Responsible 3D Printing¶

Many things go into 3D printing, so proper knowledge of the protocols is essential for producing quality prints. Additionally, 3D printers are sophisticated, delicate machines and need to be treated with the utmost care.

This guide details the rules, expectations, and best practices you’ll need to follow when 3D printing for EGN 3000L.

DFX Lab¶

Important

You must complete the DFX lab safety training before using any equipment in the lab, including our 3D printers. Find a time and sign up for the training here: see the training page.

The Foundations of Engineering Lab administration are not employees or representatives of the DFX lab, but the course’s 3D printers are located there. So, in addition to the rules outlined in this guide, you must follow the DFX lab’s rules and expectations as well. These are non-negotiable in the lab for your safety.

Note

Engineering Lab Course Printers vs. DFX Lab Printers

Foundations operates its own 3D printers within the DFX lab space. These course printers are only for students enrolled in the Foundations course and cannot be used by other students, including general DFX lab users.

If you want to use the DFX lab’s own 3D printers, you’ll need to complete DFX’s dedicated 3D printer training, and can sign up using the DFX lab’s training page.

The full list of DFX lab rules can be reviewed here, but these are some of the most important ones to keep in mind:

General operating hours are Monday through Friday 8am to 5pm when the University is normally open.
No food or drink is allowed in this lab except for the designated storage areas.
All tools, support supplies and accessory equipment housed in this lab are for consumption and use in this lab and should not be removed or borrowed unless approved by the laboratory manager.
All supplies or projects brought to the lab should NOT be stored in the lab unless a storage area has been reserved by a lab staff member.
Cleaning your work area is essential. For the rapid prototyping tools you will be shown how to leave the tool when you are finished. Do not leave personal items in this lab.
Report any equipment problem, messes left by others, water leaks, missing items, or any unusual events to a TSS staff immediately. Tool or facilities modifications to equipment should not be done unless approved by the Lab Manager.
You must be trained and certified to use the tools in this lab. Please see the NREC Office for monthly training sessions offered or card access rights to this lab.

Failing to follow the lab’s rules may result in consequences from both the lab and from the course. These can include permanent removal from the lab, fees, and/or a failing grade in the course.

### Why must you complete the DFX lab safety training before using the printers? 1. [x] It ensures you understand necessary safety protocols > Training prevents accidents and is required for lab access. 1. [ ] It grants free filament 1. [ ] It unlocks advanced printer settings ### Which of the following is allowed in the DFX lab? 1. [ ] Storing personal projects without permission 1. [ ] Bringing food and drink near the printers 1. [x] Reporting missing tools to staff immediately > Notifying staff keeps the lab safe and organized. ### If you witness a water leak or equipment problem, what should you do? 1. [ ] Ignore it and continue printing 1. [x] Report it to TSS staff right away > Prompt reporting prevents further damage or safety issues. 1. [ ] Try to fix it yourself

Printing Workflow Overview¶

It is helpful to understand the full process of 3D printing at USF. An overview of the workflow is as follows, with further sections providing additional detail:

Prepare Your Design Ensure your CAD model is ready and export it as an STL file. Double-check dimensions and make sure your design is optimized for 3D printing. See 3D Design for Printing.
Slice Your Model Use the DFX Lab desktop stations, or your own personal computer, to slice your STL file into G-code. Then export both the G-code (for the printer) and a sliced .3mf file (for Jotform submission). See Preparing to Print for details on slicing and exporting.
Request Print Permission The Foundations print lab staff must approve your files before printing. Submit your G-code file and your sliced .3mf file, along with other required materials, to the designated Jotform submission. You can find where to submit your files on your Foundations Canvas modules page.

Warning

Your .3mf file must be exported using “Export plate sliced file” from the dropdown menu in your slicer — not saved via File > Save. A regular project save does not contain the required print time, filament usage, and validation data, and will be automatically rejected by the submission system. See Exporting a Sliced .3mf for Jotform Submission for detailed instructions.
Start Your Print Check everything (filament, bed, file) and begin your print, ensuring you stay nearby for the first few layers.
Monitor Progress Check on your print periodically. Long prints don’t need constant supervision, but regular check-ins are important.
Remove and Clean Up Once finished and cooled, carefully remove your print and clean up any support material or debris. See Removing & Cleaning Your Prints.

At the Printer¶

With your G-code file ready on the USB drive:

Insert the USB drive into the printer’s USB port.
Navigate to the file using the printer’s touchscreen.
Select your file and start the print.
The printer will heat up and begin following your G-code instructions.

Tip

Keep your USB drive with you during the print. If something goes wrong, you might need to restart or adjust settings without re-slicing.

For guidance on removing the print after completion, see Removing & Cleaning Your Prints.

Rules & Etiquette around the Printers¶

Beyond the official DFX lab rules, here are some key do’s and don’ts to keep in mind when printing:

Before You Start¶

✅ DO:

Check that there’s enough filament loaded for your print (look at the spool and estimate).
Verify the build plate is clean and free of previous print residue.
Check that the build plate is properly installed and secure.

❌ DON’T:

Start a print without checking filament levels
Pause, cancel, or touch someone else’s active print without permission.
Leave prints unattended for the first several minutes after starting them.
Bump, jostle, or unlock the wheels of the printer racks.

During Your Print¶

✅ DO:

Monitor the first few layers closely – most failures happen early.
Check on longer prints periodically (every 2-3 hours for prints over 4 hours).
Take photos of any problems if you plan on requesting troubleshooting help.
Keep the area around the printer clean and organized.

❌ DON’T:

Bring food or drinks near the printers (this is a DFX lab rule).
Adjust printer settings mid-print unless absolutely necessary.
Touch or move the printer/racks while printing.
Touch hot/moving parts of the printer.
Walk away for hours without checking on your print.

After Your Print¶

✅ DO:

Let the build plate cool completely before removing your print.
Clean up any failed print material or support debris.
Return the build plate immediately after removing your print.
Report any issues or unusual printer behavior to staff.

Starting Your First Print¶

Your first print is exciting, and following these steps will set you up for success:

Pre-Flight Checklist¶

Before starting any print, run through this quick checklist:

Filament Check: Ensure there’s enough filament for your entire print, plus some extra.
Bed Preparation: Ensure the build plate is free of debris and leftover filament.
File Verification: Double-check your G-code file is correctly named so staff doesn’t cancel it.

Starting the Print¶

Load Your File Transfer your G-code file to the printer via USB-drive.
Start and Stay Close Begin the print and stay nearby for at least the first 10 minutes. This is when most issues occur:
- Watch the first layer go down – it should stick well to the build plate.
- Listen for unusual sounds (grinding, clicking, or excessive noise).
- Look for proper filament extrusion from the nozzle.

What to Watch For¶

During those crucial first layers, keep an eye out for:

Poor bed adhesion: Corners lifting or entire first layer not sticking.
Over/under-extrusion: Too much plastic (blobbing) or too little (gaps in lines).
Nozzle clogs: No filament coming out, or very thin/inconsistent extrusion.
Layer misalignment: Print shifting horizontally between layers.

Tip

If something looks wrong in the first few layers, it’s usually better to stop the print early and troubleshoot rather than letting it continue to waste time and material.

Troubleshooting Basics¶

Even experienced engineers expect to encounter failures occasionally. The key is knowing when to intervene and when to let the print continue.

Quick Decision Guide:

Cancel immediately: Major bed adhesion failure, severe layer shifts, or filament jams
Monitor closely: Minor stringing, small layer shifts, or support issues that don’t affect the main print
Quick fixes: Minor warping (press down gently on the edges), loose filament, or temperature fluctuations

For detailed troubleshooting of specific issues like warping, layer shifts, and stringing, see the Iterating Your Design page.

Safety First¶

3D printers involve high temperatures, moving parts, and electrical components. Here’s how to stay safe while printing:

What NOT to Touch¶

Warning

These components can cause burns, injury, or damage to the printer if touched during operation:

Hot End/Nozzle: Can reach 200-260°C (390-500°F).
Heated Bed: Typically 50-80°C (120-175°F).
Moving parts: Print head, bed, and any moving carriages during operation.
Electrical connections: Never attempt to repair or modify electrical connections. This includes the power cable, power supply, and any internal wiring.

Mechanical Cautions¶

Do not force any moving parts – they should move smoothly.
Never try to “help” the printer by pushing or pulling parts during operation.
Keep fingers, hair, and loose clothing away from moving components.
Do not attempt to clear jams or clogs; just stop the print and ask for help.
The filament spool should not be touched or removed. All printers have a filament sensor that will stop the print if the filament runs out or is removed. If this happens, let a TA or staff member know so they can refill the spool and continue your print. Do not try to refill the spool yourself.

If Something Goes Wrong¶

In case of critical issues, follow these steps in order:

Stop the Print: Attempt to stop the print using the screen. The job should stop immediately, and the extruder will return to the home position.
Power Off: If the screen on the printer is unresponsive, use the printer power switch, located on the back of the printer near its power cable.
Get Help Immediately: Contact a TA or DFX staff member right away. Do not try to fix electrical or mechanical issues yourself.
Document the Issue: Take photos if safe to do so - this helps staff diagnose problems and understand what went wrong.

Emergency Contacts¶

For immediate safety concerns: Call campus security or 911.
For equipment issues: Contact DFX lab staff or your TA immediately.
Never attempt repairs yourself – this can damage printers or cause further issues.

Note

Equipment can be replaced, but injuries cannot be undone. When in doubt, stop the print and ask for help. No print is worth risking your safety or the safety of others.

Personal Safety Gear¶

Close-toed shoes are the only requirement for 3D printing. However, if you are using other tools in the DFX lab, you may need specialized safety gear. Always reference the DFX lab’s safety guidelines for the specific tools you’re using.

Tip

If you have long hair, tie it back to prevent it from getting caught in moving parts. Loose clothing should also be avoided.

### Why should you stay near the printer for the first few layers? 1. [x] Most print failures happen early and can be stopped quickly > Early monitoring prevents wasted time and material. 1. [ ] The printer requires constant manual control 1. [ ] The filament changes color after three layers ### Before starting a print, which of the following should you verify? 1. [x] Filament levels, clean build plate, and correctly named file > These checks prevent common issues and cancellations. 1. [ ] Only the color of the nozzle 1. [ ] That the printer is connected to Wi-Fi ### The printer runs out of filament during a print. What is the appropriate response? 1. [ ] Replace the spool yourself immediately 1. [x] Notify a TA or staff member for assistance > Staff manage filament changes to protect equipment. 1. [ ] Ignore it and let the print continue ### What consequence might result from damaging equipment through rule violations? 1. [ ] Nothing, accidents happen 1. [x] Financial responsibility and potential loss of printing privileges > Breaking rules can lead to fees and revoked access. 1. [ ] You get more filament as compensation

Consequences for Rule Violations¶

Violating the 3D printing rules of our course or the DFX lab will lead to serious consequences.

If you break a DFX lab rule and the lab chooses to take action, the course will also impose its own separate consequences.
Breaking a course rule will result in course-level consequences but may not result in DFX lab consequences.

Consequences for rule violations are typically assessed on a case-by-case basis but can include:

Academic: Point deductions, failing assignments, or failing the course in severe cases.
Lab Access: The DFX lab may revoke entire-lab access if you violate their rules, but violating our course rules will not result in loss of access to the DFX lab.
Printing Privileges: You may lose the ability to use the course’s 3D printers. If this happens, it will be indefinite.
Financial: All violations that damage equipment or require repairs will hold you responsible for the repair cost and possible extra fees. Financial reparations are the bare minimum, and are always accompanied by conventional consequences.

Common violations include: Not cleaning up, damaging equipment, safety violations, or filament overuse.

The course will not hesitate to enforce the rules, regardless of whether you were unaware of them or simply chose to ignore them.

3D printing in EGN 3000L is an incredible opportunity to manufacture parts like professional engineers. Success requires preparation, attention, and following the rules.