GOAL
To learn about manufacturing engineering by exploring the 3D printing process
Product Engineering
3D Printing and CAD
2025-08-18_v1.0
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Breakout Development Team
CAROLINE GILLESPIE
College: Notre Dame
Major: Mechanical Engineering
GIGI BRUSCO
College: Notre Dame
Major: Computer Science / Engineering
KRISTINE BUDILL
College: Yale and MIT
Major: Electrical Engineering, BS & MS
Industry Experience: General Electric Aircraft Engines, ITT Fluid Technology, Haemonetics
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Breakout Redevelopment Team
CONNOR
College: Bucknell University
Major: Mechanical Engineering
SARAH
College: Bucknell University
Major: Mechanical Engineering
BETSY
College: Purdue University
Major: Aerospace Engineering & MBA
Industry Experience: NASA, Sophic Synergistics
TRAVIS
College: SUNY Purchase, BS ‘07
Major: Studio Production
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OUTLINE
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Introduction to Product
Engineering
PART 1
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What is Product Engineering?
Product engineering is the process of designing, developing, and improving products that solve real-world problems.
Product Engineers take ideas and then turn them into physical, usable products!
Design
Product
Prototype
and Test
Manufacture
Iterate with Feedback
Four Steps of Product Engineering:
For today’s lab, you’ll be manufacturing your own product using 3D printing! Manufacturing engineers are a type of product engineer who specialize in the production process—just like you'll be doing today.
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Building the Product…
Manufacturing Engineers!
Turning an idea into a usable product isn’t just about designing it. Someone has to figure out how to actually build the product. That’s where manufacturing engineers come in!
A manufacturing engineer designs and operates the manufacturing systems for �a product.
They choose the best technologies, material, processes to manufacture different products.
ANSWER ME!
Do you think you would enjoy being a manufacturing engineer? Why or Why not?
Type your answer here.
Hear from a
Manufacturing Engineer
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Different Types of Manufacturing Processes
ADDITIVE: start with nothing and build up a design
FORMING: apply force to create a shape
SUBTRACTIVE: remove material to create design
CASTING: liquify material and put it in mold
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What type of Manufacturing do you think 3D printing is?
ANSWER ME!
(Additive, Subtractive, Casting, Forming?)
1.
2.
3.
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3D Printing
Product Development
PART 2
ANSWER ME!
What are three Applications of 3D Printing?
1.
2.
3.
Applications for 3D Printing
This video will help you understand more about what 3d printing is.
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3D Printing is Revolutionary
3D Printing is used in rapid prototyping to make quick, inexpensive and independent models to try out new products.
The high precision and detail of 3D printers allows for finished products with complex geometries to be manufactured, such as for airplane engines.
3D printers allow for a closer link between production and consumption since are small and mobile. This allows them to create parts in areas typically hard to manufacture such as on ships and in outer space.
3D Printing removes the need for complex manufacturing tools which allows for inexpensive customization of parts.
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Benefits of 3D Printing
Quick Production - Rapid Prototyping
Clean and Safe Process (no sawing, welding, painting)
Minimal Material Waste & Recyclable Materials
Highly Accurate Complex & Custom Designs
ANSWER ME!
Why are these benefits important to companies that make 3D printed products?
Type your answer here.
Reduce Energy Consumption
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Real World Applications of 3D Printing
Personal Protective Equipment during Covid 19 Pandemic
Cement Housing Development in Texas
Choose a video to watch to learn more about a cool real world applications of 3D printing.
Printing Food and Sweets
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Introduction to TinkerCAD
PART 3
Tinkercad Instructional Video
The instructions in this video are outlined in the next few slides.
NOTE: 1 centimeter = 10 millimeters
Condensed Tutorial Guide
Getting Started with Tinkercad
Go to “www.tinkercad.com” | Select “Sign Up”
Making an Account
Choose the option to make a personal account and enter your email.
Creating a New Design
Once you are logged in, select “Create your first 3D design” or “Create” to begin tinkering.
Selecting a Shape
To make a solid object, choose one of the colored shapes on the right. To make a cut out or a hole, choose one of the grayed out shapes.
DIRECTIONS:
Drag different shapes onto the Work Plane to edit them in your design.
You can adjust their size by dragging the corner of the shape or typing in your desired dimension.
Modifying a Shape
TIPS:
To zoom in and out on a design, hit the plus and minus buttons on the left side.
To change the view of your design, move the cube in the upper left corner.
Sizing and Orientation
Tips for Placement
TIP: Make sure your shape is always on the WORK PLANE and not slightly above the ground.
Tips for Grouping Objects
CREATING A BOX:
Create a 50mm long, 60mm wide, and 30mm tall box.
Then add a box hole that is 4mm smaller on all dimensions and cut from the center of the original box.
Remember to group your two box shapes to create one piece.
Practice Activity
YOUR FINAL PRODUCT SHOULD LOOK LIKE THIS.
Lay pieces flat on the printing bed
Keep holes vertical
Separate moving or connected parts
Design simple pieces
Leaving large overhangs
Making details too small
Using exact fit instead of tolerance
Floating pieces off the grid
Interested in 3D Printing?
Good Practices
Bad Practices
Tips, Tricks, & Common Errors to Avoid
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Creating Your Own Product Engineering Solution
PART 4
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Your Task Today:
Be a Product Engineer
INSTRUCTIONS
YOUR PROTOTYPE DESIGN CONSTRAINTS:
The maximum size of your object is 200cm³
Height x Width x Length ≤ 200 cm³
Ex: Height: 5 cm, Width 4 cm, length: 10 cm
Volume ≤ 200 cm³ ✔
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Imagine you are a product engineer. Identify a problem at your home or school you would like to solve with your 3D print.
How would you use the Engineering Design Process to create a product that will solve the problem you identified?
THINK
These next slides will walk you through the design process.
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Step One: Define your Problem
ANSWER ME! What problem or challenge are you trying to solve?
Try to choose something that is solvable with a small, 3D printed object. (EX: You need a phone holder)
Type your answer here
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Step Two: Research
Type your answer here.
ANSWER ME!
What are the important features or criteria for your design solution? Is there a similar product that you could improve?
IDEAS TO INSPIRE
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Step Three: Design Solution
ANSWER ME! Draw out a sketch of your design brainstorm or insert photos here.
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Step Four: Build
Engineering Drawings!
As mentioned in the introduction video, engineering drawings are crucial for product engineering.
On the next slides, create your own engineering drawing to communicate what your final build looks like!
Tips:
Orientation cube
Flat view toggle
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Example Engineering Drawing
Refer to this slide as you complete your own engineering drawing. This engineering drawing is from the example object you made in the TinkerCAD Introduction.
Top View
Front View
Side View
Isometric View
Dimensions
Max Height: 3 cm
Max Length: 6cm
Max Width: 5cm
Total Volume: 90 cm³
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Your Engineering Drawing
Complete this slide based on your CAD Build.
Top View
Front View
Side View
Isometric View
Dimensions
Max Height: ___ cm
Max Length: ___cm
Max Width: ___cm
Total Volume: ___ cm³
Confirm your total volume is not larger than 200 cm³!
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Step Five: Test
You are almost ready to test your design!
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Optional: Freestyle
Design Section
EASY
Guided Ideas
MEDIUM
KEY CHAIN
FIDGET SPINNER
DOOR STOP
Correction -
Insert a 22mm bearing into final design– not 20mm like mentioned at the end of the video
HARD
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Step Five: Test
Type your answer here.
ANSWER ME!
Record any observations here. Does the piece look/work as intended?
ANSWER ME! When you receive your 3D printed piece,
insert a photo here.
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Step Six: Analyze Data
ANSWER ME! Record any changes that you would like to make to your design to improve its look or function. If you choose to redesign the Tinkercad model, include the updated image here.
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Reflection
ANSWER ME!
Write your answer here
What do you think went well when completing this activity?
Write your answer here
What is something you would do differently if you were to do this again?
Complete the mandatory 5-minute Exit Ticket by clicking here!
Skills Learned
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Continue to Explore
IF YOU LIKED TODAY’S BREAKOUT, �YOU MAY BE INTERESTED IN THESE TOPICS:
TYPES OF ENGINEERING RELEVANT TO TODAY’S 3D PRINTING PRODUCT DEVELOPMENT BREAKOUT:
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Manufacturing: Get Involved
ORGANIZATIONS AND PROJECT-BASED LEARNING
INTERNSHIPS/JOB OPPORTUNITIES
Society of Manufacturing Engineers (SME)
Thank you!
Any text here?
Follow up info here?
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Optional Extension Activity
Slicer Tools
OnShape
Design Challenge
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Using a Slicer to Prepare Design for Printing
Extension #1
Note: This portion of the activity requires a software download. It is optional- so if you are having trouble with the download, just submit your STL file.
How to download Prusa3D
Step 1: Click on this link!
Step 2: Follow steps to download on appropriate software
Step 3: Time to get to work!
Note: This portion of the activity is optional, so if you are having trouble with the download submit your STL file for printing.
Click this!
What is Slicing!
Then, you go to the slicer software and your file turns into “G Code.” Your design is sliced into many layers for the printer to read individually.
This G Code is sent to the printer as “instructions” and your design is printed!
You start by creating your design in tinkercad, and saving it as an STL file.
Bigger layer height = rougher surface
Smaller layer height = smoother surface
Object shell- outer layer of object
Higher object shell = stronger object
Controls density of object
Controls structure of object “filling”
Image shows different structures of printing
Importance of Tools
Layers and Parameters
Infill
Skirt- An outline surrounding the part
Brim- A single layer printed under the object
Raft- Multiple layers printed as a detachable base
Great for more complicated designs
Great if your design has overhanging parts!
Removable support material to ensure accurate printing
Importance of Tools
Skirt and Brim
Support Material
The clear material is removable and just there for support!
ANSWER ME!
What is one new thing you learned/found interesting from this tutorial?
Write down some of your ideas here.
HOW TO: Prusa Slicer Software
Watch this video for a quick tutorial on the Prusa Software!
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Using OnShape
Extension #2
What is OnShape?
What is one new thing you learned/found interesting from this tutorial?
OnShape is a more advanced web-browser based CAD and product development platform.
What is one new thing you learned/found interesting from this tutorial?
It allows people to create assemblies of multiple parts, moving simulations, and more complex shapes.
Many professional engineers today use OnShape to design, prototype, and model their ideas and products!
Getting Started with OnShape
Go to https://www.onshape.com/en/ & Press the “Create a Student Account”
Create the Account
Fill in the appropriate information and follow the instructions directed afterwards to complete your OnShape account.
If you are having difficulty setting up your account, click here.
Making your First Design!
Creating Sketches
The first step in CAD is always to make a sketch!
Creating Sketches (cont)
You will use the Sketch Tools at the top of your screen to draw your desired shape!
IMPORTANT: Change your workspace units to Centimeters
Click here for instructions on how to change units
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Using OnShape
Extension #2
What is OnShape?
What is one new thing you learned/found interesting from this tutorial?
OnShape is a more advanced web-browser based CAD and product development platform.
What is one new thing you learned/found interesting from this tutorial?
It allows people to create assemblies of multiple parts, moving simulations, and more complex shapes.
Many professional engineers today use OnShape to design, prototype, and model their ideas and products!
Getting Started with OnShape
Go to https://www.onshape.com/en/ & Press the “Create a Student Account”
Create the Account
Fill in the appropriate information and follow the instructions directed afterwards to complete your OnShape account.
If you are having difficulty setting up your account, click here.
Making your First Design!
Creating Sketches
The first step in CAD is always to make a sketch!
Creating Sketches (cont)
You will use the Sketch Tools at the top of your screen to draw your desired shape!
IMPORTANT: Change your workspace units to Centimeters
Click here for instructions on how to change units
Creating a Solid Body
You will now use your sketch and extrude it to create a solid object
Creating a Solid Body (Finished Example)
Design your Own Product
Now, use OnShape to make your product from the lab! Use the various sketch and solid tools to make your object.
There are so many tools and techniques to make any shape you want on OnShape!
Consider using solid extrude to make solid objects, cut extrude to remove material, fillet to smooth edges!
Click here for a more in-depth tutorial on all the starting tools available on OnShape!
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Your Engineering Drawing on OnShape
Complete this slide based on your CAD Build.
Top View
Front View
Side View
Isometric View
Dimensions
Max Height: ___ cm
Max Length: ___cm
Max Width: ___cm
Total Volume: ___ cm³
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Design Challenge
Extension #3
Doorknob Grip Helper
What’s the Problem?
Some people have difficulty turning round doorknobs such as those with arthritis or hand injuries.
Your Task
You are tasked with designing a simple tool that makes it easier for people to turn a round door knob using CAD.
Use the engineering design process you learned from this lab to do research, ideate, and model your product ideas!
Design Criteria
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Your Engineering Drawing on TinkerCAD
Complete this slide based on your CAD Build.
Top View
Front View
Side View
Isometric View
Dimensions
Max Height: ___ cm
Max Length: ___cm
Max Width: ___cm
Total Volume: ___ cm³
Bag Hook for Walkers/Strollers
What’s the Problem?
People using walkers or strollers often don’t have a safe place to hang their bags or belongings. If the bag swings or falls, it can be dangerous and annoying.
Your Task
You are tasked with designing a clip-on hook that can hold a bag securely using CAD.
Use the engineering design process you learned from this lab to do research, ideate, and model your product ideas!
Design Criteria
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Your Engineering Drawing on TinkerCAD
Complete this slide based on your CAD Build.
Top View
Front View
Side View
Isometric View
Dimensions
Max Height: ___ cm
Max Length: ___cm
Max Width: ___cm
Total Volume: ___ cm³
Cable Organizer
What’s the Problem?
Cable for phone, laptops, and chargers often fall behind desks or get tangled up. This can be frustrating and even dangerous if people trip over them.
Your Task
You are tasked with designing a small cable holder to keep cords organized and in place.
Use the engineering design process you learned from this lab to do research, ideate, and model your product ideas!
Design Criteria
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Your Engineering Drawing on TinkerCAD
Complete this slide based on your CAD Build.
Top View
Front View
Side View
Isometric View
Dimensions
Max Height: ___ cm
Max Length: ___cm
Max Width: ___cm
Total Volume: ___ cm³
Thank you!
Any text here?
Follow up info here?