What to do when 3D printers go wrong: Laboratory experiences

Abstract

The 3D-printing revolution is in full swing due to the expiration of a number of pivotal patents causing a proliferation of inexpensive 3D printers. While the 3D printer manufacturers' demonstration objects usually print well, student-designed objects do not, thus causing delays in student projects. This work describes 3D-printing laboratory experiences with unsuccessful prints (based on over 3000 print hours) in an undergraduate engineering 3D-printing lab using inexpensive 3D printers implementing fused deposition modeling (FDM) technology. Unsuccessful prints caused by 3D printer failures and by 3D-printing process failures are classified based on severity (catastrophic, compete, and partial failure types), analyzed, and corrected. The solutions include reprinting the failed objects using different object orientations, changing the printing material, changing the printing platform surface properties, rework by using tools like 3D pens, soldering irons, acetone treatment, etc. Student evaluations show that students understand and accept 3D-printing technology with its capabilities, potentials, and limitations. When dealing with partial failures and time limits, students prefer to correct small defects in complex objects and to reprint simple objects.