Course Content
Module 1: Introduction to 3D Printing
This section gives an overview of what 3D Printing is and is origins.
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What is 3D Printing?
00:05
3D Printing’s origin…History and Evolution of Additive Manufacturing
Types of 3D Printing Technologies (FDM, SLA, SLS, etc.)
Part 1 Quiz
00:10:00
Module 2: 3D Printers & Materials
This section gives an overview of the various 3D Printer components, 3D Printer types and materials.
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Components of a 3D Printer
Filament Types and Resin Basics
Choosing the Right Printer and Materials!
Module 2 Quiz: Materials and Printer Components
00:05:00
Module 3: 3D Printing File Types
This lesson provides a comprehensive understanding of the myriads of file extensions in the 3D Printing.
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FDM (Fused Deposition Modeling)
SLA (Stereolithography)
SLS (Selective Laser Sintering)
FAM (Fluid Additive Manufacturing)
00:00
Other Technologies.
Module 3: 3D Printing File Types
00:05:00
Module 4: Introduction to 3D Modeling
Start designing your own printable objects with easy-to-use modeling tools. This module introduces you to beginner-friendly 3D modeling software and teaches you how to create objects that are optimized for the printing process.
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Basic Design Concepts
Beginner-Friendly Software (Tinkercad, Fusion 360, FreeCAD)
Getting Started with FreeCAD!
Designing for Printability
Module 5: Slicing and G-Code
Before printing, models need to be sliced into printable layers. Learn how slicing software works, how to adjust print settings like layer height and infill, and how the slicer generates the G-code that your printer uses to build the object.
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Introduction to Slicer Software (Cura, OrcaSlicer and more)!
03:52
Layer Height, Supports, Infill, and Print Settings
Generating and Reading G-code
Module 6: The Print Process
Now it’s time to bring your models to life. Learn how to set up your printer, load materials, calibrate settings, and start your first print. This module also covers how to identify and fix common printing issues like warping or layer shifting.
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Printer Setup and Calibration
Starting Your First Print
Troubleshooting Common Issues
Module 7: Post-Processing
After printing, your model might need some finishing work. Discover how to remove supports, sand rough edges, paint your models, and combine printed parts into assemblies. These techniques can take your prints from good to great.
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Removing Supports
Sanding and Surface Finishing
Painting and Assembly
Module 8: Introduction to 3D Scanning
Learn how physical objects can be digitized using 3D scanning technology. This module introduces different scanning methods, software for cleaning and editing scan data, and how scanning is used in design, repair, and reverse engineering.
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Types of 3D Scanners
Mesh Cleanup
Retopology Applications in Reverse Engineering
Module 9: Real-World Applications
Explore how 3D printing is transforming industries like healthcare, automotive, education, and aerospace. See case studies and examples of how professionals use 3D printing to solve real problems and prototype new ideas.
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3D Printing in Industry, Medicine, and Education
3D Printing in Construction & Housing
3D Printing in Fashion and Art
3D Printing in Defense and Military Applications
Module 10: The Business of 3D Printing
In this module, students explore how 3D printing extends beyond the workshop and into the world of business, sustainability, and emerging markets. From eco-conscious manufacturing to digital entrepreneurship, learners discover how additive manufacturing is reshaping supply chains, product development, and global commerce. The module begins by examining sustainability trends, showing how 3D printing reduces waste, supports local production, and enables environmentally friendly materials. Students then move into the future of additive technologies, including bioprinting, AI-driven design, and off-planet construction. The module also highlights how 3D printing enables new business models—from custom product startups and digital part libraries to contract printing services and hybrid manufacturing workflows. Students gain insight into market opportunities, value propositions, and the strategic use of 3D printing to create value across industries. Whether learners aim to start a business, join an innovative company, or simply understand the economics behind additive manufacturing, this module equips them with the tools and trends that define the future of 3D printing as a business.
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Sustainability and Future Trends
Building a Portfolio or Business in 3D Printing
Complete a Print-to-Finish Project
Submit for Feedback and Certification
Receive Your Certificate and Bonus Gift
Private: 3D Printing Fundamentals.
About Lesson

🎯 Lesson: 3D Printing in Defense and Military Applications

⚙️ Focus: Learn how 3D printing is revolutionizing military logistics, equipment production, field repairs, and even battlefield innovation.

✅ Lesson Summary

The military sector is actively leveraging 3D printing for operational efficiency, rapid prototyping, field repairs, and scalable production. Defense organizations worldwide are adopting additive manufacturing to reduce lead times, enhance mission readiness, and enable next-gen weapon systems and vehicles.

🎓 Learning Objectives

By the end of this lesson, students will be able to:

  1. Identify how military organizations use 3D printing for logistics, gear, and vehicle components

  2. Understand how additive manufacturing contributes to combat-readiness and innovation

  3. Examine field-deployable 3D printing systems and mobile fabrication labs

  4. Evaluate the pros and cons of adopting 3D printing in military supply chains

📘 Lesson Content

🪖 1. Key Use Cases in Defense

Rapid Prototyping

  • Design and testing of new drones, weapons, body armor, or vehicles

  • Significantly reduces R&D cycles

  • Example: U.S. Air Force Rapid Sustainment Office (RSO) uses AM to prototype aircraft components quickly

Field Repairs and Parts Replacement

  • On-demand printing of critical parts in the field (e.g., broken handles, UAV propellers, medical gear)

  • Reduces dependency on long supply chains

  • Used in forward operating bases (FOBs) and even aboard aircraft carriers

Custom Equipment Fabrication

  • Weapon attachments, tactical tools, and modified fittings for mission-specific needs

  • Printed components for night vision goggle mounts, drone frames, brackets, etc.

Mobile 3D Printing Labs

  • Containerized or vehicle-mounted additive manufacturing systems for battlefield or disaster use

  • Example: U.S. Army’s Expeditionary Fabrication (X-Fab) Lab initiative

  • Deployed in remote areas for humanitarian aid or emergency response

Spare Parts for Legacy Systems

  • 3D scanning and reverse engineering to recreate outdated or rare military components

  • Keeps aging aircraft, ships, and vehicles operational longer

  • Used by the U.S. Navy and Air Force to extend platform life cycles

🛠️ 2. Military Materials and Technologies

Technology Military Application Example
FDM/FFF Tools, brackets, enclosures
SLS/DMLS Metal parts for vehicles, weapons, jet engines
SLA/DLP Medical models, lightweight sensors, optics
Composite Printing Drone airframes, lightweight load-bearing parts

Common Materials:

  • Carbon-fiber-infused nylon

  • ULTEM (high-performance thermoplastic)

  • Titanium and Inconel alloys

  • Onyx, Kevlar-infused polymers for strength and stealth

🌍 3. Global Defense Initiatives Using 3D Printing

Country Initiative or Use-Case
USA X-Fab mobile labs, 3D-printed jet engine brackets (GE), on-demand replacement parts across military branches
Israel IDF uses 3D printing for drone parts and urban warfare equipment
UK MOD 3D-printed submersibles and unmanned vehicles
Russia Testing AM for aerospace and missile systems
China 3D printing warship hull components and jet engine parts
Australia Partnerships with industry to 3D print armored vehicle parts and UAVs

📈 4. Benefits vs Limitations

Benefits:

  • Faster response times and shorter logistics chains

  • Increased readiness in remote or conflict zones

  • Customization for specialized operations

  • Maintenance of legacy platforms with scarce parts

  • Reduced cost for prototyping and low-volume production

Limitations:

  • Security concerns (IP theft, sabotage of digital files)

  • Quality control and material certification challenges

  • Size limitations of current mobile printers

  • Cybersecurity and data transfer vulnerabilities in combat zones

  • High energy demand for metal 3D printing in the field

🧠 Summary

3D printing is no longer an experimental technology in defense—it’s a tactical advantage. From mission-specific tools to war-ready drone parts, additive manufacturing is transforming the way modern militaries equip and sustain their forces.

Key Takeaways:

  • Defense forces globally are adopting AM to increase speed, adaptability, and self-reliance

  • Mobile 3D printing labs and drone part fabrication are major growth areas

  • Material certification, cybersecurity, and supply consistency remain critical challenges

📂 Optional Activity

Assignment:

  1. Research a real-world case where a defense agency used 3D printing.

  2. Create a one-slide summary or paragraph describing:

    • What was printed

    • Where and how it was used

    • Impact or results of the print

  3. Discuss whether you believe 3D printing will replace traditional manufacturing in defense.

📎 Additional Resources

 

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