11/18/2021 | 27 Likes | Education, Assembly, Casework, Chemical Resistant, Cleanroom, ESD Environments, Heavy Duty, Industrial Facilities, IT & Computers, Manufacturing, Material Handling, Monitoring Applications, Sample Processing, Tech Lab, Verticals & Applications, Wet Lab, Workplace Bulletin,

As the Covid pandemic subsides (hopefully once and for all) and classrooms reopen, many teachers are engaging with their students face-to-face for the first time in over a year.

Along with the relief that comes from a return to in-person learning comes a little bit of anxiety.

How can teachers help their students catch up on the learning objectives they may have missed out on during the pandemic?

What’s the best way to go about it?

With students returning to school, now it’s time to upgrade your makerspace facilities to help students gain valuable STEM skills – by learning how to use 3D printers and CNC machines.

These tools encourage students to pursue their creative ideas and passions while developing important skills in product design, mathematics, engineering, material science, and software programming.

In this article, we’ll take a high-level look at some of the key makerspace technologies (in 3D printing and CNC machining) that will help STEM students become prepared for future jobs in science and technology – from robotics to manufacturing and everything in-between. We’ll also look at some key tips that facility planners need to know when designing a makerspace layout, including important safety and health information.

Additive Manufacturing

What is Additive Manufacturing and its Role in Industry?

When you hear someone from the manufacturing industry talk about additive manufacturing, you can think of it as an umbrella term for building objects one layer at a time – as opposed to traditional machining techniques (such as milling), which removes – or subtracts – material from a piece of metal for example.

Isn’t this the same as 3D Printing you ask?

The answer is yes, generally speaking, you can use the terms interchangeably, although the technology is advancing rapidly, and in some cases, we have additive manufacturing equipment that doesn’t bear much resemblance to a printer with a print head.

Terminology aside, additive manufacturing/3D printing is now widely adopted by the industry for prototyping part designs. Increasingly it’s also now used for production parts as well, from engine nozzle parts made of exotic Inconel that power Elon Musk’s rockets to support custom frames and brackets produced by Ford for their cars and trucks.

u-shaped workbench for electronics manufacturing — Formaspace not only builds custom furniture for makerspaces and student laboratories, we also build industrial solutions for manufacturing companies and factories. Shown above is a U-shaped workbench built for an electronics manufacturing company, which features our proprietary ESD protective surface that keeps sensitive electronic components safe from static electric shocks.

3D Printing Software Choices

Many students find many mathematics lessons and computer programming projects to be too theoretical, but 3D printing projects are anything but. The end product, a printed object, is very enticing and motivating for students.

Let’s start at the beginning of the process, which is how we use software to design parts and describe them, so the 3D printer knows how to make them.

There are several ‘disciplines’ to learn to make 3D printed objects from start to finish, but as we’ll see in a second, you can jump into the later stages by using pre-made models.

· 3D Modeling Software

More advanced students are eager to learn how to create their own models suitable for printing – and they can by using a wide variety of 3D software, from the open-source Blender to Z-Brush’s pen-based virtual sculpting software.

Learning these tools can really help students learn how to visualize in 3D space; however, if you want to jump ahead, free pre-built models can be downloaded from resources such as Thingverse, allowing students to print existing models, leaving the design of original content for a later day as part of a more advanced course.

· STL Conversion Software

The format that 3D Printers use to create printed objects is a network of triangles that describe the surface, dubbed the STL format. While many 3D software packages may use more sophisticated surface representations (such as NURBS) internally, they almost always offer an STL export option – or you can use standalone software packages (or plugins) that can convert a variety of 3D formats into STL. (Pre-built models may already be available in the STL format, saving you a step.)

· Slicing and Armature Software

3D printers need to know what the cross-section of the model looks as it prints each level. Slicing software, such as Cura or Prusa, translates the STL model into a series of levels (or slices) that the printer can understand, usually written as “G Code.” Also, some models may have cantilevered arches that overhang during the printing process (think of printing a road bridge with big arches) – to keep these areas from sagging, most slicing software allows you to design temporary “support structures” that will be removed once the print job is complete.

· 3D Printer Specific Control Software

Finally, you will need to customize the print job to match your printer’s characteristics (such as nozzle size), ambient temperature conditions, and material choice, as well as the print speed and quality, the temperature of the build plate, etc. These settings can often be set in the slicer software, or you can override them using the 3D printer’s control panel.

Budget 3D Printer Choice: Entry Level Fused Deposition Modeling (FDM)

The least expensive and most common 3D printing technology found in most makerspaces is called Fused Deposition Modeling (FDM) – which is a fancy way of describing a classic 3D printer design that takes in a little bit of plastic filament at a time (via the ‘extruder’) which feeds it through a flexible hose (the ‘Bowden tube’) into a heating element (called the ‘hot end’) which comes out as molten plastic through a nozzle positioned at the exact location determined by the G-code. For longer runs, such as building a wall section of a part, the hot plastic may come out in a continuous pass, in other areas, the nozzle may appear to hop up and down to apply hot plastic to individual areas. Once the plastic cools (a quick process as the amount of material is very small), the printer can move to print the next layer and the next, until the process is complete.

Companies such as Creality and Prusa offer competent entry-level FDM printers in the under $500 and under $1000 price range, respectively.

At these price points, you will generally be required to assemble your printer from a kit when you receive it, but this is an educational process in itself, teaching students (and teachers!) the ins and outs of how to assembly guide wheels, stepper motors, traveling gantries and more.

mobile workstation desk — Mobility and flexibility are key objectives for makerspace facility managers. Formaspace is a leader in building industrial-strength mobile workstations, such as the desk shown above, which can be easily positioned to meet changing needs, even throughout a single day.

Useful FDM Printer Upgrades

The Creality Ender 3 is a classic printer, but the earlier versions (before V2) often required some upgrades to deliver consistent performance. These include swapping out a metal extruder (the original is plastic), adding a low-friction Teflon Bowden tube, installing an upgraded “hot end” (to handle higher temp requirements of alternative filament materials, such as ABS) as well as upgrading the stepper motors to have less bounce (as well as produce less noise).

Fortunately, the newer Creality Ender 3 V2 addresses many of these issues. You may also wish to monitor 3D printer forums and comment on YouTube channels (some are suggested below) for other tips and upgrade ideas.

Some users also prefer an automatic way to level the build plates (e.g. the surface that the FDM printer deposit the plastic on) rather than rely on a trial-and-error method of adjusting leveling screw under the plate. BL Touch makes an accessory bed leveling tool, and manufacturers such as Creality are starting to include this feature in their higher price point printers.

What You Need to Know about FDM Printers

Working with 3D Printers in a makerspace or classroom situation is all about managing expectations.

The impatient among us may find the process very tedious and the wait for print times very long.

This can lead to frustration. For example, instructors who create a lesson plan where all the students deliver a final 3D printed project may need to have a Plan B, such as sending the models to a mail order service bureau, such as Shapeways, to get all the student projects printed by the end of the term.

It’s also a good idea to set expectations upfront.

The cost of filament becomes a real issue for makerspace operators, as inevitably, some material is spoiled in failed printing attempts. (Sadly, the spoiled filament cannot be recycled easily to create new filament without a trip back to the factory.) Also, most common print materials, with PLA being the most common, need to be kept dry, so don’t unseal new packages until they are ready for use. You can store opened reels of filament in vacuum-sealed freezer bags (just don’t freeze them!) or use a dedicated food dehydrator to dry the material out – but don’t get PLA too hot, or it will melt. (This can even happen to your PLA models if left in a hot car on a sunny summer day.)

Over time you will get a feel for a particular machine and which settings make it “happy,” as well as some clever tricks, such as spraying the bedplate with old school AquaNet hair spray before each print to create a sticky surface that the printed model will adhere to. (Wipe it off with a gentle cleaner after each use, and reapply again just before printing the next job.)

Small 3D printed objects are a good place to start because they print faster and use less material. If a student wants to print out a whole set of chess figurines or the entire cast of a Star Wars movie, you need to gently guide them toward a small version of their favorite character.

Unsure of what 3D printers can do? All of the useful shop tools above were made using 3D printed components.

3D Printer Facility Safety and Maintenance Tips

3D printers are fun to watch in action, but curious fingers need to stay away – the stepper motors are strong and don’t know when human hands are in the way. And the hot end is, unsurprisingly, hot and could burn students who try to “fix” a printing mistake while the printer is in operation.

Avoid injuries by isolating 3D printers with a safety divider.

In fact, in a makerspace setting, it’s a good idea to create standalone booths with transparent safety barriers to house the printers in operation. This not only helps reduce ambient printer noise (which can be quite distracting), it also allows you to control the temperature and install extractor fans to pull fumes into outside exhaust ducts. Let’s address the temperature issue first: while PLA filament generally prints fine at normal room temperatures, some of the more advanced filaments, such as ABS and its variants, need an elevated temperature for optimal print quality. Venting to the outside becomes important here, as ABS and other plastics produce unhealthy off gases that should not circulate within the room.

While you may be using PLA at the start, it’s quite likely you’ll want to try more durable, stronger materials (such as ABS, etc.), so it’s best to play it safe and plan for isolating your printers and providing adequate ventilation from the start of the planning process.

Finally, let’s talk about the unattended operation of 3D printers. To be blunt, we recommend against this.

Sometimes print jobs go awry due to a software bug, a model that slips off the print bed, or other misfires. This can result in a massive waste of time and yards of spoiled filament.

In some cases, there is a possibility of a fire – for example, if a stepper motor jams and the hot end comes in contact with mounds of misprinted filament.

To get around the need to monitor the print job in person, many users have invested in a Raspberry Pi-based device called the OctoPrint, which allows for remote monitoring of print jobs. However, in our view, this is a safety issue, and relying on remote monitoring is not the same as being there in person where you could take action to put out a fire or call 911 for help.

Upgrade Path: Stereolithography (SLA) 3D Printers

The 3D printing industry is very competitive, and innovations are being introduced all the time.

Makerspaces wanting to upgrade their 3D printer technology have many choices, depending on the budget.

For example, Creality is seeking to create its own ecosystem by moving many of the software steps (including sharing models between users, a la Thingverse) into a Creality cloud solution, allowing users to manage print jobs, including slicing models and starting print jobs, using an app on their phone.

There are also several more advanced printing technologies to choose from, including printers that can print multiple material types in one print job, combining, for example, different color plastics with shiny metal or soft, rubber-like materials.

The good news is that the principles students learn by mastering basic FDM printers apply to these more advanced technologies, so, as we said in the title of this article (with our apologies to Frank Sinatra and New York), if you can make it here, you can make it anywhere.

Having said that, one advanced printing technology is coming down in price, making it a potential upgrade for mainstream makerspace operators: Stereolithography (SLA) 3D Printers.

Rather than heating plastic and depositing it with a nozzle, SLA printers use a laser beam to “draw” the pattern of a slice of plastic (e.g. a level in FDM speak) directly onto a bath of special liquid thermoset resin. The laser changes the resin properties, causing it to harden, and the resin bath is moved vertically* to repeat the operation, e.g. produce the next layer, and the one after that, etc. until the part is complete.

*Some SLA printers print from the bottom up, while others print from the bottom down.

Depending on the resin and laser setup, the resulting model can be smoother, with greater detail, than comparable FDM printing methods. And, unlike FDM, there may also be less need (if any) for adding temporary support armatures.

On the other hand, there are some downsides to SLA printing. In many cases (if not all), the raw printed models need a post-printing curing process to harden the plastic; this is often done by exposing the part to UV laser light in a ‘rotisserie’ stand (some stands also double as wash stations to remove excess resins.)

The resins are also problematic. You need to be very careful to wear protective PPE, including protective gloves, face shields, and masks to protect against fumes. Indeed a fume hood is recommended to extract the fumes away from the workspace. The resins also need a secure locker for storage, possibly an explosion-proof cabinet, if so required.

A wet sink is also a necessity for washing the printing equipment when done. We recommend using water-soluble resins only; resins that require alcohol thinners for cleanup are too problematic for a makerspace environment and create an unnecessary fire risk as well as posing problems for disposing of used thinners, which should never go down the drain.

custom laboratory cabinet solution with a sink — Many educational facilities need to add a wet sink to their school laboratory or makerspace operations. Shown above is a custom cabinet solution built by Formaspace for a leading university lab in California. It features a heavy-duty black epoxy top, sink, and backsplash, with powder-coated steel frames with cabinets, plus two phenolic resin shelves overhead, which, like the epoxy top, are highly resistant to chemical spills.

Finally, when selecting an SLA printer, pay attention to the cost of the consumable items, which not only include the cost of the thermoset resin, but also the cost of resin vats (if used). These have a clear flat bottom panel which allows the laser light to pass through and, in many cases, need to be replaced after a set number of uses – beware that these can be expensive to replace in some printer models.

Recommended Channels to Learn More about FDM and SLA Printing

CNC Machining (CAD-CAM Manufacturing)

What is CNC Machining (CAD-CAM Manufacturing) and its Role in Industry?

We introduced the term additive manufacturing at the top of this article, a term which is meant to distinguish itself from more traditional “subtractive” manufacturing methods, such a computer numerical controlled (CNC) machining and milling, a field that’s now often lumped into the broader category of CAD-CAM (computer-aided design and computer-aided manufacturing).

The good news for makerspace operators is that the miniaturization process that’s taken place with 3D printing has also spilled over into CNC machining, with some very basic machines coming onto the market with sub $500 price points.

Again, as with 3D printing, we have to set some reasonable expectations.

Are these basic CNC machines very capable? Frankly, the answer is no.

They are quite limited, with most only able to handle softer materials, such as wood, plastic, copper, and to some extent aluminum. Certainly no steel or harder materials!

‘What’s the point?’ you might ask.

Well, these are genius tools for teaching students how to program CNC machines, as they use the same type of G-code (albeit most likely a subset) as used in most industrial CNC setups.

And frankly, isn’t it more practical to have a student accidentally destroy a $300 device by inputting an improper G-code instruction than to crash the tooling of a big machine worth tens of thousands if not hundreds of thousands of dollars?

Here is another example of a mobile workstation. This one is designed to support a computer that can be easily moved to connect to different equipment, such as CNC machines, either for diagnosing or providing routine hardware maintenance.