设置
快速交货
免运费
国际贸易术语
支付类型
市场产品
制造商零件编号 KT-PR0055NA
LULZBOT TAZ PRO S
LulzBot
3D Printed Circuit Boards
2023-07-20 | By Lulzbot
License: See Original Project 3D Printing
Courtesy of Lulzbot
Guide by Lulzbot
Description
Inside every modern electronic device, Printed Circuit Boards (PCBs) create connections that allow appliances, computers, and machines to function. PCBs have now evolved to allow for infinite possibilities in any application. In this lesson, our students will be designing and creating their own PCB through the utilization of 3D printers and conductive filaments!
Introduction
Lesson Overview:
The world of modern electronics and technology would not be what it is today without the invention and consistent innovation of printed circuit boards, or PCBs.
A printed circuit board is a device that creates electrical connections between components that are secured to the PCB. A PCB combines layers of conductive and insulation materials in order to allow electricity to flow in designated paths. Through this real-world design challenge, students will be challenged to create a PCB of their own!
Utilizing an engineering design process, students will identify the roles PCBs play in industry, as well as how they are produced. Students will be able to research and brainstorm different solutions, as well as design their own prototype solution that puts this technology to use! Once designed, students will utilize 3D printers to manufacture custom 3D printed circuit boards as we learn how this modern rapid prototyping technology can combine a variety of materials for infinite possibilities. Understanding how these technologies work, as well as how to create them, are vital skills for any future designer or engineer working to create electronics.
Various 3D printed circuit board prototype examples with a LulzBot TAZ Pro 3D printer
Utilizing an Engineering Design Process:
An Engineering Design Process, or design loop, is a method used by scientists, designers, and engineers to develop solutions to our everyday problems. Through a design loop, students will develop skills in problem solving as they brainstorm solutions and work to create a prototype through hands-on activities.
Design loops come in many shapes and sizes, but none are ever truly ending. The “last” step of any design loop is redesign, or reflection, where we look at what we’ve learned in our developed prototype to improve upon its design. Not being afraid of failure is a powerful concept that leads to greater success and implementation of problem solving.
Lesson Objectives:
Students will be able to identify the benefit of a printed circuit board, as well as how this innovation has impacted the growth of modern technology systems
Students will understand the fundamentals of conductivity and how to combine conductors and insulators to make circuit boards
Students will combine 3D printed materials with electronic components to make real-world electronic prototype solutions
Students will utilize an engineering design process to develop their own solutions to a real-world problem
Students will utilize computer aided design (CAD) software to create a 3D model that can be produced on a 3D printer
Students will understand how 3D printers work and how they are used in an industrial setting
Students will be able to safely apply prototyping techniques to construct designed solutions to real-world problems
Materials:
This is a list of materials each student will need to complete this lesson:
Pencils, rulers, drawing paper
Computer or tablet with Internet access
Computer Aided Design (CAD) software
3D Printer with both conductive and non-conductive filaments
Assorted components to include in prototyping such as batteries, switches, LEDs, resistors, wire, copper tape, motors, and more
Click here for sample models shown throughout this lesson
Modifications:
In addition to this lesson plan, see our One Page Brief [PDF] that can be used to guide students through the lesson. Additional examples as to how this lesson could be modified are:
Additional tools and components to include in fabricating prototypes such as batteries, switches, LEDs, or soldering irons
For beginners, providing guidelines in model dimensions or templates to start creating PCBs with will aid in learning CAD
Incorporating digital components or micro controllers such as an Arduino or Micro:bit may allow for integration with computer science and additional real-world connections and challenges
A dual-head 3D printer is not required for creating printed circuit boards or conductive models, see methods for printing multiple materials with both dual and single extruder printers in the “Printing!” section of this lesson
Considerations:
Based upon the age of your students, introduce the concepts of printed circuit boards, electronics, conductors and insulators, and rapid prototyping techniques using terms and concepts familiar to their prior experiences and needs.
There is an added challenge when creating PCBs as designs must not only ensure form and function in terms of being able to be 3D printed, but also must consider the flow of electricity in order to function as a circuit board. When working with electronics, special care must be taken to prevent short circuits and damaging components or creating potential hazards when fabricating prototypes. Discuss safety and proper prototyping techniques.
Proper safety procedures should be introduced to students when working in any makerspace or lab environment. When students are around machines such as 3D printers, or using tools to cut or glue materials, students must be informed of potential hazards and taught how to use these resources safely. For reference, see the safety resources by ITEEA.
Assessments:
Opportunities for formative assessments will take place through observations and discussions between students as they interact with the content in this lesson. For summative assessment, we recommend utilizing a rubric to assess how a student was able to apply the engineering design process to solve an open-ended problem. Example Rubric - PDF
Essential Questions:
What is a printed circuit board, and how is it used?
Why are both conductive and insulation materials needed for making functioning circuit boards?
What components are needed to create a functioning circuit?
How can we use technology to design a solution to a real-world problem?
When utilizing the dual extruder print head on the LulzBot TAZ Pro 3D Printer,
we are able to print both non-conductive (green spool) and conductive (black spool) PLA filaments simultaneously!
Identify the Problem
Electronics and Circuits
Before getting into creating printed circuit boards and their functions, it is important forstudents to have a general understanding of electronics and simple circuits first. In thislesson introduction, cover the topics of electricity, AC vs DC, conductors vs insulators,components, polarity, analog vs digital, series vs parallel, and basic circuitry using termsand examples suited to your students’ prior understandings and needs.
We suggest you cover the basics of conductivity and polarity by allowing your studentsto get hands-on with fundamental electronic components, like batteries, switches, LEDs,and breadboards. Discuss the importance of both conductors and insulators and therelationship between them when creating functional circuits, such as on a breadboard.Also discuss the flow of electrons, as well as how to connect safely and properly yourcomponents using batteries and resistors in order to ensure components are not damaged, and short circuits are not created. Using a circuit simulation program like Tinkercad Circuits may allow for students to engage with this content and additional materials online or remotely in a simulated real-world environment.
There are endless possibilities in creating electronic circuits and prototype solutions. When using components like lights, switches, motors, or buzzers, students can create anything from a flashlight to an alarm for their lunch box! This lesson introduction will not only offer crucial understandings to foster success in creating printed circuit boards later in the lesson, but also engage and excite your students as they gain greater understandings with items and products, they interact with everyday!
Resources:
Sample circuits and electronic components for prototyping and exploration.
Objectives:
Students will identify the fundamental principles of electricity and how electronic circuits function
Students will combine components, conductors, and insulators to create functioning simple circuits
Teacher Instructions:
Open discussions to gauge prior understandings of electricity and electronic circuits. Encourage students to explore circuit creation in a safe lab environment. Procedures must be in place to ensure student safety during experimentation. Discuss short circuits and potential risks prior to beginning the activity.
A prototype flashlight circuit created using analog components and a breadboard.
What Are Printed Circuit Boards?
With a basic understanding of creating electronic circuits, students may begin toidentify the complexity in modern electronics such as a computer, phone, or 3D printer.Challenge students to think how small components must be in order to fit into a smartphone as comparisons is made between the basics circuits they may have created ona breadboard. Most breadboards are around the same size as a smart phone and students may have used a breadboard to make a basic circuit that does one or two things, like a light or an alarm. Imagine how many components and functions a smart phone has, from antennas to cameras, buttons, and a screen, then imagine fitting them all on a single breadboard!
This is where printed circuit boards, or PCBs come in! A PCB is a laminated device that sandwiches layers of conductors and insulators in order to make complex circuits fit in compact packages. A PCB is designed by organizing components in locations that correspond to how they need to be connected. PCBs are then fabricated in a variety of methods, from machining using a CNC mill, chemical etching, screen printing, laminating or gluing layers, or even 3D printing! PCBs can also be created to come in all shapes and sizes, as well as both rigid and flexible designs.
Nearly every modern electronic device has at least one PCB, from your toaster oven to a car key or your smart phone. Without PCBs and innovations in PCB fabrication, modern technology systems could not exist!
Objectives:
Students will identify the significance of PCBs, and how they have allowed for technology to evolve over time.
Teacher Instructions:
It’s difficult to emphasize the significance of PCBs in terms of modern technology innovation. Discuss real-world examples and create connections using terms that suit your students’ needs. Offer examples of how PCBs can be made, as well as the evolution of PCB fabrication in correlation with the demand of modern technology and computing systems.
This complex printed circuit board is the motherboard from a LulzBot 3D Printer
Without printed circuit boards, modern electronics devices would not be possible. In combination with modern rapid prototyping technology like 3D printers, creating PCBs has never been more accessible for designers and makers like you! To demonstrate these innovations, you will design and create a PCB for a functioning electronic device using computer aided design software and a 3D printer.
Specifications and constraints play an important role in a design challenge as they define the limitations and standards that our solution must achieve. For our design challenge, you must abide to the following as you create a prototype printed circuit board solution:
You must safely combine conductive and insulation materials to create a PCB
Your PCB must include at least 3 components and perform at least 1 function
Your 3D model build volume may not exceed 36 in3
You have 1 day to brainstorm, 4 days to build, and 1 day to test & evaluate
Objectives:
Students will be able to identify the role specifications and constraints play in a real-world design challenge.
Teacher Instructions:
There is no one answer to any solution, nor is there one specific set of constraints for any design challenge. See examples for how to adapt and modify the specifications and constraints of this design challenge under the “Modifications” and “Considerations” section of the lesson introduction.
Brainstorm Possible Solutions
Why Solutions and Not Solution?
The second step of our Engineering Design Process is “Brainstorm Possible Solutions.” A key part of this step is solutions being plural, meaning more than one. Why do designers and engineers think of more than one way to solve a problem?
Objectives:
Students will obtain a greater understanding of how the engineering design processed is used to solve real-world problems.
Teacher Instructions:
Adapt key phrases, concepts, and terms to best fit your students’ needs. Main idea is there is NEVER any one solution to a problem. If possible, provide an example that relates to your students’ lives, like all of their different shoes, or phones, or video game consoles. Emphasize the importance of variety and why we must, as designers, think of as many ideas as possible.
Brainstorming Our Solutions
In this step of the engineering design process, students will begin to identify what type of electronic circuit they wish to create. Specifications and constraints play a key role in design as students identify what components and materials they have to work with.
During this stage, students may sketch what their final prototype will look like, as well as begin to put together a bill of materials for what they need. Students should also consider and plan their circuit’s schematics, or how components will be connected within the prototype in order to ensure proper function and performance. Provide templates and resources for creating schematic diagrams, such as planning documents or circuit design software.
Prior to fabricating final PCBs and prototype solutions, initial prototypes should be created using simulation software, or prototyping tools such as breadboards as discussed in the first step of this lesson. Removing any flaws in our designs now will lead to greater success later in the engineering design process.
Teacher Instructions:
Emphasize coming up with as many ideas as possible as students will tend to want to go with their first idea. Also reiterate the real-world specifications and constraints of the design challenge and ensure students are factoring them into their designed solution. See the “Modifications” and “Considerations” section of the lesson introduction for more examples on how to modify this design challenge to cater to available resources.
Resources:
Design Challenge Brief Document [PDF]
Thumbnail Sketching Document [PDF]
Technical Drawing Paper [PDF]
Objectives:
Students will consider different possibilities as they brainstorm their prototype solutions
Students will plan and design a functioning electronic circuit with identified components
Students will prototype their circuit using physical components or simulation software
Example 3D printed circuit board that combines analog components, such as a pushbutton, resistor, battery,
and LED to make a simple light circuit
Printed on a LulzBot Mini 2 with conductive and non-conductive PLA
Develop a Prototype
What is 3D Printing?
Step 3 of the engineering design process is all about constructing our prototype solution! In this step, we are going to get hands-on with software and machinery to create our final designs.
One of the key prototyping machines used by today’s professional designers, engineers, and scientists is a 3D printer. There are a lot of different types of 3D printers out there, but all 3D printers create physical objects you can touch, and hold based on a 3D design or digital model. Some 3D printers melt rolls of plastic into the model, while others use light to harden a liquid resin. There are even 3D printers that can print concrete, metal, or living cell tissue!
LulzBot 3D printers use the fused deposition modeling process (FDM) that feeds and melts spools of filament through a nozzle, kind of like glue traveling through a hot glue gun. The plastic is fed, or extruded, layer by layer to create the model designed in computer aided design (CAD) software. Some 3D printers, like the LulzBot TAZ Pro Dual Extruder, has more than one nozzle and extruder to allow for multiple materials to be printed together!
When combining multiple types of filaments together, like rigid plastics with flexible ones, or conductive materials with insulators, endless possibilities can be made! But you don’t necessarily need a dual-extruder 3D printer to combine filaments, as discussed later in the “Printing!” section of this lesson.
Objectives:
Students will be able to identify how 3D printers work, and how to use them safely.
Teacher Instructions:
Introducing and over viewing the resources available for prototyping before beginning construction is key. Make sure your students know what resources are available, as well as how to use them safely. Introduce any additional resources available for prototyping during this step (see Modifications in lesson introduction.)
A LulzBot TAZ Pro with the Dual Extruder print head
creating a 3D printed PCB using both conductive and non-
conductive PLA filament to create a prototype
Developing our 3D Models
Now that we’ve brainstormed our prototype PCB designs, it is time to begin to fabricate them! But before we can 3D print our parts; we need a 3D design. To create this, we will use computer aided design software, or CAD. There’s plenty of great free CAD programs out there, we recommend Tinkercad, FreeCAD, Fusion360, or OnShape for students.
When creating 3D printed circuit boards, an added challenge arises as we need to design conductive and insulation channels in our models to ensure functionality. To assist, we recommend using PCB design software like KiCAD, Fritzing, or Fusion360 to create complex multi-layer designs. Many CAD programs like Tinkercad allow you to import vector designs from 2D design software. Combining applications may allow for students to create complex paths with greater ease.
When creating models that work, we must also consider the properties of conductive filament. Proto-Pasta’s conductive PLA has a greater conductivity across a single layer rather than between multiple layers. This means that stronger electrical connections can be made with models that are thin, rather than tall. When creating holes for components to fit into, shapes that are too small will not be printed accurately. We recommend using 1/6” as a hole diameter and dimension for creating tolerances. Note, model shrinking and required tolerances can vary based on filament, printer, printing conditions, and print orientation.
Lastly, designs that will be manufactured on dual extruder printers may vary from ones that can be produced on single extruder printers. Dual extrusion printers allow for materials to be blended within layers, while single extrusion requires filament changes to occur from layer to layer. Consider available resources when creating your 3D models - See more details about layer changes in the next step.
Resources:
Computer or Tablet
USB Mouse (Recommended)
CAD Software & Guiding Tutorials
Objectives:
Students will utilize CAD Software to create a 3D model of their designed solutions.
Teacher Instructions:
Students may better understand the purpose of CAD after being initially introduced to rapid prototyping production machinery. For beginners, experimentation is key when learning the basics of CAD software. Offer students guidelines for dimensions and tolerances as they begin to create their designs in CAD (see Modifications in lesson introduction). Using specialized software or 2D vector drawing programs may assist in creating PCB models that both function and that can be accurately 3D printed.
A LulzBot TAZ Pro with the Dual Extruder print head
creating a 3D printed PCB using both conductive and non-
conductive PLA filament to create a prototype
Printing
Once students have completed their designs, it’s time to download and prepare them to use Cura LulzBot Edition. Cura is not a CAD program in that it allows you to design your models. Instead, Cura “slices” models layer by layer to create a program file, or Gcode file, for the 3D printer to read. This Gcode file is a set of directions that the 3D printer follows as it prints your model.
In general, we recommend PLA filament for most classroom uses as it’s a safe plastic to print in schools and prints easily in nearly any setting. PLA works well for most applications and comes in many variations that include varying color and properties. When creating our 3D printed circuit boards, we will be combining two different types of PLA - conductive and non-conductive!
Dual extrusion 3D printers like the LulzBot TAZ Pro allow users to print two different types of filaments at the within the same layer. This would allow you to merge two models together in Cura LE to create a single part printed with two extruders and two different types of filaments. Dual extrusion opens up new opportunities for prototyping as different filaments can be combined within the same layer, allowing for infinite geometric freedom in your designs!
However, multi-material printing can be achieved with a single extruder 3D printer as well! Instead of printing two materials within the same layer, a print can be paused at a specific layer, then the filament can be changed. This will allow a user to begin a print with an insulator filament, pause, then finish with a conductive filament to create a fully functional PCB! Using Cura LE, you can modify your GCode to do this automatically. Using the Modify G-Code extension under the Post Processing in the extensions menu, you can choose to pause at height or layer in order to allow autonomous pausing for easy filament changes!
In addition to choosing the type of filament, we also must choose our printing detail, or layer height. The smaller the layer height, the smoother and higher detail our models will be. In general, printing at the high speed or standard detail setting will allow for student designs to be printed quickly and at an effective quality for medium to large size models. We must also consider our model density when printing with conductive filaments. A low infill density will create a more hollow model which would be less conductive. Ideally, insulator parts can be printed with a low density while conductor parts can be printed at a high density, or 100% infill. This can be achieved easily by adjusting your print settings per extruder in Cura LulzBot Edition.
Objectives:
Students will understand how 3D models designed in CAD are prepared and sent to 3D printers for manufacturing.
Teacher Instructions:
Depending on your student age group and classroom resources, the teacher may need to slice the models for the students. Ensure proper settings are chosen for selected filament and model quality. Reference LulzBot guides and tutorials for assistance.
Preparing a prototype flashlight to be 3D printed on a LulzBot TAZ Pro Dual Extruder 3D printer in Cura LE
Modifying Gcode to pause at a specific layer for a filament change while preparing
a circuit board model to be printed on a LulzBot Mini 2 in Cura LE
You may also need to consider support material when printing models with overhangs or potential structural flaws. Support material is automatically drawn by Cura and adds filament structures that can be removed after printing. When printing with multiple types of filaments, consider where supports will be placed before choosing which extruder (on dual extrusion printers) will be printing the supports. For example, if supports need to be placed within a slot for a battery that is made of conductive filament, the supports should also be conductive. This will ensure no insulation material is placed or left where the model must be conductive. The same goes for areas that must be insulated too. If you print supports with conductive material that spans across insulated areas, accidental electrical connections might be made!
Discussing Gcode is a good lesson in itself! Gcode is a list of directions for the machines to follow and can be read using a basic text program. When creating specialized post processing modifications like pausing at a specific layer, an advanced used can manually edit the GCode files to add these commands. Did you know early CNC machines required people to write Gcode manually? Luckily, we have Cura for that now!
Creating a 3D printed circuit board using both non-conductive and conductive PLA filaments on a
single extruder LulzBot Mini 3D printer by pausing at a specific layer height to change filaments
Constructing our Prototypes
In the final part of this stage in the engineering design process, we must construct our prototypes after all parts have been 3D printed. Depending on available resources and the specifications and constraints of the challenge, this step may involve assembling 3D printed parts together, installing electronic components in a simple design, or creating a complex PCB one component at a time. Time will vary based on how many materials and resources students have to build with.
To connect components to a 3D printed circuit board, a variety of methods can be used. Proper fit and snap together install is ideal, or components can be secured using glue, conductive paste, melting the filament around the connection, or even solder!
Remember, proper safety procedures should be introduced to students when working in any makerspace or lab environment. When students are around machines such as 3D printers, or using tools to cut or glue materials, students must be informed of potential hazards and taught how to use these resources safely. For reference, see the safety resources offered by ITEEA.
Resources:
Materials and tools for prototype construction.
Objectives:
Students will use available resources and apply proper safety techniques to construct their prototype solutions.
Teacher Instructions:
Available resources and additional materials will vary based upon the specifications and constraints of the design challenge. For examples, see the “Modifications” and “Considerations” sections in the lesson introduction. Safety is key. Ensure all students have been trained to use any available tools or resources and organize your room to ensure these resources can be monitored accordingly.
Assembling conductive 3D printed parts onto a 3D printed circuit board with an integrated potentiometer and switch
Printed on a LulzBot Mini 2
Test and Evaluate
Testing Our Solutions
In this stage of the design process, it is time to get hands-on with our designed prototype solutions in order to determine the effectiveness and success through testing!
Depending on the type of product or solution created, testing and evaluation steps may vary from student to student. During this stage, students should record the successes and failures of their prototype solution in order to obtain understandings of how well their prototypes perform. Consider the following questions to guide evaluation:
Does the prototype function as intended?
Are all components secured properly?
What could be improved in terms of user interaction or prototype performance?
How does this printed circuit board and electronic prototype device compare to those of industry or production quality?
Challenge students to work collaboratively as they test each other’s prototype solutions under real-world specifications and constraints through the eyes of a creator and consumer. As each prototype solution may differ in performance and function, guidelines for offering meaningful and constructive feedback may be needed.
Resources:
Planning document or notebook to record findings and discoveries during testing stages of the design process.
Objectives:
Students will apply the engineering design process as they test the performance of their prototype solutions in a real-world setting.
Teacher Instructions:
Challenge students to think critically as they compare their designed solutions to the identified problem at hand, as well as existing solutions. Remind students that these are PROTOTYPES, not finished models and that failure or room for improvement is expected and GOOD when designing solutions to real-world problems.
3D printed flashlight prototype example with integrated circuit board and push button
Printed on a LulzBot TAZ Pro Dual Extruder combining both normal and conductive PLA filaments
Redesign
No design is perfect, nor is it ever truly finished. As new technology is developed, improvements like cost, speed, performance, or aesthetics can always be made. When considering redesign, we must look at both the successes and failures of our prototypes. A failed design does not mean we failed; it means we have room to improve upon for the next prototype solution.
Consider findings from testing and evaluating your 3D printed circuit board prototype solution, as well the feedback obtained through sharing your solution with your peers as they tested it under real-world constraints. What worked well? What could be improved? Create a sketch or schematic diagram of an improved prototype design with changes you would make to allow your prototype to better meet the evaluation criteria and solve our real-world problem. Your sketch should be neat and label the changes you are making to improve your solution’s performance.
Resources:
Planning document or Drawing Paper [PDF]
Objectives:
Students will utilize the engineering design process to reflect and improve upon their designs as they create a proposed redesigned solution.
Teacher Instructions:
Stress the importance of failure in design and engineering. No one enjoys failing, or not doing well, but the redesign step is a chance to reflect on both the good and bad of our designed solutions. Additionally, we can use observations made from existing solutions and collaborating with our peers as we create a proposed redesign with everything we’ve learned.
Drawn and written redesign activities both work well with varying learning styles, we recommend a combination of the two. If time permits, students may use CAD to make a 3D model of their redesigned solution or even attempt to create a new solution entirely.
Sample layered light prototype example with an integrated circuit board
Printed on a LulzBot TAZ Pro Dual Extruder combining both normal and conductive PLA filaments
Have questions or comments? Continue the conversation on TechForum, DigiKey's online community and technical resource.
Visit TechForum
