From Thread to Thing

Investigate how a 3D printer turns a thread of plastic into a bird: the layers it builds, the extruder that feeds the thread and the hot end that melts it, the motors that place every line, the G-code a slicer writes, and the limits that gravity, heat and colour set. Taught on a working desktop 3D printer on a workbench. Eleven investigations for ages 12 and up.
Library
Course cover

Something from nothing

Lesson 1
Something From Nothing image

Something From Nothing

A bird grows on a plate that started empty.
Start
Lesson 2
A Millimetre of Thread image

A Millimetre of Thread

The thread creeps into the toolhead, and the line it becomes races across the plate.
Start
Lesson 3
Hot Only at the Tip image

Hot Only at the Tip

The nozzle is as hot as an oven, and a few centimetres above it the metal is barely warm.
Start

A blind machine that follows orders

Lesson 4
Who Moves, the Nozzle or the Plate? image

Who Moves, the Nozzle or the Plate?

Three motors move this printer in three directions, and one of them moves something you would never expect.
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Lesson 5
The Printer Is Blind image

The Printer Is Blind

It places every line to a fraction of a millimetre and never once checks where its nozzle is while it prints.
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Lesson 6
The Recipe Nobody Reads image

The Recipe Nobody Reads

The printer is making a bird and has no idea what a bird is.
Start

Fighting gravity, heat and time

Lesson 7
Mostly Air image

Mostly Air

The cube looks solid all the way through, and inside it is mostly air.
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Lesson 8
Printing on Thin Air image

Printing on Thin Air

Six planks lean further and further out over the plate, and only some of them print clean.
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Lesson 9
Why Not Just Go Faster? image

Why Not Just Go Faster?

The printer can fly at 500 mm/s, and still the slicer slows it down.
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Lesson 10
The Corner That Lifts image

The Corner That Lifts

The print stuck perfectly, until its corners peeled up by themselves.
Start
Lesson 11
Four Colours, One Nozzle image

Four Colours, One Nozzle

Hoo comes off a printer with one nozzle in four colours.
Start

Review and assessment

Lesson 12

Test: From Thread to Thing

Review the course ideas by applying them to new situations, with kind feedback after every answer.
Locked till you take the prior lesson