Overview

This project is well-summarized by the YouTube video linked above. This post reproduces the information presented therein.

3D printing bridges the gap between the amorphous, abstract digital realm and the physical, concrete real world. When a student holds something in her hands that she designed only a few hours earlier, she sees how the work she does on a computer can have tangible and potentially far-reaching results. I think it is crucial that additive manufacturing technology be available for students.

Leveraging the flexibility, dependability, and low production costs of 3D printing, I am designing school supplies that can be 3D printed for a fraction of the cost of buying a comparable product. My objective is to help schools save enough money by printing supplies over the course of one year to offset the cost of a 3D printer.

Inspiration

Throughout high school, I led free programming classes in a local makerspace for students in under-served districts. During one class, I noticed that a student was enamored by the 3D printers. She told me that her school couldn’t afford such expensive equipment. She also mentioned that she didn’t have a music program, which resonated with me because music has been such an integral part of my education.

That got me thinking: how could I offset the cost of expensive equipment and enriching programs so that underfunded schools could afford them? The answer was simple: cheaper supplies!

The surest way to cut costs is to cut out the distributer. 3D Printing supplies in-house also cuts out the manufacturer, subverting the supply chain altogether. Schools only need to cover the cost of materials, which are very inexpensive for FDM 3D printers.

Design

Before sitting down to design a new item, I meet with teachers to identify school supplies and manipulatives that are in high demand. Digital calipers in hand, I then begin the drafting process. Once I have a general design, I model a prototype in a CAD software. Then begins the laborious process of giving my creations dimension. After a prototypical design is finished, I print a few copies and run them through a series of stress tests to identify any weaknesses, and ensure that the design adequately performs its intended function. I tweak my design, reprint, retest, and redesign until everything works properly.

All of my models are designed to be printed in PLA, an incredibly affordable eco-friendly thermoplastic.

Proof of Concept

I have designed ball-and-stick models, conic section manipulatives, geometric solids, alphabet puzzle tiles, and musical instrument components. In collaboration with my school district, I have introduced a pilot program at an elementary school, where teachers and students provide feedback that I use to improve the usability of my models.

The single most significant thing I’ve made is a fully 3D printable trumpet mouthpiece. It was my first successful design, and it demonstrates how 3D printing can be used by underfunded schools to offset the expenses of enriching programs. A comparable mouthpiece, with only marginally superior performance, costs at least 60 dollars. Instead of spending 720 dollars on a dozen new mouthpieces, band directors can print them out for three dollars—that’s 717 dollars saved—more than enough to purchase a 3D printer.

If you haven’t watched it yet, check out this YouTube video explaining the project: