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Module 3: Print Setup & Execution

Duration: 3 hours | Microcredential: MCCPDL-U02M3-v1.0

Module Overview

This hands-on module covers the complete SLA print workflow from file preparation through starting the printer. Students learn part orientation for minimum supports, support structure generation, exposure setting configuration, vat preparation, and safe printer startup. The module emphasizes that SLA prints are precision operations requiring exact positioning and stable exposure parameters.

Learning Objectives

  1. Prepare 3D models for SLA: scale, orientation, hollowing (if applicable)
  2. Generate support structures using software: density, thickness, orientation
  3. Configure exposure settings: layer thickness, exposure time, base layers
  4. Set up printer: vat inspection, resin type verification, platform cleaning
  5. Execute print startup: verify bed level, confirm resin coverage, start job
  6. Monitor initial layers: detect adhesion failures early, pause/resume if needed

Key Concepts

  • Part Orientation: Minimize supports; consider layer lines visible in final part
  • Support Structures: Tree-based vs. linear; removal difficulty vs. surface quality trade-off
  • Exposure Settings: Custom per resin; under-cure = weak; over-cure = surface distortion
  • Vat Maintenance: FEP film inspection (scratches cause adhesion failures); resin filtration
  • Build Platform: Level critical; misalignment causes layer adhesion failures
  • Job Monitoring: First 3 layers most critical; check adhesion before proceeding

Time Allocation (180 min total)

Segment Duration Activity
Review & Safety Reminders 10 min PPE requirements, chemical safety, ventilation check
Slide 1: Model Preparation & Orientation 20 min Presentation: scaling, hollowing, support-minimization strategies
Activity 1: Model Orientation Exercise 25 min Students orient 2-3 sample models for optimal printing
Slide 2: Support Generation & Configuration 20 min Presentation: software tools, support density, removal considerations
Activity 2: Support Structure Design 30 min Students generate supports for their design file in software
Break 15 min —
Slide 3: Exposure Settings & Tuning 20 min Presentation: layer thickness, base layers, exposure time calculation
Slide 4: Vat Prep & Platform Setup 15 min Presentation: inspection, leveling, resin type verification
Activity 3: Hands-On Vat Inspection & Setup 30 min Supervised: students inspect FEP film, level platform, verify resin
Slide 5: Print Startup & Initial Monitoring 15 min Presentation: firmware startup, first layer verification, pause procedures
Activity 4: Print Startup 30 min Supervised: students load file, start print, verify first 3 layers

Assessment Strategy

  • Formative: 10-question quiz on support design and exposure settings
  • Practical: Successfully orient and support a complex part; configure appropriate exposure settings
  • Competency: Successfully start a print with good first-layer adhesion

Standards Covered

  • ANSI/ISO 52901:2020: Additive Manufacturing General Principles
  • ISO 52891:2022: Resource Efficiency in Additive Manufacturing

Prerequisites

  • Completion of Module 1 (SLA Technology & Resin Chemistry)
  • Completion of Module 2 (Chemical Safety & PPE) with passed safety certification
  • Basic 3D CAD familiarity (SLA software similar to FDM slicer)

Resources Needed

  • SLA printer (Formlabs Form 3, Anycubic Photon, or equivalent)
  • SLA software with support generation tools
  • Sample resin (Standard, Tough)
  • Vat inspection kit: magnifying glass, FEP film cleaner, cloth
  • Platform leveling tools: level gauge, paper feeler gauge
  • Monitoring checklist: first-layer verification steps

Success Criteria

  • Score ≥70% on knowledge quiz
  • Correctly orient part to minimize supports while maintaining strength
  • Generate supports with appropriate density for part geometry
  • Configure exposure settings within recommended range for chosen resin
  • Successfully prepare vat and platform for printing
  • Achieve good first-layer adhesion on actual print (≥80% platform coverage)

Next Steps

  • Module 4: Post-Processing & Curing (complete print → finished part)
  • Advanced: Multi-resin printing, custom exposure tuning, advanced support strategies

Last Updated: 2026-03-18