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Modules, Lessons, Labs - Overview and Introduction: Introduction to Autodesk Fusion 360 & 3D Printing

Why Fusion 360 is Ideal for 3D Printing? 

Fusion 360 is particularly strong for 3D printing workflows because it combines precise parametric modeling with mesh repair, slicing preparation, and export tools. It allows students and professionals to go from concept sketch → 3D model → printable file in one software.

• Software Type - Cloud-based CAD/CAM/CAE platform

• Best For - 3D modeling, design-to-manufacture workflows

• Educational Focus - Digital design, prototyping, and engineering

• 3D Printing Role - Model creation, validation, and STL export for additive manufacturing

• Key Benefit - All-in-one tool that combines design, engineering, and manufacturing in one platform

Fusion 360 3D Printing Support:

• Designing mechanical or artistic 3D parts for printing.

• Adjusting tolerances and fits for printed components.

• Analyzing stress and structure before printing functional parts.

• Exporting STL/OBJ files directly for slicer software (e.g., Cura, PrusaSlicer, or Bambu Studio).

• Using add-ins and extensions for print preparation and lattice generation.

Key Features and Capabilities of Fusion 360.  It's more than just a 3D Printing tool.

• 3D Modeling - Create parametric, freeform, or mesh-based models using solid, surface, and sculpting tools.

• Assemblies - Design and simulate how parts fit and move together in real-world conditions.

• Simulation - Test models for strength, stress, motion, and thermal effects before production.

• Manufacturing (CAM) - Generate toolpaths for CNC milling, turning, and cutting operations.

• Rendering - Produce realistic, photorealistic images of designs for presentations and visualization.

• Collaboration - Cloud-based storage allows for real-time teamwork, version control, and remote access.

• 3D Printing Integration - Export models as STL or OBJ files, verify printability, and prepare designs for additive manufacturing workflows.

By mastering these skills, students will be empowered to design and prototype their own creative solutions, learning how to think like engineers and designers in a rapidly evolving technological landscape.

Author: Jim Burnham - TopClown@STEAMClown.org. License: Distributed as Open Source. (With some ChatGPT thrown in for good measure) 

Prerequisites:

• No explicit prerequisite course work or coding knowledge is required, but students are expected to have a good understanding of basic computer principles and interested in gaining hands-on experience with Fusion 360 and 3D printing.

Caution & Safety  Considerations:

Primer:  "Aaron, I can imagine no way in which this thing could be considered anywhere remotely close to safe. All I know is I spent six hours in there and I'm still alive... You still want to do it?"

• As with any activity, please make sure you are using appropriate safety equipment.   If you are coding, writing, reading, or working a lab, make sure you stand up and stretch every hour or so,  Please consider any safety issues connecting to a Raspberry Pi, Arduino, computers and other electronic equipment.

Essential Questions:

1. How can we transform digital designs into real-world objects using 3D printing?

2. How does the geometry of a 3D model influence its strength, functionality, and aesthetics when 3D printed?

3. What are the key steps in turning a digital design into a 3D-printed object, and how can we optimize each step?

4. In what ways can 3D printing be used to impact fields like medicine, architecture, fashion, and engineering?

Key Academic Vocabulary or Concepts:

Fusion 360 - 3D Printing, and CAD:

• Additive Manufacturing - A process of creating a 3D object by building it layer by layer from digital models. Also known as 3D printing.

• CAD (Computer-Aided Design) - Software used to design and model 3D objects digitally. Fusion 360 is a CAD platform that prepares parts for 3D printing.

• Prototype - A physical model created to test design concepts, form, and fit before mass production. Fusion 360 and 3D printing make rapid prototyping possible.

• STL (Stereolithography File) - A file type used to export 3D models from Fusion 360 into slicer software. Describes the surface of a 3D object as a mesh of triangles.

• OBJ File - A 3D file format similar to STL but includes color and texture information, often used for multi-material or full-color printing. 

• Mesh - A digital surface made up of connected triangles that describe a 3D shape. 3D printers read mesh data to create layers.

• Watertight (Manifold Model) - A 3D model with no holes, gaps, or intersecting surfaces — essential for successful 3D printing. Fusion 360 can check for and repair non-manifold geometry.

• Export (Save as Mesh) - The process of converting a Fusion 360 solid model into a 3D printable mesh format such as STL or OBJ.

• Slicer - Software that converts a 3D model file (STL/OBJ) into G-code by dividing it into layers and setting print parameters. 

• G-Code - A set of machine instructions generated by the slicer that tells the 3D printer how to move, extrude, and build each layer.

• Tolerance - The small, allowable difference between designed dimensions and actual printed part size. Typical FDM 3D printing tolerance: ±0.2 mm.

• Clearance - The designed spacing between moving or fitting parts to ensure they don’t fuse during printing. Common in hinges, sliding parts, or enclosures.

• Wall Thickness - The distance between inner and outer surfaces of a model’s wall. Should be at least 1–2 mm for most FDM prints to maintain strength.

• Overhang - Any part of a model that extends outward without direct support underneath. Overhangs greater than 45° usually need supports.

• Support Structures - Temporary printed material added under overhangs or bridges to prevent sagging. Removed after printing.

• Infill - The internal lattice structure inside a 3D print that provides strength while saving material. Common infill patterns: grid, honeycomb, gyroid.

• Layer Height - The thickness of each printed layer. Smaller layers improve detail; larger layers print faster.

• Print Orientation - The position of the model on the print bed. Affects surface quality, strength, and need for supports.

• Build Plate (Print Bed) - The surface on which the 3D model is printed. Models should be designed with a flat base for good adhesion.

• Adhesion - How well the first layer sticks to the build plate. Can be improved with rafts, brims, or skirts in the slicer.

• Draft Angle - A slight taper (1–3°) added to vertical walls to improve printability and part release from supports.

• Bridge - A horizontal span of material printed between two points with no support beneath it. Design bridges with short distances or use supports.

• Shell - The outer wall layers of a 3D printed part. More shells = stronger part, longer print time.

• Resolution - The level of detail in a 3D print, controlled by layer height and XY precision. Fusion 360 can export high-resolution meshes for detailed models.

• Scaling - Resizing a model in Fusion 360 or the slicer to change print dimensions while maintaining proportions.

• Tolerance Fit Types - Types of mechanical fits between parts:

  • Clearance Fit: Loose and easy to assemble

  • Interference Fit: Tight, press-fit connection

  • Transition Fit: Balanced between loose and tight

• Boolean Operations (Combine / Cut / Intersect) - Tools in Fusion 360 that merge or subtract bodies to create printable solids. Useful for joining multiple shapes into one watertight object.

• Orientation for Strength - Models should be oriented so layer lines align with expected forces for better mechanical performance.

• Section Analysis - A visualization tool in Fusion 360 that “slices” through a model to inspect wall thickness and internal geometry.

• Lattice Structure - An advanced pattern used to reduce material weight while maintaining strength. Fusion 360 includes lattice tools in its Additive Manufacturing workspace.

• Additive Manufacturing Workspace - Fusion 360’s environment dedicated to 3D printing setup — including orientation, slicing preview, and support generation.

• Build Volume - The maximum physical space your 3D printer can print within (X, Y, and Z dimensions). Designs must fit inside this area.

• Raft / Brim / Skirt - Features added by the slicer to improve bed adhesion:

  • Raft: A thick base under the model

  • Brim: Extra lines around the base

  • Skirt: Outline around the model, not touching it

• Print Time Estimation - The total predicted time to print a model, based on slicer settings and layer count.

• Material Shrinkage - The slight reduction in size that occurs as printed material cools. Considered when designing tight-fit parts.

• Post-Processing - Finishing steps after printing — sanding, painting, gluing, or assembling parts.

• Filament - The thermoplastic material used in FDM 3D printers, such as PLA, ABS, or PETG. Fusion 360 doesn’t use filament directly but designs must consider material properties.

  • PLA (Polylactic Acid) - A popular, biodegradable filament that’s easy to print with — ideal for prototypes and student projects.

  • ABS (Acrylonitrile Butadiene Styrene) - A strong, heat-resistant filament often used in functional parts but requires higher temperatures and enclosed printing.

  • PETG (Polyethylene Terephthalate Glycol) - A durable filament combining the strength of ABS and the ease of PLA printing.

  • TPU (Thermoplastic Polyurethane) - A flexible, rubber-like filament that can bend and compress while maintaining shape. Used for phone cases, gaskets, tires, or vibration dampers.

Unit Topics and Lessons

Text Books, Reference, Tutorials & Other Online Resources:

Lectures, Lessons, Labs:

Reference, Attribution & Resources:

Teachers - Unit, Module and Lesson Plans

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Standards Alignments & Objectives:

I’ll work on getting these in, but it’s the last thing I want to work on :-) When I have them updated, I’ll move to the top of the Lesson Plan. 

• NGSS: <list standard numbers>

• California CTE Standards: <list standard numbers>

• Related Instructional Objectives (SWBAT):  <list standard numbers>

• CCSS: nnn, RSIT: nnn, RLST: nnn, WS: nnn, WHSST: nnn, A-CED: nnn, ETS: nnn  <list standard numbers>

• Main Standard:

• Priority standards:

• National Standards:

Resource Attribution:
Sites Referenced or Summarized:

• Reference Text Book - Basic College Mathematics with Early Integers 4th edition - Elayn Martin-Gay - University of New Orleans - Pearson

• Reference Sites - 

Images:

• https://imgbin.com/png/ZJtzkYZZ/under-construction-png

• 
  

Random Stuff To Sort

Slide 4: The Fusion 360 3D Printing Workflow

Fusion 360 → Slicer → 3D Printer

Step

Description

1. Concept & Design

Create a 3D model using Fusion 360’s modeling tools (sketches, extrusions, fillets, etc.).

2. Model Validation

Check measurements, wall thickness, and clearances for real-world fit.

3. File Export

Export the model as an STL or OBJ file for your slicer software.

4. Slicing

Open the file in a slicer (e.g., Cura, PrusaSlicer, Bambu Studio) to generate G-code.

5. 3D Printing

Send G-code to your printer and fabricate the part layer-by-layer.

6. Post-Processing

Clean, sand, or assemble printed parts as needed.

Slide 5: Key Modeling Tools for 3D Printing

Fusion 360 provides flexible modeling approaches depending on the design type:

Tool Type

Use Case

Example

Parametric Modeling

Engineering parts with precise dimensions and constraints

Mechanical brackets, enclosures

Freeform (Sculpting)

Organic, curved, or ergonomic shapes

Toys, ergonomic grips

Direct Modeling

Modifying imported meshes or STLs

Fixing downloaded 3D models

Surface Modeling

Thin, complex shapes

Car bodies, shells

Mesh Editing

Adjusting STL or OBJ files

Repairing broken 3D scans

Slide 6: Designing for 3D Printability

When creating designs for 3D printing, geometry and tolerances are key.

Design Tips:

• Wall Thickness: Maintain at least 1–2 mm for FDM printing.
  
  

• Overhangs: Avoid angles >45° or use supports.
  
  

• Tolerance: Leave 0.2–0.4 mm clearance between moving or mating parts.
  
  

• Orientation: Design flat surfaces to print against the bed for stability.
  
  

• Supports: Plan where they will be needed before exporting.
  
  

💡 Pro Tip: Use Fusion 360’s Section Analysis and Inspect → Measure tools to verify dimensions before exporting.

Slide 7: Checking the Model Before Printing

Fusion 360 includes tools to ensure your part is ready for 3D printing:

• Inspect → Interference: Checks that parts in an assembly don’t overlap.
  
  

• Inspect → Thickness Analysis: Ensures parts meet printable wall thickness.
  
  

• Mesh Environment: Allows conversion and repair of mesh data (STL/OBJ).
  
  

• Combine & Join: Ensures models are watertight solids before export.
  
  

A "watertight" (manifold) model means there are no holes or gaps in the surface — a requirement for successful 3D printing.

Slide 8: Exporting for 3D Printing

Fusion 360 simplifies file export for 3D printers:

Method 1:

1. Select your solid body.
   
   

2. Click File → 3D Print.
   
   

3. Choose your output format (STL or OBJ).
   
   

4. Check “Send to 3D Print Utility” if you want to open your slicer directly.
   
   

5. Adjust refinement (resolution) for high-quality surfaces.
   
   

6. Click OK to export.
   
   

Method 2:

• Right-click on the body in the Browser → Save as Mesh
  (This allows more advanced mesh export options.)
  
  

Tip: STL files are best for solid parts; OBJ files are better for multi-color or textured prints.

Slide 9: Importing into the Slicer

After exporting your model:

1. Open your slicer software (e.g., Cura, PrusaSlicer, Bambu Studio).
   
   

2. Import the STL/OBJ file.
   
   

3. Adjust:
   
   

   • Print orientation
     
     

   • Layer height
     
     

   • Infill percentage
     
     

   • Supports and adhesion type
     
     

4. Preview the slicing to check time and material use.
   
   

5. Export G-code to your printer (SD card or direct connection).
   
   

Slide 10: Example Student Project Workflow

Goal: Design and 3D print a functional keychain flashlight case.

Step

Fusion 360 Activity

Skill Focus

1

Sketch profile and extrude body

2D → 3D modeling

2

Add holes and battery compartment

Parametric design

3

Check fit and wall thickness

Measurement & tolerance

4

Export STL and slice

File preparation

5

3D print and assemble

Fabrication & iteration

Resource Key:

<Unit> - <Module Name> - Lessons - Daily/Weekly Lesson Plan

Key: 📰 Slides / Audio 🎧 / 📽️▶️ Video/YouTube / 🎧▶️📽️ Audio/Video / ✨ Resources /  🖼️ Tutorial / 📖 Reading Activity / 📝 Writing Activity / 📖 📝 Reading/Writing / 📟 Coding / 🛠️ LAB Activity / 🚀 Quiz /  🔎 Review /  ✔️ Mastery Check / ✍️ Sign Up /🍕 Extra Credit / 🕸️ Web Links / 👩🏽‍🎓🧑🏽‍🎓🧑🏿‍🎓👩‍🏫 Class / 🏵️📜📃 Certificate / 🗂️ 📈 Collecting Survey Data

/🧟 Review / 🦾 Practice / 🆙Level Up /

🎚️🦑📤🎯  🚧

- 🦑 Special Project -

Assignment Type: ⚓ Establishing (Minimum Standard) / ⛏️ Developing (Digging Deeper) / 💎 Aspiring (Putting It Together)

This is an ⚓ Establishing Assignment (Minimum Standard)  - "Everyone Do" Assignment

This is an ⛏️ Developing (Digging Deeper) - "Everyone Should Do, To Stretch" Assignment

This is an 💎 Aspiring (Putting It Together)  - "When you have done the ⚓ Establishing and⛏️ Developing" Assignment

• 🚀 Formative Quiz - 🔎 Review

• 🚀 Quiz -🔀 Mastery Path

• 🚀 Summative Quiz -✔️ Skills Mastery Check

Quiz - verify that they are all listed as a "Formative", "Mastery Path", or "Summative" 

• 🚀 Formative Quiz - These are quizzes that the students can take a few times. I have them either set for unlimited times, or 3-5 times, where the final score is their average. The idea is that these Formative Quizzes are designed for students to learn and master a skill.  while I want them to ger 100%, and when it's set to unlimited tries, the student should get 100% eventually.  When the quiz is set to 3-5 tries with an average, then they should be prepared and should take the quiz seriously. I set the quiz to not show the right answer, but I do let them see their wrong answer.  I also put the explanation of the right and wrong answer in the right and wrong answer prompt for each question.  That way they can see why they got the answer wrong and learn from that experience.  

  • 8.1.0.3.2.4 - Python - Ch 3 - Functions - Quiz #2 -Built-In Functions - 🚀 Formative Quiz

• 🚀 Quiz -🔀 Mastery Path - These Mastery path quizzes are to be presented after the student has had a chance to do some labs and some Formative quizzes.   The goal is to let students have 2 chances to take this quiz, and take the average of the 2 attempts.  Based on the average, they will be presented with a Canvas Mastery Path, where they will have an option for take additional quiz and assignments to help with remediation.  This will get them ready to take the Summative Quizzes.

  • 8.1.0.3.3.1 -  Python - Ch 3 - Functions - Mastery Quiz #1 - 🚀 Quiz -🔀 Mastery Path

• 🚀 Summative Quiz -✔️ Skills Mastery Check - These Mastery path quizzes are to be presented after the student has had a chance to do some labs and some Formative quizzes.   The goal is to let students have 2 chances to take this quiz, and take the average of the 2 attempts. That will be their final module/subject topic grade.

  • 8.1.0.3.3.1 -  Python - Ch 3 - Functions - Skills Mastery Check Quiz #1 - 🚀 Summative Quiz -✔️ Skills Mastery Check