Activity 001: Resin Print Orientation and Support Lab¶
Activity ID: U2M3-ACT-001 Duration: 40 minutes Objective: Students will orient a complex model for resin printing, generate and evaluate support structures, and analyze cross-section profiles to minimize peel forces. Group Size: 2-3 students per station Materials Cost: ~$0 (software-only activity)
Overview¶
Students receive a provided STL model (a miniature figurine with overhangs, thin features, and concave surfaces) and use a resin slicer to explore different orientations. They analyze cross-sectional area per layer, support placement, and drain hole positioning, then select an optimized configuration and justify their choices.
Materials & Equipment Needed¶
- Computer with resin slicer installed (ChiTuBox, Lychee, or UVTools)
- Provided STL file: "ProtoLab_Figurine_Test_v1.stl" (from lab shared drive)
- Orientation analysis worksheet
- Calculator
Instructions & Procedure¶
Phase 1: Initial Analysis (5 min) 1. Import the figurine STL into the slicer 2. Examine the model from all angles and identify: - Areas with overhangs greater than 45° from vertical - Thin features (weapons, fingers, clothing details) that may break during printing - Concave surfaces that could trap resin (undercuts, bowls, hollows) - The "display side" — the most important surface that should have minimal support marks 3. Document these features on your worksheet with annotations
Phase 2: Orientation Comparison (15 min) 4. Configure three different orientations: - Orientation A: Standing upright (feet down) at 0° tilt - Orientation B: Tilted back 30° with feet toward the build plate - Orientation C: Tilted 45° to the side (student's optimized choice) 5. For each orientation, use the slicer's layer preview tool to find: - The layer with the LARGEST cross-sectional area (record the area in mm²) - The total number of layers - Whether any early layers have "islands" (disconnected sections) 6. Generate automatic supports for each orientation using "medium" support settings 7. Record for each orientation: - Number of supports generated - Total support volume (if available in slicer) - Location of support contact points relative to the display surface
Phase 3: Optimization (15 min) 8. Select your preferred orientation based on: - Lowest maximum cross-sectional area (minimizes peel force) - Fewest support contacts on the display surface - No islands in early layers - Reasonable layer count (not excessively long print time) 9. Manually adjust supports: - Remove supports from critical detail areas (face, front display surface) - Add heavy supports at the lowest points (nearest the build plate) - Ensure no unsupported overhang spans more than 3mm - Add supports to any island layers identified in step 5 10. If the model is solid and thicker than 4mm anywhere, hollow it: - Wall thickness: 2.0mm - Add two drainage holes: one at the lowest print point (3mm diameter), one as a vent at the highest point (2mm diameter) 11. Run final layer preview scrub — check every 10th layer for unsupported areas
Phase 4: Documentation (5 min) 12. Screenshot your final orientation showing support placement 13. Record your final statistics: orientation angle, max cross-section area, support count, estimated print time, estimated resin volume 14. Write a 3-sentence justification for why your chosen orientation is optimal
Discussion Points¶
- How much did the maximum cross-sectional area change between 0° and 30° tilt?
- Where did the automatic support generator place supports that you would move?
- What trade-offs did you make between support placement and display surface quality?
- How did hollowing affect the estimated resin volume and print time?
Expected Outcomes¶
- Tilted orientations (B and C) should show 30-60% reduction in maximum cross-sectional area vs. upright (A)
- Students should remove supports from the figurine's face and front surfaces
- Island layers should be identified and supported in at least one orientation
- Hollowed models should show 40-60% resin savings
Assessment Rubric¶
| Criterion | Excellent (5) | Proficient (3) | Needs Improvement (1) |
|---|---|---|---|
| Orientation Analysis | All three orientations fully analyzed with cross-section data, island detection, and support counts | Two orientations analyzed with partial data | One or no orientations properly analyzed |
| Support Optimization | Manual support adjustments protect display surfaces while ensuring structural adequacy | Some manual adjustments but missing critical supports or leaving marks on display surface | No manual adjustments or unsupported areas remain |
| Hollowing and Drainage | Correctly hollowed with properly placed drainage and vent holes | Hollowed but drainage holes missing or poorly placed | Not hollowed or incorrectly configured |
| Justification | Clear technical reasoning citing peel force, surface quality, and structural considerations | Basic reasoning with some technical merit | No justification or non-technical reasoning |
Safety Considerations¶
- No physical safety hazards in this software-only activity
- Ensure ergonomic workstation setup for extended computer use
Last Updated: 2026-03-19