Unit 01: FDM 3D Printing

Unit Metadata

• Microcredential ID: MCCPDL-U01-FDM-v1.0
• Title: Fused Deposition Modeling (FDM) 3D Printing Fundamentals
• Version: 1.0
• Credit Hours: 12 (3 hours per module)
• Target Audience: Prototype Design Lab participants, makers, makers engineers
• Prerequisites: None; basic mechanical aptitude recommended

Unit Description

This unit provides comprehensive coverage of Fused Deposition Modeling (FDM) 3D printing technology, from fundamental physics through advanced troubleshooting. Students will gain hands-on competency in operating FDM printers, optimizing print quality, and troubleshooting common failures. The unit emphasizes print reliability, material science, and safety protocols essential for production-quality 3D printing.

Standards Alignment

• ANSI/ISO 52901:2020 - Additive Manufacturing General Principles - Terminology and Definitions
• ISO 52911-1:2019 - Design and Modeling Part 1: Guidance for Geometry and Tolerances
• ASTM F3122-14 - Standard Guide for Evaluating Mechanical Properties of 3D Printing Resins
• OSHA 1910.1200 - Hazard Communication Standard (thermoplastic fume hazard awareness)
• ANSI Z535.4-2011 - Safety Labels and Signs - Criteria for Safety Symbols

Learning Outcomes

Knowledge

• Understand the thermoplastic extrusion process and how temperature, pressure, and velocity affect print quality
• Identify components of FDM printer architecture and their functional roles
• Explain the relationship between print speed, layer height, and mechanical properties
• Recognize how material properties (tensile strength, glass transition temperature, durometer) impact printer settings

Skills

• Properly load and unload filament without cross-threading or contamination
• Perform bed leveling using feeler gauge, BLTouch, or manual adjustment methods
• Configure slicer software for custom print profiles and material-specific settings
• Diagnose and correct print failures including warping, layer adhesion, stringing, and under-extrusion
• Generate optimized toolpaths for strength-critical and prototype-speed applications

Competency

• Produce print-ready files from CAD models with appropriate supports and orientation
• Execute multi-hour printing jobs with proper monitoring and intervention procedures
• Apply material selection logic based on functional requirements (mechanical, chemical, thermal)
• Maintain printer hardware to manufacturer specifications and establish preventive maintenance schedules

Unit Structure

Module	Title	Duration	Focus
M1	FDM Technology Fundamentals	3 hours	Printer architecture, thermoplastics, physics of extrusion
M2	Machine Setup & Calibration	3 hours	Bed leveling, nozzle care, filament loading, temperature profiles
M3	Slicing Software & Print Preparation	3 hours	Slicer configuration, supports, infill, orientation, G-code
M4	Print Execution & Troubleshooting	3 hours	Live monitoring, failure diagnosis, post-processing, maintenance

Assessment Strategy

Formative Assessment

• In-module quizzes (10-15 questions per module, multiple choice and matching)
• Hands-on competency checkpoints (bed leveling verification, filament load test)
• Print quality rubrics (visual inspection, dimensional accuracy, surface finish)

Summative Assessment

• Practical Print Project: Design and execute a specified print with custom supports, demonstrating Module 3 competencies
• Troubleshooting Scenario Test: Given a failed print or misconfigured settings, diagnose root cause and prescribe remediation
• Unit Safety Certification: Verification of proper PPE use, emergency procedures, and thermal hazard awareness

Portfolio Evidence

• Photo documentation of 5 successful prints with varying complexity/materials
• Configuration files demonstrating printer profile customization
• Maintenance log showing preventive care execution

Instructional Resources

Primary Resources

• FDM Printer Hardware: Commercial FDM printers (Prusa, Creality CR-10, Ultimaker recommended)
• Slicing Software: Cura (free), PrusaSlicer (free), Simplify3D (paid reference standard)
• Calibration Tools: Metal feeler gauges, BLTouch probe, leveling print files
• Support Materials: PVA, HIPS, or proprietary support filaments
• Material Library: PLA, PETG, ABS, TPU with documented thermal profiles

Reference Standards

• Manufacturer datasheets (thermal profiles, material compatibility, print speed limits)
• ASTM F963-21: Standard Consumer Safety Specification for Toys
• ISO 527: Plastics—Determination of Tensile Properties

Learning Platforms

• This MkDocs curriculum (self-paced + instructor-led)
• Manufacturer video libraries (Prusa, Ultimaker technical documentation)
• Open-source resources: Reprap wiki, community forums with moderation

Accessibility Considerations

Visual Accessibility

• High-contrast slide decks and graphics (minimum 4.5:1 WCAG AA standard)
• Alt text for all diagrams describing functional relationships, not just content
• Printed reference materials available in large print (16pt minimum)
• Screen reader compatible markdown and PDF versions

Auditory Accessibility

• Lecture videos include captions and full transcripts
• Instructor notes provide speaking points for non-verbal instruction
• Loud FDM printer environment accommodated with quiet work zones for discussion

Motor Accessibility

• Adaptive equipment guides (left-handed nozzle cleaning tools, ergonomic feeler gauge holders)
• Pre-leveled printer stations available for students with fine motor limitations
• Video demonstrations allow observation without hands-on requirement
• Neurodiverse accommodation files provide alternative task sequences

Cognitive Accessibility

• Modular structure allows self-paced learning with flexible checkpoints
• Technical terminology introduced with visual diagrams and plain-language definitions
• Chunked content (15-20 minute segments) with built-in breaks
• Choice in assessment modality: quiz, practical demonstration, or written explanation

Neurodiversity Accommodations

• ADHD: Kinesthetic activities, timers, checklist-based procedures, frequent breaks
• Autism Spectrum: Visual protocols, predictable routines, sensory-aware laboratory setup
• Dyslexia: Graphic organizers, spoken instruction options, extended time on written assessments
• Sensory Processing: Sensory profile questionnaire, quiet workspace options, notification of loud environments

Unit Learning Path

START → M1 Fundamentals
        ↓
        → M2 Setup & Calibration (hands-on printer operation)
        ↓
        → M3 Slicing & Preparation (software + CAD integration)
        ↓
        → M4 Execution & Troubleshooting (synthesis + advanced problem-solving)
        ↓
        → Portfolio Project (design, execute, document)
        ↓
        → Unit Assessment + Certification
        ↓
        END (Ready for Unit 02: SLA, Unit 03: Laser, or Unit 04: CNC)

Success Criteria

• All 4 modules completed with 70%+ quiz scores
• Successful execution of 3+ multi-hour prints with <5% failure rate
• Accurate troubleshooting of at least one simulated failure scenario
• Demonstration of proper safety procedures (PPE, thermal hazards, filament handling)
• Maintenance log documenting preventive care (nozzle cleaning, bed inspection, calibration checks)

Next Steps

• Enroll in Unit 02: Resin SLA 3D Printing (complementary additive process)
• Advanced elective: Multi-material printing, custom slicer profiles, print farm management
• Integration with Unit 03 & 04 for full 4-process design lab certification

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Last Updated: 2026-03-18 Maintained By: MCC Prototype Design Lab Curriculum Development Contact: [Lab Coordinator Email]