Course Content
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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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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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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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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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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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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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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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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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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Private: 3D Printing Fundamentals.

🎯 Lesson: Troubleshooting Common Issues

🧠 Focus: Diagnose and fix common 3D printing problems like bed adhesion failures, stringing, under-extrusion, layer shifting, and more.


✅ Lesson Summary

Even the best-prepared print jobs can run into issues. This lesson walks learners through identifying and resolving frequent FDM and resin printing problems, helping them recognize visual symptoms and apply quick, effective fixes.


🎓 Learning Objectives

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

  • Identify visual signs of common 3D printing issues

  • Understand the root causes behind failed prints

  • Apply proper adjustments in hardware, slicer, or materials

  • Maintain a troubleshooting mindset to improve over time


📘 Lesson Content


🟨 1. Poor Bed Adhesion

Symptoms:

  • First layer not sticking

  • Corners lifting (warping)

  • Print detaches mid-print

Causes & Fixes:

Cause Solution
Bed not level Re-level the bed or rerun auto-leveling
Incorrect Z-offset Adjust Z-offset for proper nozzle height
Dirty bed surface Clean bed with isopropyl alcohol
Too cold bed/nozzle Raise bed temp (e.g., PLA: 60°C, ABS: 100°C)
Printing too fast Lower first layer speed to 20–30 mm/s
Use adhesion aids Add glue stick, painter’s tape, or PEI sheet

🟧 2. Stringing / Oozing

Symptoms:

  • Thin “hairs” or strands between parts

  • Blob-like artifacts on retractions

Causes & Fixes:

Cause Solution
Retraction too low Increase retraction distance/speed
Nozzle too hot Lower nozzle temp in 5–10°C steps
Poor filament storage Use dry filament; avoid moisture
Travel moves slow Enable “Combing” and increase travel speed

🟥 3. Under-Extrusion

Symptoms:

  • Gaps between lines or layers

  • Thin or missing walls

  • Clicking sound from extruder

Causes & Fixes:

Cause Solution
Partially clogged nozzle Clean nozzle or replace with a fresh one
Inaccurate E-steps Recalibrate extruder (see Module 6.3)
Filament diameter mismatch Check filament size (1.75mm vs 2.85mm)
Too low flow rate Increase flow rate in slicer

🟩 4. Over-Extrusion

Symptoms:

  • Bulging layers

  • Blobby corners

  • Overly thick walls

Causes & Fixes:

Cause Solution
E-steps too high Recalibrate extruder
Flow rate too high Reduce flow % in slicer (e.g., Cura: 90–95%)
Incorrect filament diameter Double-check slicer setting vs real diameter

🟦 5. Layer Shifting

Symptoms:

  • Sudden or repeated lateral shifts in the print

  • Jagged walls or misaligned parts

Causes & Fixes:

Cause Solution
Loose belts or pulleys Tighten X/Y belts and pulley grub screws
Printing too fast Reduce print speed in slicer
Stepper motor overheating Add cooling or lower stepper current
Obstructions on bed path Check cable routing and smooth axis motion

🟫 6. Nozzle Clogging

Symptoms:

  • No filament extruding

  • Clicking extruder

  • Gaps or weak first layer

Causes & Fixes:

Cause Solution
Debris or burnt filament Perform a cold pull or clean with needle
Low-quality filament Use reputable filament brands
Incorrect temp settings Check material’s recommended print range
Over-retraction Reduce retraction distance/speed

🟪 7. Resin Printing-Specific Issues

Problem Symptom Solution
Layer Separation Delaminated prints Increase base layer exposure and bottom layers
Supports failing Model falls off supports Add more supports and increase support tip size
Suction forces Warped or broken layers Use hollow models with drain holes
Incomplete curing Soft or tacky surface Extend UV exposure or cure time

🔁 8. How to Troubleshoot Systematically

  1. Observe the issue clearly (take photos)

  2. Identify the most likely root cause

  3. Apply ONE change at a time (e.g., change temp or retraction)

  4. Re-test and document the result

  5. Use calibration models (e.g., stringing test, cube, benchy) to compare

🛠️ Tip: Keep a print log to track slicer settings, materials, and problems.


🧠 Summary

3D printing isn’t just plug-and-play—it’s part printing, part diagnosing. Troubleshooting builds your technical intuition. Most common problems have clear visual symptoms and proven fixes once you learn what to look for.

🧩 With time and patience, every failed print becomes a valuable lesson.


📂 Optional Activities

Assignment:

  1. Choose a print that failed or had a quality issue

  2. Identify and document the problem (photos encouraged)

  3. Describe what setting or hardware adjustment you used to fix it

  4. Re-print and share the before/after results


📎 Additional Resources

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