1 Week Intermediate Camp

Day 1: Introduction to 3D Printing & Fusion 360 Basics

• Icebreaker Activity: Students introduce themselves and share something they’d like to create.

• What is 3D Printing? Overview of 3D printing technology, filaments, slicing software, and real-world applications.

• Show & Tell: Showcase real 3D-printed objects and discuss their design process.

• Fusion 360 Basics:

  • Creating an account & understanding the interface.

  • Learning essential tools: sketching, extruding, fillets, and chamfers.

• Design of the Day: Balloon Dragster (Part 1)

  • Introduction to designing multi-part objects for assembly.

  • Sketching and creating the chassis of the dragster.

  • Learning how to use constraints and parameters to ensure proper fit.

  • Saving and preparing designs for Day 2.

Day 2: Completing & Printing the Balloon Dragster

• Review Prints from Day 1 (if any test prints were completed).

• Continue Fusion 360 Design:

  • Balloon Dragster (Part 2) – Designing the wheels, axles, and balloon holder.

  • Adjusting and refining the design to ensure smooth assembly.

  • Exporting and slicing final models.

• Printing & Assembly:

  • Begin 3D printing Balloon Dragster parts.

  • Discuss best practices for support material and print orientation.

• Wrap-Up:

  • Any remaining prints will be completed overnight.

  • Preview of next day’s project.

Day 3: Articulated Creature Design

• Review & Discussion: Recap of Fusion 360 tools used so far.

• Design of the Day: Articulated Creature

  • Learn how to design chained, or linked, joints for an articulated model.

  • Discuss optimal angles and tolerances for smooth movement.

• Export, Slice & Print:

  • Students prepare their designs for printing.

  • Choose filament colors and slice their models.

• Print Troubleshooting & Refinements:

  • Identify and fix common print issues like layer adhesion and overhangs.

  • Discuss print orientation and support strategies for articulated designs.

Day 4: Impossible Pass-Through Design

• Review & Discussion: Go over prints from previous days and discuss key learnings.

• Fusion 360 Lesson:

  • Learn how to draw on multiple planes for complex geometry.

  • Apply dimensions and constraints to control design features.

  • Explore Sweep & Revolve tools to create smooth, organic shapes.

• Design Challenge:

  • Students create their own Impossible Pass-Through design (e.g., a solid shape that appears to pass through another).

• Export & Slice: Prepare files for printing, discuss print settings for complex designs.

• Start Printing & Troubleshooting Session: Monitor first layers, review common print issues.

Day 5: Fidget Friday & Camp Wrap-Up

• Review & Discussion: Reflect on skills learned throughout the week.

• Design of the Day: Fidget Switch Toy

  • Learn how to design a print-in-place mechanism.

  • Incorporate springs and moving parts in Fusion 360.

  • Apply lessons from constraints, fillets, and tolerances for smooth movement.

• Export, Slice & Print:

  • Finalize designs and prepare them for printing.

  • Discuss best print settings for functional moving parts.

• Camp Showcase & Wrap-Up:

  • Students present their favorite print from the week.

  • Hand out Awards & Certificates!

  • Group photo & closing remarks.