3D Printing In the MakerLab

Overview

3D printing, also known as additive manufacturing, is a process of producing three-dimensional objects from digital models to create tangible prototypes. It builds objects layer by layer, enabling complex geometries and rapid prototyping.

3D printing in the MakerLab is full service. Patrons submit a ticket and include the design file(s) in .obj or .stl format. Staff will verify the file and communicate any potential issues. If adjustments are needed, patrons will need to edit and resubmit the file by replying to the ticket email. Completion time will depend on dimensions, complexity, and current demand for the machines. Please submit projects at least 1 week ahead of time. When the print is completed, patrons will be notified via email. Completed projects will be held for one week. After that, unclaimed items will be discarded.

Equipment

Prusa Mark 4 3d Printer

Prusa MK4

The Prusa MK4 is a high-precision FDM (Fused Deposition Modeling) 3D printer known for its reliability and ease of use. It features automatic bed leveling, high-speed printing capabilities, and compatibility with various filament types, including PLA, PETG, and ABS.

Build Volume: W x D x H, 250 x 210 x 220 mm (9.84 x 8.3 x 8.6 inches)
Required file units: millimeters

Fusion3 3d Printer

Fusion3 Edge

The Fusion3 Edge is a professional-grade, enclosed FDM (Fused Deposition Modeling) 3D printer designed for professional and industrial applications. It offers a large build volume, high-speed printing capabilities, and compatibility with a wide range of engineering-grade materials.

Build Volume: W x D x H, 368 x 368 x 343 mm (14.5 x 14.5 x 13.5 inches)
Required file units: millimeters

Design Considerations

Wall Thickness

  • Minimum recommended: ≥ 0.8 mm (2 perimeters with a 0.4 mm nozzle)
  • Thin walls may not print properly or be structurally weak.

Overhangs & Bridging

  • FDM can handle overhangs up to ~45° without support.
  • Bridges work best under 10–20 mm.
  • For more aggressive angles or long bridges, add supports or redesign with angles and arches.

Holes & Tolerances

  • Holes often print slightly undersized due to material expansion.
  • Compensate with +0.1 to +0.3 mm clearance.
  • Post-processing (drilling, reaming) may be required for precise fits.

Tolerances for Assembly

  • Allow 0.2 - 0.5 mm clearance between moving or mating parts.
  • Test and iterate fit tolerances - especially for snap fits, sliding joints or gear meshing.

Support Considerations

  • Avoid unnecessary supports by:
    • Splitting parts into multiple prints
    • Redesigning geometry with chamfers/fillets instead of overhangs

Threaded Parts & Inserts

  • Use heat-set inserts or brass threaded inserts for strength.
  • If printing threads, use coarse threads

Material Choice

  • Choose materials based on part function:
    • PLA: Easy to print, rigid, brittle
    • PETG: Tough, semi-flexible, good for functional parts
    • ABS: Strong but warps easily
    • Nylon, PC, CF blends: Stronger but need tuned settings

Post-Processing Options

  • Sanding
  • Drilling
  • Tapping
  • Priming/Painting