3D Design & Printing Course

Lesson 1 • Overview of 3D Modelling Approaches

Compares solid, surface, and mesh modelling paradigms. Helps students select the right approach for mechanical, organic, or architectural design goals.

Lesson 2 • Design Intent and Sketching for 3D

Teaches translating a concept into annotated 2D sketches before modelling. Connects ideation habits to cleaner, more purposeful 3D geometry.

Lesson 3 • Navigating Professional Design Software

Covers viewport navigation, toolbar layout, and file management in industry-standard 3D software. Reduces interface friction so students focus on design rather than controls.

Lesson 1 • Edge and Face Manipulation

Teaches selecting, moving, scaling, and extruding edges and faces to refine geometry. Precise face editing is critical for achieving designed tolerances and clean topology.

Lesson 2 • Primitive Shapes and Boolean Operations

Introduces cubes, spheres, cylinders, and cones as building blocks. Boolean union, difference, and intersection combine primitives into complex forms efficiently.

Lesson 3 • Extrusion, Revolve, and Sweep Tools

Covers profile-based modelling operations that generate 3D forms from 2D curves. These tools are fundamental to mechanical and product design workflows.

Lesson 4 • Organic Sculpting Fundamentals

Covers brush-based sculpting tools for creating freeform, organic shapes. Complements hard-surface techniques and expands the range of forms students can produce.

Lesson 1 • Dimensional Accuracy and Units Setup

Establishes correct unit systems, scale, and grid settings before modelling functional parts. Accurate units prevent costly errors when physical prototypes are produced.

Lesson 2 • Assembly Modelling and Constraints

Introduces multi-body and assembly environments where individual parts are mated and constrained. Students verify fit, clearance, and motion before committing to production.

Lesson 3 • Fillets, Chamfers, and Draft Angles

Teaches applying edge treatments that reduce stress concentrations and aid part release from moulds. Proper draft angles are mandatory for injection-moulded and cast parts.

Lesson 4 • Technical Drawing and Annotation

Covers generating 2D engineering drawings with dimensions, tolerances, and notes from 3D models. Drawings communicate design intent to manufacturers and collaborators.

Lesson 1 • Resin and SLA/MSLA Printing

Introduces photopolymer resin printing, UV curing, and the differences between SLA and MSLA. Resin printing delivers higher detail for jewellery, dental, and miniature applications.

Lesson 2 • FDM Printing Process and Materials

Covers fused deposition modelling mechanics, filament types, and typical applications. FDM is the most accessible technology and the starting point for most practitioners.

Lesson 3 • How Additive Manufacturing Works

Explains the layer-by-layer material deposition principle common to all additive processes. Understanding this principle clarifies why design rules differ from subtractive manufacturing.

Lesson 4 • Powder Bed and Industrial Processes

Surveys SLS, MJF, and metal powder bed fusion for high-performance applications. Students understand when industrial processes justify their higher cost and complexity.

Lesson 1 • Orientation, Infill, and Strength Strategy

Explains how print orientation and infill pattern affect mechanical strength and surface quality. Students optimise orientation to place layer lines perpendicular to primary loads.

Lesson 2 • Overhangs, Bridges, and Support Strategy

Covers overhang angle limits and bridging distances that determine where supports are needed. Strategic support placement reduces post-processing time and surface damage.

Lesson 3 • Tolerances and Fit for Printed Assemblies

Teaches applying clearance and interference tolerances to printed parts that must mate or move. Correct tolerances eliminate the need for excessive sanding or forced assembly.

Lesson 4 • Wall Thickness and Minimum Feature Size

Defines minimum wall thickness and feature size limits for each printing technology. Undersized walls collapse or fail to print, making this knowledge critical for success.

Lesson 1 • Infill, Shells, and Top/Bottom Layers

Configures internal structure and outer shell count to meet strength and surface requirements. These settings directly control material usage and part durability.

Lesson 2 • Slicer Interface and Workflow Overview

Introduces the slicer workspace, model import, and the path from STL to G-code. Understanding the full workflow prevents configuration errors that cause print failures.

Lesson 3 • Support Generation and Configuration

Teaches automatic and manual support placement, density, and interface layer settings. Proper support configuration is the single largest factor in post-processing effort.

Lesson 4 • Multi-Material and Colour Printing Setup

Introduces dual-extrusion and filament-change workflows for multi-material or multi-colour prints. Students configure purge towers, prime lines, and material transition zones.

Lesson 1 • Chemical Smoothing and Vapour Polishing

Introduces solvent-based smoothing for ABS and resin parts to eliminate layer lines chemically. Safety protocols and ventilation requirements are emphasised throughout.

Lesson 2 • Sanding, Priming, and Filling

Teaches progressive sanding grits, filler primer application, and spot putty for smooth surfaces. This sequence is the foundation of a professional paint-ready finish.

Lesson 3 • Support Removal and Initial Cleanup

Covers safe removal of supports and rafts using appropriate tools for each material. Proper technique prevents surface damage and reduces finishing time significantly.

Lesson 4 • Functional Post-Processing Techniques

Covers heat-set inserts, drilling, tapping, and bonding to add mechanical functionality to prints. These techniques bridge the gap between prototype and production-ready part.

Lesson 1 • Project Planning and Design Brief

Teaches defining scope, constraints, and success criteria before starting a 3D project. A clear brief prevents scope creep and aligns design decisions with real requirements.

Lesson 2 • Iterative Prototyping and Testing

Covers rapid iteration cycles: print, test, measure, and revise until requirements are met. Structured iteration is faster than attempting perfection in a single print.

Lesson 3 • Portfolio Documentation and Presentation

Teaches photographing, documenting, and presenting 3D design work for professional portfolios. Strong documentation communicates process and competency to clients and employers.

Lesson 4 • Full-Scale Capstone Project Execution

Students design, slice, print, and finish a complete functional object from brief to final part. This project integrates every skill from modelling through post-processing.