3D Printing: Design to Slice

By the end

What you'll build

• Explain FDM process physics - melt, extrude, solidify - and why printed parts are weakest between layers (Z anisotropy)
• Apply design-for-printing rules for overhangs (the 45-degree-from-vertical limit), minimum walls, hole compensation and assembly clearances
• Read a part drawing in first-angle (IS/BIS) projection and distinguish it from third-angle
• Diagnose STL and mesh problems - non-watertight surfaces, non-manifold edges, flipped normals, coarse tessellation, unit errors
• Model a specified part in your own free CAD tool and verify its volume and surface area against hand-computed values
• Choose slicing settings - layer height, perimeters, infill, supports and orientation - and articulate what each one trades away
• Select an FDM material (PLA, PETG, ABS/ASA, TPU, nylon) appropriate to a part's job and printing constraints
• Estimate a print's material cost, machine-time cost and a bureau-style quote with a failure margin, using deterministic Python
• Troubleshoot common print failures - warping, stringing, under-extrusion, delamination, elephant's foot, pillowing - from symptom to fix

Curriculum

What's inside

6 modules · 33 lessons

1. 01

   How FDM Actually Works

   5 lessons
   • What This Course Is - and Is Not
   • FDM Physics: Melt, Extrude, Solidify
   • Lab: Filament In, Length Outpython lab
   • Checkpoint: FDM Physicsquiz
   • Vocabulary: The FDM Machineflashcard sr
2. 02

   Design for FDM: Overhangs, Walls and Clearances

   6 lessons
   • Overhangs and the 45-Degree Rule
   • Walls, Holes and Minimum Features
   • Reading a Part in First-Angle Projection
   • Lab: Overhang Angle Calculatorpython lab
   • Drill: Design-for-FDM Numbersfill blank
   • + 1 more lesson
3. 03

   STL and Mesh Hygiene

   6 lessons
   • What an STL File Really Is
   • Mesh Errors: Non-Manifold, Flipped Normals, Holes
   • Vocabulary: STL and Mesh Termsflashcard sr
   • Inspect the Block: Measure and Sanity-Checkmodel viewer
   • Find the Mesh and Export Mistakesquiz
   • + 1 more lesson
4. 04

   Slicing: From Model to Toolpaths

   6 lessons
   • The Slicer's Job: Layers, Perimeters, Infill
   • Supports, Adhesion and Orientation
   • Orient the Block for Printingmodel viewer
   • Lab: Layer Count and Print Timepython lab
   • Drill: Slicing Settingsfill blank
   • + 1 more lesson
5. 05

   Materials

   4 lessons
   • The FDM Material Ladder
   • Vocabulary: Material Propertiesflashcard sr
   • Lab: Material Mass and Costpython lab
   • Checkpoint: Choosing a Materialquiz
6. 06

   Cost, Time and Failure Troubleshooting

   6 lessons
   • Estimating Cost and Time Like a Bureau
   • Lab: Full Job Quote Estimatorpython lab
   • Print Failures and Fixes
   • Troubleshoot the Failed Printquiz
   • Model It and Verify: L-Bracketfill blank
   • + 1 more lesson

The shape of it

How this course works