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: Fused Deposition Modeling (FDM)

✅ Summary

Fused Deposition Modeling (FDM), also known as Fused Filament Fabrication (FFF), is the most accessible and widely used 3D printing technology. It builds objects layer by layer by melting and extruding thermoplastic filament through a heated nozzle. In this lesson, you’ll explore how FDM works, what materials it uses, key settings for slicing, and why it’s a popular choice for prototyping and hobbyist applications.

🎯 Learning Objectives

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

  • Describe how FDM 3D printing works from file to finished print

  • Identify common filament materials and their properties

  • Adjust slicing parameters like layer height, infill, and retraction

  • Recognize the strengths and limitations of FDM

  • Select FDM for appropriate use cases in prototyping and creative projects

🔁 1. How FDM Works: The Process Step by Step

1.1 Model Preparation

  • A digital 3D model (usually STL or 3MF) is created using CAD software.

  • This model is imported into slicing software (e.g., Cura, Orca Slicer), which slices it into layers and generates G-code instructions.

1.2 Printer Setup

  • A spool of thermoplastic filament is loaded into the extruder.

  • The FDM printer includes a heated nozzle, a build platform, and motors to move the nozzle in X, Y, and Z directions.

1.3 Extrusion & Layer Building

  • The filament is heated and pushed through the nozzle.

  • The printer deposits the melted material onto the build plate, tracing the sliced layer.

  • Once a layer is complete, the print head moves up or the bed lowers, and the next layer is deposited.

1.4 Cooling and Bonding

  • The plastic cools and solidifies quickly, bonding to the layer below.

  • Cooling fans help control this process to prevent warping.

1.5 Infill and Support

  • Infill adds structure inside the part (usually a grid or honeycomb pattern).

  • Supports are temporary structures that hold up overhangs during printing.

🧵 2. Filament Materials Used in FDM

Material Description Best For
PLA Easy to use, biodegradable, low-temp Prototypes, decorative objects
ABS Stronger, heat-resistant, prone to warping Enclosures, tools
PETG Water-resistant, flexible, strong Outdoor parts, containers
TPU Flexible and elastic Gaskets, phone cases
Nylon Durable, abrasion-resistant Gears, mechanical parts

Specialty filaments include wood, metal, and carbon-fiber infused materials.

⚙️ 3. Essential Print Settings (Slicing FDM Models)

🔹 3.1 Layer Height (Resolution)

  • Determines print detail. Lower height = smoother prints

  • Common settings:

    • 0.2mm (standard)

    • 0.1mm (high resolution)

    • 0.3mm+ (draft/fast prints)

  • Smaller layers = longer print time but better detail

🔹 3.2 Shell Thickness

  • Refers to the number of perimeter walls.

  • Standard = 2 shells (0.8mm); strong prints = 4–5 shells

  • Impacts strength more than infill

🔹 3.3 Retraction

  • Pulls filament back when moving between islands to prevent stringing

  • Too little = oozing; too much = jams

  • Essential for clean prints

🔹 3.4 Infill Density

  • Controls how solid the inside of the print is

  • 10–20% for decoration, 40–50% for strength

  • 0% for fast drafts, 100% for full solid parts

  • Infill pattern also affects strength and appearance

🧰 4. Applications of FDM

✅ Prototyping

  • Functional Prototypes: Test fit, form, and function

  • Proof-of-Concept Models: Demonstrate ideas before committing to tooling

  • Product Development: Ergonomics and market feedback

  • Custom Tooling: Jigs and fixtures for production

  • Architectural Models: Scaled buildings for presentations

✅ Hobbyist and Personal Projects

  • Repairs and Custom Parts: Replacements for household items or devices

  • Miniatures & Models: For tabletop games, dioramas, displays

  • Arts & Crafts: Sculptures, home decor, custom jewelry

  • STEM Education: Robotics, engineering design, physics experiments

  • Gadgets & Accessories: Mounts, holders, phone stands, etc.

💡 5. Advantages of FDM

  • ✅ Low Cost: Affordable printers and materials

  • ✅ Accessible: Beginner-friendly, large support community

  • ✅ Versatile Materials: From flexible to rigid filaments

  • ✅ Fast Prototyping: Great for iteration and design testing

  • ✅ Scalable: From home use to professional prototyping

⚠️ 6. Limitations of FDM

  • ❌ Visible Layer Lines: Affects finish and detail

  • ❌ Lower Resolution: Not ideal for miniatures or ultra-fine features

  • ❌ Strength Limitations: Parts may break or delaminate

  • ❌ Warping/Cracking: Especially with ABS and Nylon

  • ❌ Anisotropic Strength: Weaker along layer lines

🧠 7. Summary

Fused Deposition Modeling is an ideal entry point into the world of 3D printing. It offers affordability, flexibility, and ease of use—making it perfect for students, hobbyists, and professionals alike. While it may not match the detail of resin or the strength of industrial methods, its benefits make it a staple in prototyping, manufacturing, and maker communities.

📂 Resources & Further Reading

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