3D Printed Basic Sign

Challenge: To produce a sign for display as part of a group display.
Background: Students had a display as part of a cluster of schools and students display for a local evening.   Students were looking for ways to display thier work with something creative and original- that would also be eye catching.
Level of Difficulty:  Low.  Students were able to produce this sort of thing extremely easily - it was created with the basic interface available from Tinkercad, with simply the lettering overlaid over top.  This typical design would expect to be created in a two minute timeframe - which all students in the classroom (Y5/6 - ten year olds) are capable of this.
Timeframe: Six hours - this print could have been radically altered depending on the depth of the lettering and the font.  The students raised the lettering 5mm from the base of the plate, this easily could have been reduced to reduce the print time, to still maintain the affect. 
Size: The base plate was 15cm across and had a height of 6cm.   The depth of the plate was 5mm and the lettering was raised a further 5mm from the base of the plate. 
What we would do differently: The choice of the font with the lettering was basic, and the letting itself was not as clearly defined on the base of the 'y'.  The students also hadn't used the capital 'm' for the lettering, which they should have done.   Potentially the students could have designed holes for screws depending on what it was to be attatched to. 
Next Stepts for students: To use a font that better suited for the display of the sign.  They could have included photograph/images related to the topic as part of the sign.

3D Printed Watch Stand

Design as shown from above

Challenge: To produce a working watch stand suitble for the storage of a worn watch.
Background: This design idea actually came from a parent of the student concerned who challenged the student to create a watch stand so that he would have a better organised room and his personal posssesions would be in a better place.  The student has been responsible for a number of designs on this page and was working a an advanced level (for a Y5 student in New Zealand, which makes the student ten years old).  The student came up with the idea, the design - including using Tinkercad to provide the key elements and shapes as clearly shown.   The student came with the entire project in mind and the teachers only input was to provide the hardware to complete the

Side of design

task.
Level of Difficulty: Low - the design shown above has the three key elements.   The student designed the base, sides and main bar in under three mintues.   The dimensions took slightly longer however the student wanted to print the design first, to see how it looked before adding any additional features (see below).  This sort of design should be easily completed by students of any age.
Timeframe: The design took ten hours on a regular infil setting and as with every recent (2017) design on this blog was completed with a 8mm nozzle.  As an aside I personally visited a school last week who had an Ultimaker 3 and had completed a first set of prints, I would hesitate to suggest based on the speeds etc that they were using a 4mm nozzle and high infill settings - this was going to prove to be extremely problematic moving forward for a class/school situation.
Size: The base plate for the design was 14cm across and 7cm wide.   It was a height of 9cm.  It was discussed during this print that a similar designed Headphone stand would be worth investigating for a future work project/design.  The width of the plate was 5mm.
What we would do differently: This student was intent on running a print prior to discussing the adding of personal touches to the print - the obvious basic one was a name on the plate or the side of the design, which would have had minimal design required.   The most pleasing aspect of the design was that ever aspect of the design came from a ten year old who had identified the problem, a soultion, came up with a practical design that worked and the featured print was the first attempt.
Next Steps for the Students: Personalising the design is the obvious one that has already been discussed.  We are investigating the practicality of creating some form of headphone stand or wall mount, although the size may vary.   Also discussed student adding a draw, into the base of the design which has him thinking of ways to complete it successfully.

3D Printed Christmas Giftbox

As shown from above with dividing internal wall

Challenge:  To produce a personalised box, that has a working lid and been personalised for a student to give as a gift. 
Background: This student has designed a series of increasingly complicated prints, during the course of the year.   He was looking to push and challenge himself, hence some of the features that were added to the design of this box.

Failed lid

Level of Difficulty: Medium-Hard.   The box itself required considerable reworking and redesign.  It had a series of personally designed features to make the box unique but also allow it to be recognisable.   The lettering that was set into the base of the box, the lid and the drop down nature of it, the internal bar to divide the base into two compartments all required considerable design, testing and reworking.  The lid required a complete reworking, as the initial handle failed as it was not thick enough and shattering as the rafting was removed.

Christmas decorations

Timeframe: This was printed in two seperate pieces.  The first was the base, followed by a seperate lid.  The  base print meant that the lid could be resized (and subsequently was) to ensure that it fitted correctly (as it did not following the first print).  The lid took eight hours, so a combined print time for both pieces was obviously eighteen hours.  Given circumstances little would be changed from the original design to reduce the level of printing required. 

Lid in place on the base.

Size: The dimensions of the box were 12cm long, 8cm wide and 6cm long.  The width of the printed sides varied from 5mm to 1cm depending on the aspect of the design.  The lid had similar dimensions including a drop down.   
What we would do differently: The lettering went right through the wall of the print - this type of design can cause problem with the rafting removal around there.  An example is shown above left, if you view the inside of the 'M' the right hand side has been removed, this was by the teacher taking extreme care to avoid doing so.    The fit with the lid was there - however it would have been better to have a more robust lid with a better fit.
Next Steps for the Students: This design has been repeatedly completed by students including increasing complex additions to the basic design from the Tinkercad Interface.  At time some of the students tend to create designs that are overly elaborate - and this was bordering on the case in this.
 

3D Printed Delux iPad Stand

 Above: iPad Stand as shown from above 

Challenge: Student wanted to create a personalised iPad stand to support device use at home and in the classroom.  Student has designed a number of prints in the past and the intention was to include significant bells and whistles to improve its design and challenge the student.

Stand viewed from above

Background: A completely original design, with additional features that were not included in the iPad stands that were developed earlier in the year, the link to these on this blog is here.  The student who created this design and printed it is ten years old.
Level of Difficulty: Medium - student wanted to incorperate a design with the stand, their name, a hole to store additional objects and have a working stand.  The student drafted and initial designs were challenged to be improved to include more features not combined together.

Above: iPad Stand in use.

Timeframe: Ten hours. Given the size and the details in this project this represented a minimum time of print (where rafting for instance was at a minimum).  This was conducted with a 8mm nozzle on a regular print setting.
Size: The demensions of this print were slightly affected by the designs and not consistent throughout.  The base was 15cm in length and 7cm long.   The Minion design at the end of the stand was 6cm long and 6cm high.   The student cleverly included his name on the head of the minion and this formed the basis of the hair of the stand. 
What we would do differently: Nothing - the student created something unique that was a significant improvement on the previous designs in this series, the only significant feature that needed to be improved was the location of the hole for additional storage, depending on which item was stored the iPad itself would mean that it couldn't fit.  This location needed to be refined.
Next Challenge for student: to relocate the hole to a place on the iPad stand where it didn't have an issue with the lean of the iPad itself.     

3D Printed Student Bag Hook V2.0

Challenge: Student wanted to design a personalised bag hook, that would be functional and personalised.   This design was originally created with a 'cone' shape, testing revealed that the bag would simply slide off making the design not work.   This design was created to adjust and solve this problem.
Background: Student was showing creative design instincts having previously been responsible for the jewellery box design amongst others.   The first design had failed, this was an attempt at an improvement to resolve the issue.

Level of Difficulty: Medium.   The design premise is basic, however there has already been a considerable reworking of the original design based around problem solving.  There is another area that requires considerable redesign - as viewed in the photograph above you can clearly see that the screw holes in the base of the plate are 2cm across.  This clearly would not work with anything other than extremely heavy and large bolts, which would not suit the purpose of this design.   
Timeframe: Seven hours - this design should require further refinementm the hook itself at present is 6cm from the base, the purpose could be achieved by having something half this distance. 
Size: The dimensions of the print are a depth of 5mm.   8cm wide, 12cm high.   As mentioned the hook comes out 6cm from the base.   The rectangle is 3.5cm by 3cm with a width of 2mm.   The base plate has a depth of 5mm.  Strength testing is required to see what weights of school bags could be held up and what the timeframe would be.
What we would do differently: The task needs to undergo strength test see what weight of school bag could be held and for what length of time.   The holes for the two screws to attatch to the wall need to be resized and redesigned. 
Next Steps for the Students: To considerably redesign the mounts for the wall and to possibly have a third screw hole at the bottom of the design.   The size of these needs to be refined.   There is a clear need for significant strength testing based on the size of the design, the weight of school bag that it can safely have (relative to the wall) and the length of time it will hold it for, which would be an amazing Mathematics lesson.

3D Printed Mouse House - Extended Version

Print showing the entrace to the 'Mouse House'

Background: Student to designed a container that would contain a working mouse trap.  This would protect a domestic animal or young child from setting off the trap accidentally.  This is the second version of this project, with the first featured here on this website (although this was considerably larger).
Background: This was students first individual attempt at 3D Printing by the student who was nine years old.   It was for a showcase (which has featured on a number of projects that have been featured on this site).
Level of Difficulty: Medium.   The design was significantly large (see details of the Printing Time).  The basic shape was from the Tinkercad interface wtih the addition of a hollow out section for the placement of the trap.   This design was printed with an extremely large amount of 'rafting' to allow the shape to be completed.
Timeframe: Twenty-Seven hours.  Given this fact this was a 'one off' print this was acceptable, the print itself could have been resized given the design brief, which would have leant itself to a considerably shorter print time.

Size: The dimension of this print were considerable - 15cm at the height of the roof structure.   The print was 15m long and 12cm wide.   The width of the walls was 5mm thick. 
What we would do differently: The print allowed a student to have his first experience with 3D printing and great a significant design.  The student could have personalised this design with thier name either externally or internally.   The shape/size came about as the result of the students experience with 3D Printers - while it worked it could have had considerable redesigning.
Next Steps for Students: As above - redesigned and personalised.

3D Printed Movember Cookie Cutter

This variation came through Twitter today, combining an idea from a post on this blog to include it as part of the 'Movember' (New Zealand Prostrate Cancer Awareness) idea.  Great stuff Nathan.

Expected Print Time: Depending on Nathan's set up, nozzle size and PLA Filament in use we would expect this print to run in the forty five minute timeframe.

Thoughts: This will allow a group of students potentially to be exposed to 3D Printing, the print time is extremely realistic given the task and its a fantasitc idea to link it in with a relevant fundraising cause.   

3D Printed Presentation Props Part 2

Challenge: As noted previously to enhanee a presentation for the local community and group of schools.  The displays were static and generally two dimensional, by adding 3D figures 
Background: The presentations had the typical 'science fair'/board set up and we were looking at something to enhance the presentation, by adding additional features, in a 3D sense, to improve or have a point of difference.  Due to the auidence (adults) and timeframe the props were for the most part used from a search on Tinkercad.  These were not designed by students - they were created by third parties and re-sized and printed by the students.

 Left: One group was presenting about the 'Pests' in the School area.  They identified that feral cats were one of the creatures and used a 'cat' search to locate this design, which was then increased in size for a ten hour print.

 Left: The 'Pests' group also identified Hedgehogs (which are protected in parts of Europe, but considered a pest here in New Zealand.  This was located from a general search by students on Tinkercad and then re-sized for a ten hour print.

Left: As part of a 'Machine' themed display this student located a series of machine cogs, printed them out and then hung them from the display board to form a border.  Each cog took approximately forty minutes so the tray of nine shown here was six hours altogether.

3D Printed Presentation Props

Glow Worm

Challenge: To choose suitable props to enhance a school presentation.
Background: This is another task to enhance a presentation to take place for the local community and a cluster of schools.  The classroom was developing projects based around two similar themes, gaden worms and glow worms.   As a result of conversation with the teachers of the classrooms an offer was made to enhance the presentations by producing 3D printed models that would then be mounted on the boards.   For the 'glow worm' presentation glow-in-the-dark filament was used.   Due to the timeframe available a decision was made to go with pre-produced material, that was not student created.  (this is the second time this has occurred on this blog, the first being the 'rat' print listed previously which is also linked to this presentation.
Level of Difficulty: Minimum, none.   These prints were sourced from pre-produced locations (in this case a generic search on Tinkercad) and not requiring any student created input.  The only factor that slightly complcated matters was the use of glow-in-the-dark filament for the glow worm.  This filament as a general rule is more difficult to print and requires a adjusted temperature and multiply tries to compete successfully. 

Full display, worms in green

Timeframe: Approximately 40 minutes per worm.  They varied in size and as a consequence the time for each individual piece was different.   The times was a minimum required and as a sourced prints, other than altering the size, minimum changes could be made.
Size: As above the size of the worm/glow-worm varies on a case by case basis.  The longest in the series is shown top left, 12cm.   The worms featured in the display on the right at right angles were this size but split in half due to the angle of the bend.

Collection of 'Tinkercad Worms"

What we would do differently; If time had not been a constraint then it would have been preferable for students to design and create their own individual and unique worms.  Given what students have produced in the past, this would have been more than possible.  On a positive - two furher teachers were provided with practical examples of something produced with 3D Printing, and their displays were enhanced.
Next steps for students: The obvious  is for the students to design the worms or animals from scratch.  This would be well within their capabilities and the animal shapes and design could be inspired to create their own versions that would more than suit the purpose.

3D Printed Glow in the Dark Container

Container with lid

Challenge: To produce a working container for a School display that is functional and able to store items.   Glow-in-the-dark filament was used to create a point of interest/wow factor.  Container would need to feature a working lid that worked in conjunction with the base.
Background: Group was looking for an item to feature as part of their display for a school and cluster (group of schools) showcase taking place for the parents and local community.    The students had a background in design using Tinkercad having spent most of the year working on the projects featured on this site.  Students were nine and ten years old.   Design was created using Tinkercad and Cura for Printing.
Level of Difficulty: Low.  The students design was complicated only by the filament used.  With our experience with the glow-in-the-dark-filament, instead of regular PLA the quality of the print tends to be compromised slightly, we have investigated changing the print settings but tend to get more challenged prints.   The basic Tinkercad interface was used to produce the base, the lid, the drop

Filament 'burn' shown on container

down lid on the inside and the handle.  We ran the print twice to get a better result from the filament with exactly the same design and settings (this was the first of the new roll of filament).
Timeframe: Six hours.   Print times are exactly the same regardless of the filament used.  The shape could have been slightly refined depending on the purpose of the container of what it was holding.
Size: The base design was 8cm across and 8cm high.   The width of the internal walls was 5mm.   The lid had similar dimension being 7cm across, a 1cm depth in total (including 5mm drop down lid) the handle was 3cm high.    As noted these dimensions were created by the students with the design of the container in mind rather than specific for the project.
What we would do differently: The name of the students and the group that they working as part of could have been included in the design - the lid itself while it had a drop down aspect fitted losely.  Both these things could have added considerably to the design and the project. 
Next steps for students: Research the temperature settings for Glow-in-the-dark filament and then experiment with alternative temperature to reduce the 'burn' part of the printing process shown.   As noted above the container could have been more personalised. 

3D Printed Mouse Trap House

Mouse House with trap insert visible

Challenge: To produce a 'Mouse Trap House' that is a structure built to hold a mouse trap to ensure that it can still activate but isn't able to be accessed by a third part such as a pet or young child.
Background: Student was producing a 3D print for the first time as part of the a class project for a showcase that is taking place involving a group of local schools.   Class and students had been looking at mouse traps and determined that if an animal was able to access them or a child was able to access them easily then they could be dangerous.  The solution was to create an orginal design that was capable of housing the Mouse Trap itself, allowing the mechanism to fully operate but would not allow the trap to accidently set off.

Level of Difficulty: Medium.   The design was complicated by a significant internal aread that needed to be able to house the mouse trap, with enough space for the trap to be able to spring, with the trap fitting inside it.  This required the removal of considerable rafting from inside the design.
Timeframe: Ten hours of total print - the design could have benefitted from slight revision, however the internal mechanics of mouse trap and the housing goal determined a lot of the shape and size.  There could have been less infill with the design.

The Mousetrap used in conjunction

Size: The base of the design was 7cm across,   the height of the design was 6cm, the thickness of the sides throughout the design was 5mm (which is pretty much the minimum required to make this print successful).   The length of the design was 6cm.   The variations and specifics of the design were based to house and keep the mousetrap - which was a 'The Better Mousetrap By Intruder' brand of plastic, spring based mousetrap.   This mousetrap is quite sensitive and one of the issues with it is that it could easily be set off by movement.
What we would do differently: The challenge for the student was to build something that works in conjunction with a particular  brand of Mousetrap.   Testing is required to ensure that enough space has been produced/created to allow the spring and the trap to fully set and then release when the pressue plate is touched by a mouse.
Next Steps for Students: This project is going to undergo testing as described above to ensure that it is still able to function.  The idea is innovative and creative and addresses a specific problem related to the use of the mousetrap and has been student driven, created and produced - a great result.

3D Printed Dual Desk Tidy

Design shown from above

Challenge: For student to create an original design that would allow working material - pens and pencils etc. to be stored on the desk of two students with a shared design. Students creating this design were ten year old students.
Background: These projects had been attempted earlier in the school year, however these students (two were involved in the design) sat adjacent to each other and as such wanted to create something that they would be able to each use.  They used Tinkercad and built the designs from scratch, to personalise the design they etched or sank their names into the side of the hexagon shape that made up the storage tower.

Above: Lettering shown on storage 

Level of Difficulty: Low-Medium.   The students were personalising the design by the addition of thier names, they also used an unusual shape with the design which the class had not utilized before.  The lettering was sunk lightly into the design, so the angle of the design meant some of the letters in the names were clearly visible and others were slightly more difficult to see.   The students identified this as rafting at one point and 'knock it through' however this the case and it left a letter of one name looking different from the rest.  Given the basic shape if they had attempted all the letters to be rafting then the design would have been considerably more challenging.
Timeframe: Eight hours on a 8mm nozzle and regular print settings.  There was not a lot of material that could have conceivably been removed from the print or added to it.
Size: 1cm base, 13 cm wide, 7cm high.  The barrel portions of the design were 9cm from the base.
What we would do differently: Minimal - the only issue that developed was consistency with the lettering as it inconsistent, although this was related to the shape of the object which the students were using as a feature of the design.
Next Step for the Students: More challenging projects as this was completed to the students satisfaction and not more material could be added or the design modified.