For my multi-filament additive manufacturing project, I designed and printed a spinner coin. The outer ring spins freely around the center, combining both functional movement and customized design elements made possible through multi-filament 3D printing. 

What is Multi-Filament 3D Printing?
Multi-filament 3D printing is the process of using two or more different filaments in a single print, enabling multi-material or multi-color designs. This technique enhances both the functionality and allows multi-color parts, offering greater versatility in prototyping and production. 

Spinner Coin

I designed and printed a custom spinner using white PLA for the body and blue PETG for the top layer with text. The design includes AMLA and acknowledgments to Skills Inc. and CPTC. Inspired by a military-style keychain with a spinning border, I recreated the concept with my twist.

The spinner features a circular platform with a hole and a central rod that spins freely, with stoppers to keep the parts aligned. I used Fusion 360 to design a joint for the moving parts and prepared it for multi-filament printing.

A key lesson was that PLA and PETG don’t bond well, affecting durability. We adjusted print parameters—lowered fan speed, reduced feed rate, increased nozzle temperature—to improve adhesion, which helped significantly.

Unfortunately, the part broke before I could photograph it, and we ran out of time to reprint. Despite this, the spinner worked as intended, proving the concept and settings were successful.

Multi-Filament 3D Printing #2: Flash Logo 

I created a custom Flash logo from scratch in Fusion 360 by tracing an imported image in 2D, then extruding parts to different heights for depth. Filleting edges gave it a smooth, professional look.

Printed in yellow PLA and red PETG, I made the entire part yellow except for selective red layers for the inner details to minimize filament changes and purge time.

The red PETG had some adhesion issues, likely due to insufficient layers or temperature settings. I see this as a learning opportunity to improve future prints.

What is Selective Laser Sintering?

Selective Laser Sintering (SLS) is an advanced 3D printing technology that uses a high-powered laser to fuse small particles of powdered material, typically nylon or other thermoplastics. During printing, a thin layer of powder is spread across the build platform, and the laser selectively sinteres (melts and fuses) the particles together based on the 3D model. The build platform then lowers slightly, and a new layer of powder is spread on top. This process repeats layer by layer until the part is complete. Since the loose powder supports the object during printing, no additional support structures are needed, making SLS ideal for printing complex geometries and functional prototypes. 

Selective Laser Sintering (SLS) Badge:

For my SLS badge, I chose Nylon 12 powder for durability and detail. Refilling the powder involved careful handling to avoid inhalation. I poured nylon powder into the cartridge and loaded it into the printer. The powder flow automatically stopped near the max fill line, preventing mess.

After preheating, the Fuse 1 printed the badge layer by layer by fusing powder with a laser.

Post-printing, cooling the cartridge to about 50°C was necessary before unpacking to prevent warping and burns.

Using the Fuse Sift glove box, we safely handled the powder to retrieve the parts. We brushed away powder with large and small brushes, and used a pick tool for detailed areas without damaging the part.

Finally, the badge was media blasted in the Fuse Blast machine, which cleaned residual powder using fine plastic beads, leaving a clean, finished part.

SLS Badge Reflection 

This was my favorite additive manufacturing project, especially the post-processing stage where sanding and finishing brought the badge to life.

The badge commemorates a gaming community meaningful to me. Using Fusion 360’s canvas, I traced and extruded the badge design and added my in-game names and dates on the back.

After printing and cooling, I unpacked the parts carefully in the Fuse Sift and cleaned the details. The media blasting gave it a professional finish.

I’m proud of the entire process and the skills I gained.

What is Resin printing?
Resin 3D printing, also known as SLA (Stereolithography) or MSLA (Masked Stereolithography), uses liquid photopolymer resin that is cured layer by layer using ultraviolet (UV) light. In SLA, a laser traces and cures each layer, while in MSLA, a UV light source shines through an LCD screen that masks the desired pattern for each layer. The build platform gradually lifts the object out of the resin vat as each cured layer is added. This method produces highly detailed, smooth-surfaced prints, making it ideal for miniatures, dental models, jewelry, and precision parts. However, printed parts must be washed in isopropyl alcohol and cured under UV light after printing to fully harden. 

I designed a battery storage unit to organize scattered batteries at home. The rectangular dispenser holds 16 batteries arranged 2 across and 8 high.

To add personality, I decorated the surface with 3D models from previous projects and added a clear “AA” label.

After designing the part, I sent it to the resin printer for fabrication. Once the print was complete, the part was covered in numerous internal supports. Since the resin must be fully cured before handling, we first washed the part with isopropyl alcohol to remove excess uncured resin. Then, we carefully removed the supports from both the top and bottom of the piece. Finally, the part was placed in a UV curing machine, which rotated it to ensure that every surface and crevice was evenly exposed to UV light for thorough curing. 

One issue I encountered was that the hinges cured and fused together with the main part, rendering the top door non-functional. When I applied force to try to free the hinge, it broke. To improve the design, I would increase the clearance around the hinges to prevent fusion during printing and make the walls thinner to enhance flexibility and durability.

The design is practical and shows how resin printing can solve everyday problems with custom, functional objects.

What is TPU?

TPU (Thermoplastic Polyurethane) is a flexible, rubber-like filament commonly used in 3D printing for parts that require elasticity, durability, and impact resistance. It can bend, stretch, and return to its original shape, making it ideal for applications like phone cases, seals, and wearable items. 

TPU Phone Case

For my TPU project, I designed a phone case for my iPhone 15 Plus requiring flexibility. I measured the phone and added a custom design.

However, I made critical mistakes: the camera cutout was not sized or placed correctly, and the case was slightly too narrow.

These errors taught me the importance of precise measurements for fit and critical features in flexible prints.

Professional Life Goals and Plans

I am a motivated and multidimensional individual actively pursuing career paths in STEM, cosmetology, and acting. In the short term, I am training to compete in the SkillsUSA National Lathe Competition, with the goal of winning the gold medal. I continue to refine my machining and 3D modeling skills while exploring opportunities across three distinct career fields.

Long-term, I aim to earn a degree in mechanical or aerospace engineering and build a meaningful career within the STEM field. I also plan to master machining and eventually achieve financial independence through a stable, fulfilling career. A key aspiration is to own and operate my own business, ideally a barbershop, once I’ve built enough experience and financial stability.

Currently, I’m nearing the completion of my internship with the Advanced Manufacturing Leadership Academy at Skills Inc. I’m actively preparing for the SkillsUSA competition, saving for barber school, and submitting acting reels for auditions. My pathway includes attending university for engineering, continuing to hone my acting craft, and developing a loyal client base as a barber before launching my own shop.

Personal Life Goals and Plans

Beyond professional development, I am committed to improving my physical and mental well-being. My short-term goals include recovering fully from recent surgery, returning to the gym, rebuilding muscle, and improving overall health. I also aim to enjoy life more, make time for meaningful experiences, and continue growing wiser through reading and self-reflection.

My long-term personal goals include traveling the world to experience different cultures, purchasing my dream car, and achieving complete mastery over my mindset and emotional health. Currently, I’m recovering from surgery and just beginning to dive into philosophy to deepen my understanding of life. I’m also prioritizing mental health, acknowledging it as a vital area for growth.

To reach these goals, I plan to remain consistent with my recovery and workouts, approach life with a more grateful and thoughtful mindset, and make intentional decisions that support my mental and physical health.

B-R-E Challenge & Prototype

As part of the Brainstorm, Research, and Experiment (B-R-E) challenge, I tackled a daily frustration: dropping items between the car seat and the center console. This issue is inconvenient, hard to clean, and potentially dangerous if it distracts drivers. After exploring solutions such as using a gripper tool or retrieving items only when parked, I chose the most practical option—a seat gap filler. It prevents items from falling into the gap and makes retrieval easier and safer.

For my prototype, I crafted a folded paper model with a cutout for the seatbelt. If developed further, I’d design it to fit snugly around the seatbelt holder, slightly oversized to be secured by the seat itself. I also considered using Velcro strips for added stability. With further development, this concept could evolve into a functional, user-friendly car accessory.