Ask Me Something: The art of 3D printing

The technology of 3D printing is revolutionizing how we design, build and innovate.  

From creating custom tools to printing entire buildings, it’s reshaping industries and education, alike.  

Leading the charge in helping make 3D printing more accessible is Sean Mason, BSc (Eng)’21, senior manager of technical services at the University of Calgary’s Schulich School of Engineering. 

Learn more about how the technology works, its surprising applications and how anyone on campus can get started. 

What is 3D printing and how does it work? 

3D printing is an additive manufacturing process. It starts with a digital 3D model, usually created using CAD (computer-aided design) software. That model is then processed through slicing software, which breaks it down into thin layers and generates a toolpath. The 3D printer follows that path, building the object layer by layer until it's complete. 

How has 3D printing evolved over the past decade? 

It’s become much more affordable and accessible. More companies are making printers, which drives prices down. We can print with plastics, metals, ceramics and bio-inks. With all this mass production, a lot of the parts and components needed to build a 3D printer have become much more consistently made. 

What materials can be used in 3D printing? 

We use a range of materials. In addition to different types of plastics, we also print in metals like stainless steel, titanium and copper. In our biomechanics lab, we even have a bioprinter that can print human tissues using bio-inks. And, in construction, concrete is used to print structures. 

What are some of the most innovative applications of 3D printing that people might not be aware of? 

It’s being used in some really creative ways. In the food industry, for example, people are using 3D printers to decorate cakes with detailed images. In construction, large-scale printers can build entire rooms or small houses using concrete. It’s not just for plastic parts anymore. 

What are some common misconceptions about 3D printing? 

Some 3D prints can still take several hours. We often have some of our 3D printers running overnight. They aren't plug and play. There is a lot of calibration, a lot of tinkering, a lot of setting them up and playing around with them before you actually learn all the ins and outs of a 3D printer. Also, 3D printing doesn’t replace traditional manufacturing. It complements it. You still need subtractive [relating to a substrate, the underlying or fundamental base of something] methods for many tasks. 

How is 3D printing being used in the field of engineering and education at the Schulich School of Engineering? 

We’ve integrated 3D printing into many undergraduate labs. In the thermodynamics lab, for instance, students print turbine models using PLA [a bio-based and biodegradable plastic alternative to traditional petroleum-based plastics], a common 3D-printing material. Capstone projects (final assignments in which students apply what they learned to a real-world problem) also rely heavily on 3D printing for prototyping. Our student teams and clubs use it to create parts for competitive vehicles and other projects. 

Can you share a memorable project from the Makerspace involving 3D printing? 

One standout was a student from our rocket team who used our new metal 3D printer to create a rocket nozzle. It hasn’t been tested yet, but it’s a big step forward. Another fun one was a student who 3D-printed an entire costume from The Lord of the Rings and came to class in full character for Halloween. It was really impressive. 

What advice would you give to someone looking to start their journey in 3D printing? 

My recommendation would be to start small. There are affordable printers out there and PLA is a great beginner material. Failures will happen, but they're a great opportunity to learn. And, if you’re on campus, come visit the Makerspace. We offer workshops and can help you learn everything from CAD modelling to printing.