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3D Printer

Learning aim

Understand how 3D printers work, identify suitable materials for 3D printing, analyse the pros and cons of 3D printing compared to traditional manufacturing methods, and evaluate the environmental impact of 3D printing.

1) REMEMBER / UNDERSTAND

Purpose - so that I can describe the process and materials used in 3D printing.

2) APPLY/ANALYSE

Purpose - so that I can compare the advantages and disadvantages of 3D printing versus traditional manufacturing methods.

3) EVALUATE/CREATE

Purpose - in order to evaluate the environmental impacts of 3D printing and justify my viewpoint.

How does a 3D printer work?

The basics.

Strands of plastic (or other materials) are fed into a print head, which is heated up to melt the material. The print head moves around very precisely in three dimensions and lays lines of plastic (or other materials) onto the print bed ,the table on which it prints. The printer does this over and over, building up layers of plastic until it forms a 3D part.

Help Videos

Watch the following videos to help you understand this topic in even greater detail.

How does 3D printing work?

A brief overview of 3D printing and how it works

Part 1 Ultimate beginners guide to 3D printing

What is 3D printing?

A brief overview of 3D printing and how it works

Part 2 Ultimate beginners guide to 3D printing

What are the advantages and disadvantages of 3D printers?

Advantages

Some advantages are:

1. Rapid Prototyping - 3D printers allow designers and engineers to quickly turn ideas into physical models. This speeds up testing and improvement compared to traditional manufacturing.

2. Customisation - Each item can be uniquely tailored—perfect for personalised products such as medical implants, custom tools, or hobby models—without increasing cost.

3. Reduced Waste - Most 3D printing is additive manufacturing (building layer by layer), which uses only the material needed. This produces far less waste than cutting or milling.

4. Cost-Effective for Small Batches - It’s often cheaper to produce small numbers of items using a 3D printer instead of paying for expensive moulds or factory setups.

5. Complex Designs Are Easy - 3D printers can create shapes and internal structures that would be impossible or very difficult with traditional tools.

6. Faster Innovation - Since models can be printed, tested, and redesigned quickly, industries such as engineering, medicine, and architecture can innovate more rapidly.

7. Accessibility for Education - Students can learn hands-on skills in design, engineering, and problem-solving by printing real objects from their own digital creations.

8. On-Demand Production - Objects can be printed whenever needed—useful for spare parts, tools, or replacement components without storing large inventories.

Advantages of 3D printing

Disadvantages

The disadvantages are:

1. Slow Production for Large Items - While good for small parts, 3D printers can take many hours (or even days) to create bigger or detailed objects.

2. Limited Materials - Most affordable 3D printers can only use a few materials such as PLA or ABS plastic. Industrial materials (metal, carbon fibre) are expensive and require specialist machines.

3. High Initial Cost - Good-quality printers, plus the software and maintenance, can be costly for schools or small businesses to purchase.

4. Possible Structural Weakness - Items printed in layers can sometimes be weaker than traditionally manufactured parts, especially along the layer lines.

5. Safety Concerns - Some printers produce fumes or fine particles that require proper ventilation. The heated nozzle and bed also pose a burn risk.

6. Intellectual Property Problems - Its easy to copy and print designs found online, which can lead to copyright and ownership issues.

7. Post‑Processing Require - Printed items often need sanding, painting, or support removal to look good, which adds extra time and effort.

8. Environmental Impact - Although waste can be low, the plastic used is often not biodegradable, and failed prints or supports contribute to waste.

Disadvantages and Advantages of 3D printing

What type of products could be made?

Quick prototypes/test models

Food

Houses

Body parts

What types of materials can be used?

Plastics

Chocolate

Concrete

Metal

Do 3d printers have an environmental impact?

1. Plastic Waste - 3D printers often use plastic, and if a print goes wrong or breaks, it becomes waste.
Some plastics used are not biodegradable, meaning they don’t break down naturally.

2. Energy Use - 3D printers need electricity to heat the nozzle and run for long periods.
If the electricity comes from non‑renewable sources, it can harm the environment.

3. Microplastic Pollution - When plastic is melted during printing, tiny particles called microplastics can be released.
These can be harmful if they get into the air or water.

4. Fumes and Air Pollution - Heating plastic can release small fumes and particles.
These can affect air quality unless the printer has good ventilation.

5. Waste From Supports - Some designs need “supports” during printing.
These supports are removed and thrown away, creating extra waste.

6. Material Production Impact - Making the plastic filaments or resins used in printers requires energy and resources, which can create pollution.

7. Hard‑to‑Recycle Materials - Not all 3D printing materials can be recycled easily, so a lot of used or broken prints end up in landfills.

8. Shipping and Packaging - Filament spools and printer parts often come in plastic packaging and are shipped long distances, adding to carbon emissions.

Literacy Activity

Success Criteria

To progress you MUST use the following:

Be prepared, listen carefully, watch the videos, read the resources, you could do independent research and ask questions.
Use the word bank provided.
Use technical vocabulary.
Use paragraphs.
Use correct punctuation.
Use correct grammar.
Use correct spelling.
Check your own work once you have finished
Check your own work once you have finished with AI feedback tools.
Don't forget to respond to the feedback to make further progress.

Your Progress

From the literacy challenges below select your differentiated activity.

Challenge 1

Challenge 2

Challenge 3

Word Banks

Below are useful key words / terminology for you to use to improve your work.

How does a 3D printer work? - Additive manufacturing, Layer‑by‑layer, 3D model, CAD (Computer‑Aided Design), Slicing software, STL file, Towpaths, Extrude, Nozzle, Filament, Heated bed, Deposits material, Melts.

Materials used - PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene), Concrete, Steel powder, Aluminium powder, Wood‑filled filament, Ceramic materials, Chocolate (for food printers), Sugar (for food printers), Bio‑materials.

Advantages - Accuracy, Precision, Complex geometry, Detailed features, Customisation, Rationalisation, Rapid prototyping, Speed (for small parts), Efficiency, Repeatability, Consistency, Less manual labour, Reduced human error, Less waste, Time‑saving (for small items), Safe (less risk of injury).

Disadvantages - Slow production, Long print times, Print failures, Limited strength, Material limitations, Restricted material choices, High energy use, Overheating, Clogging, Support structures, Wasted material, Cost of filament, Machine cost, Size limitations, Noisy, Fumes, Not ideal for mass production.

Environment - Plastic waste, Non‑biodegradable, Landfill, Energy consumption, Electricity use, Carbon emissions, Pollution, Microplastics, Fumes, Air quality, Material waste, Failed prints, Recycling, Eco‑friendly materials, Sustainable use, Renewable energy, Resource use, Environmental impact , Waste management.

Sentence Starters

Below are useful sentence starters for you to use to improve your work.

How does a 3D printer work? - A 3D printer works by... The process begins when... First, a digital model is created using... This file is then sent to the printer, where... Inside the printer, the material is... The extruder heats the filament so that... The melted material is then deposited... Each layer is formed by... Once a layer cools and solidifies... This process is repeated until...

Materials used - 3D printers can use a wide range of materials such as… One of the most common materials used in 3D printing is… Another material often used in 3D printing is… More advanced printers are capable of printing with… In industrial settings, materials such as… are used because…

Advantages - One major advantage of using a 3D printer is… A key benefit compared to hand and power tools is… 3D printers allow designers to create… Another advantage is that 3D printing can produce… 3D printers can create complex shapes that…Customisation is easier as… A 3D printer can save time when… It also reduces human error because… Unlike traditional tools, 3D printers can… Another benefit is that 3D printing often creates less waste since…

Disadvantages - One significant disadvantage of using a 3D printer is… A major limitation compared to traditional tools is… 3D printing can be slower because… Another disadvantage is that printed parts may… A common issue is print failure, which happens when… Material options are limited since… Most home 3D printers cannot use materials such as……3D printers also require maintenance because… There is a disadvantage in cost because… The size of objects is restricted since… Another drawback is that the printer may produce fumes, which…

Environment - One environmental impact of 3D printing is… A major concern is that 3D printing can produce… Many 3D printing materials are harmful because… Failed prints and support structures often lead to… Another environmental issue is the amount of energy used, which… 3D printers can contribute to pollution when… The fumes released during printing can affect… Many commonly used plastics are non‑biodegradable, meaning… Waste can increase if users… Some materials can be recycled, but this depends on…Environmental damage can be reduced by… Using eco‑friendly materials helps because… Comparing 3D printing to traditional manufacturing shows that… Electricity consumption becomes a problem when… A positive environmental impact is possible if…

Hall of Fame (WAGOLL)

Our School Technology Department

There are five identical 3D printers of the 'fused-filament' type in use within the D&T department. They are located in classrooms 1G2, 1G3 and the D&T 'back office'. They operate using unheated beds and use PLA filament which is non-toxic and biodegradable.

These are freely available for students to use in Key Stage 4 under supervision (not for safety reasons, for reasons of avoiding wastage of expensive materials!).

These machines present minimal hazards to operators other than the heat produced by the extrusion nozzle which reaches up to 190 degrees centigrade. For this reason the inspection lid must be closed during operation.

Students are to be shown via whole-class demonstration how to load and unload PLA filament from the machine and how to export .stl files, slice them, apply supports and send them to the machine for printing. Individual students will require advice due to the bespoke nature of 3D printing CAD models.