routers and hand tools)

• Advantages of 3d printing: precision, complexity and set and forget nature 

• Disadvantages of 3d printing: slow speed, moderate material cost and schools generally only have several machines so whole classes can’t print together

• This set of attributes makes them perfect to create instructional aids, tools, jigs and molds
   

• Instructional aids and their links to projects and syllabus points (Demonstration)

  • Gearing ratios and leverage

  • Beam designs

  • Working cross sections of various mechanisms

  • Wave patterns

 

• Jigs and fixtures (Mixed mode - Presentation/ Demonstration/ CAD session)

  • Jigs can be used for multiple material types and profiles and are highly customisable

  • Jigs can be re-used for student cohorts of varying age and experience

  • Open CAD software and demonstrate the process of designing simple custom jigs for a range of geometries. Teachers can watch or follow along on their CAD packages
     

• Moulds (Mixed mode - Presentation/ Demonstration/ CAD session)

• Background of molding and the different kinds of mold design required for varied applications including:

  • Pouring

  • Stamping

  • Vacuum

  • Oven cure

  • Compression

 

• Open CAD software and create simple molds from step files of designs encountered online

• Examine overhangs and create pull lines, design alignment features, release geometry (chamfers & pins) and and discuss the use of multi part and flexible molds

 

12:30pm - 1:30pm: Lunch and Workshop tour

 

1:30pm - 2:45pm: Module 3 - Jigs in action (Practical)

 

• Jig Use - experience how to create/ acquire and use:

  • Custom Shims,  spacers and washers

  • Contour gauge

  • Custom wood mitring guide

  • Custom geometry tube mitring guides 

  • Custom sanding blocks

  • Drill dowel guide

  • Welding and soldering jigs

  • Dovetail and Finger joint guides

 

2:45pm - 3:15pm: Afternoon tea

 

3:15pm - 4:30pm Module 4 -Mould session (Practical)

 

• Examine the design considerations and material choices of a series of pre printed moulds. The moulds will progress from basic one part moulds to intricate multi piece moulds. How to prepare mould surfaces for varying material layups will also be discussed.
   

• Create parts from these moulds in a range of materials including

  • Wax

  • Soap

  • Plaster 

  • Urethane foam

 

• Create silicone moulds from 3d prints and use these to allow complex shapes and overhangs to be cast in a range of materials