Design for additive manufacturing with Fusion
Lesson details
Learning outcome
I can prepare models for 3D printing, taking into account the environmental impact of the materials used.
Key learning points
- When designing, it is important to take into account how the product will be manufactured.
- There are basic design for manufacture rules to follow when 3D CAD modelling.
- It is important to know the capabilities and limitations of 3D printing when designing.
- The circular economy should be considered when selecting 3D printing filament.
- 3D models need to be prepared for printing using a slicing application.
Keywords
DFM - design for manufacture
FFF - fused filament fabrication
Filament - thermopolymer material used by 3D printers to create objects
Fillet - adding a round to the edge of a solid body
Body - a single continuous shape
Common misconception
3D printing is sustainable because it is an additive manufacturing process with minimal waste.
3D printing filament is a thermopolymer. As with all manufacturing processes, there needs to be consideration of the materials used, their sources and disposal.
Teacher tip
Having examples of failed 3D printed parts will give pupils a btter understanding of the desgin contraints.
Equipment
Access to Fusion. Downloadable greenhouse model.
Licence
Lesson video
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Prior knowledge starter quiz
6 Questions
Q1.Why do designers use 3D CAD models before making a product?
Q2.The process of creating an object by adding material layer by layer is called manufacturing.
Q3.What should designers always consider when choosing a material for 3D printing?
Q4.Match each term to its meaning:
plastic material used in FFF printing
a solid 3D shape within the model
converting a 3D model into printable layers
Q5.Why is it important to understand a printer’s capabilities and limitations?
Q6.The concept of keeping materials in use for as long as possible is part of the economy.
Assessment exit quiz
6 Questions
Q1.When designing for 3D printing, what does Design for Manufacture (DFM) help with?
Q2.The FFF method of 3D printing stands for Fused Fabrication.
Q3.Why do designers use a slicing application before printing?
Q4.Match each DFM rule to its benefit:
reduces stress and improves print quality
prevents print collapse or distortion
improves strength and reduces print time
Q5.Which of these actions best supports the circular economy?
Q6.The main material used in Fused Filament Fabrication is called ...
To help you plan your 10 design and technology lesson on: Design for additive manufacturing with Fusion, download all teaching resources for free and adapt to suit your pupils' needs...
To help you plan your 10 design and technology lesson on: Design for additive manufacturing with Fusion, download all teaching resources for free and adapt to suit your pupils' needs.
The starter quiz will activate and check your pupils' prior knowledge, with versions available both with and without answers in PDF format.
We use learning cycles to break down learning into key concepts or ideas linked to the learning outcome. Each learning cycle features explanations with checks for understanding and practice tasks with feedback. All of this is found in our slide decks, ready for you to download and edit. The practice tasks are also available as printable worksheets and some lessons have additional materials with extra material you might need for teaching the lesson.
The assessment exit quiz will test your pupils' understanding of the key learning points.
Our video is a tool for planning, showing how other teachers might teach the lesson, offering helpful tips, modelled explanations and inspiration for your own delivery in the classroom. Plus, you can set it as homework or revision for pupils and keep their learning on track by sharing an online pupil version of this lesson.
Explore more key stage 4 design and technology lessons from the Systems approach to design: Sustainable Futures unit, dive into the full secondary design and technology curriculum, or learn more about lesson planning.