Digital Fabrication

3D printing, laser cutting and CNC.

Overview

What the area is for, equipment at a glance and who the Area Champion is.

Overview

Digital Fabrication Overview

Digital Fabrication covers the machines that turn a computer design into a physical part: 3D printers, the laser cutter and CNC. The 3D printers live in the print lab; the laser and CNC are in the laser/CNC shop.

3D printing and laser cutting are self-serve once you have been trained.

Equipment at a glance

The current list of equipment, with locations and which machines need training, is in Atlas: https://atlas.waukeshamakers.com.

The 3D printers with maintenance pages in this book are:

Pages in this book

Before you work here

To be confirmed: whether members supply their own filament and laser stock or the shop provides some, and how members send jobs to the printers. See also **Facility Operations: Consumables**.

Learning to design

New to 3D design? The Fusion 360 Basics class walks you through your first model. The class outline and handout are in Classes and Instructors: Fusion 360 Basics, and the cheat sheet is in this book.

Area Champion

To be confirmed: who the Digital Fabrication Area Champion is and how to reach them. See **Volunteer Runbooks: Area Champions** for what Area Champions do.

Overview

Fusion 360 Cheat Sheet

A quick reference for designing parts in Autodesk Fusion 360. This is the handout from the Fusion 360 Basics class; see Classes and Instructors: Fusion 360 Basics for the class itself.

The core workflow

This is the process you will repeat for almost everything you build:

  1. Sketch a 2D shape on a plane or face.
  2. Extrude it into 3D (add material).
  3. Sketch on a face of your 3D object.
  4. Cut to remove material (extrude inward).
  5. Fillet to round edges and finish.
  6. Repeat steps 3 to 5 to add detail.

Keyboard shortcuts

Shortcut Action
S Search bar (find any tool by name)
L Line
C Circle
R Rectangle
D Sketch Dimension
E Extrude
F Fillet
Q Push/Pull
M Move/Copy
Ctrl+Z / Cmd+Z Undo

Tip: press S and type the name of any tool. It is the fastest way to find anything.

Mouse navigation

Action Control
Orbit Middle mouse button
Pan Shift + middle mouse button
Zoom Scroll wheel
Reset view Click the house icon on the view cube (top right)

Practice project: phone stand

The class project. Dimensions are included so you can rebuild it at home.

Step 1: Base

  1. Create Sketch on the XZ plane (the floor).
  2. Draw a Rectangle: 70 mm x 80 mm.
  3. Finish Sketch.
  4. Extrude (Symmetric): 10 mm.

Step 2: Back support

  1. Create Sketch on the back face (the 70 mm x 10 mm face).
  2. Draw a Rectangle from the top-left corner: 70 mm wide x 60 mm tall.
  3. Finish Sketch.
  4. Extrude: 10 mm (away from the base).

Step 3: Phone slot

  1. Create Sketch on the top face of the base.
  2. Draw a Rectangle: 50 mm x 4 mm, positioned 5 mm from the back wall.
  3. Finish Sketch.
  4. Extrude as Cut: -8 mm (leaves a 2 mm floor).

Step 4: Fillet

  1. Select Fillet (or press F).
  2. Click the top edges of the back support; radius 5 mm.
  3. Optionally fillet the bottom edges of the base: 3 mm.

Dimensions reference

Feature Size
Base 70 x 80 x 10 mm
Back support 70 x 60 x 10 mm
Phone slot 50 x 4 mm, 8 mm deep cut
Fillets 5 mm (top), 3 mm (bottom)

Stuck? Check here first

Problem Fix
Can't see my sketch Click the Home icon on the view cube
Extrude is grayed out Click Finish Sketch first
Extrude didn't cut Undo, redo the extrude, and change Operation to Cut
Sketch lines are still blue Add dimensions to fully constrain the sketch (it still works if you don't)
Can't select a face Zoom in and hover until the face highlights, not an edge
Model disappeared Check the eye icons in the Browser panel (left side)

What to learn next

  1. Components: organizing multi-part models.
  2. User Parameters: named variables for dimensions.
  3. Patterns: repeating features in circles or grids.
  4. STL Export: File, Export, STL, so you can 3D print your design.

Resources

Equipment SOPs

One page per tool. Reading an SOP does not replace training or certification.

Equipment SOPs

Laser Cutter

Reading this page does not replace training. You must be checked off on this tool before using it.

The laser cuts and engraves sheet materials using a focused beam. It is self-serve once you have been trained.

To be confirmed: the full operating procedure (model, startup, focusing, job setup, ventilation, shutdown). Only the rules below are sourced so far. The machine's details are in Atlas: https://atlas.waukeshamakers.com.

Certification required

Yes. See Training and Certification: How Certification Works.

The rule posted on the machine

Never leave the laser unattended while it is running. Stay with the machine for the whole job, watching it, not just in the room. Lasers can set the material on fire, and a small flare-up becomes a real fire within seconds when nobody is watching. If you need to step away, pause or stop the job first.

Before you start

While it runs

When you are done

Maintenance

Routine maintenance procedures and checklists.

Maintenance

Prusa MK4 Maintenance

Regular maintenance checklist for the Original Prusa MK4 (Nextruder). It follows Prusa's own guide: Regular printer maintenance (MK4/S, MK3.9/S).

How often

Interval What
Before every print Some items; see Prusa's guide linked above
Every 200 print hours Axes (rods and bearings), belts, fans and the Nextruder (sections 2 to 8)
Yearly, or every 600 to 800 print hours Electronics check (section 9)

Supplies

Do not lubricate the Z-axis lead screws or trapezoid nuts. Do not open the Nextruder gearbox unless Prusa support asks you to; the primary gear and idler bearings need no lubricant.

1. Before you start

2. General cleaning and hotend

3. Hotend thumb screws and nozzle seating (printer off and cold)

4. Smooth rods and bearings (X, Y, Z)

5. Belts and pulleys

6. Fans

7. Nextruder (drive gear area)

8. Print sheets

9. Electronics (yearly, or every 600 to 800 hours)

10. Firmware

11. Recalibrate

Afterwards

Record anything you found, what you did about it, and whether follow-up is needed. If the printer is not safe to use, tag it out of service: see Shop Safety: Tagging a Tool Out of Service and Reporting It.

Maintenance

Prusa MK3S+ Maintenance

Regular maintenance checklist for the Original Prusa i3 MK3S+. If there is more than one MK3S+, go through the whole checklist for each printer. It follows Prusa's own guide: i3 Printer Regular Maintenance.

How often

Interval What
Every couple hundred print hours Cleaning, axes, belts, extruder, fans, sheets (sections 2 to 7)
Every 600 to 800 print hours, or at least yearly Electronics check (section 8)

Supplies

Do not lubricate the Z-axis lead screws or trapezoid nuts. Prusa explicitly warns against this.

1. Before you start

2. General cleaning

3. Smooth rods and bearings (X, Y, Z)

4. Belts and pulleys

5. Extruder (Bondtech gears and idler)

6. Fans

7. Print sheets

8. Electronics (every 600 to 800 hours, or at least yearly)

9. Nozzle

10. Firmware and slicer

11. Recalibrate

Prusa recommends recalibrating after maintenance.

Afterwards

Record anything you found, what you did about it, and whether follow-up is needed. If the printer is not safe to use, tag it out of service: see Shop Safety: Tagging a Tool Out of Service and Reporting It.

Maintenance

Bambu Lab X1C and AMS Maintenance

Maintenance checklist for the Bambu Lab X1 Carbon printer and its two filament units, the AMS 2 Pro and the original AMS (Gen 1). It follows Bambu Lab's guides:

How often

Interval What
Every 3 to 5 days if ABS is printed often Clean the Micro Lidar window
Every 2 weeks Check AMS desiccant and humidity
Monthly (every 5 rolls if printing ABS/ASA) Clean carbon rods and re-tension belts
Every 2 months (monthly with abrasive filaments) Replace AMS PTFE tubes
Every 3 months Grease Z lead screws; replace the activated carbon filter under heavy use
As needed Nozzle wiper, nozzle, silicone sock, build plates

Supplies

Do NOT grease the X-axis carbon rods. Grease causes abnormal resistance and makes cleaning harder; the bearings are self-lubricating. Power off and unplug the printer before any mechanical work.

X1C printer

1. Before you start

2. General cleaning

3. Carbon rods and belt tension (do these together)

Procedure: Bambu Wiki: Carbon rods clearance and cleaning

4. Z-axis lead screws (every 3 months)

5. Nozzle wiper

6. Hotend and extruder

7. Micro Lidar

8. Activated carbon filter and fans

9. Build plates

10. Cables and PTFE path

AMS 2 Pro and AMS (Gen 1)

11. PTFE tubes

12. Feeders and filament path

13. Desiccant and humidity

14. AMS test

15. Recalibrate the X1C

Afterwards

Record anything you found, what you did about it, and whether follow-up is needed. If the printer is not safe to use, tag it out of service: see Shop Safety: Tagging a Tool Out of Service and Reporting It.

Maintenance

Anycubic Kobra 2 Max Maintenance

Maintenance and troubleshooting checklist for the Anycubic Kobra 2 Max (V-wheel gantry, belt tensioner knobs, auto leveling). Sources:

History: this checklist was first written to bring this printer back into service, so it starts with a diagnosis step. Use that step whenever the printer is acting up; otherwise follow the routine schedule.

Confirm the model on the label on the back. This page is for the Kobra 2 Max. The older original Kobra Max is mechanically similar but its menus differ; see Anycubic: Kobra Max hot end replacement.

Routine schedule

Interval Task
Before each print Clean the bed; check the nozzle for buildup
Monthly Check eccentric nuts and belt tension; clean the V-slots
Every 3 months Grease the Z lead screws; clean the extruder gears; blow out the fans
As needed Nozzle replacement; firmware updates

Supplies

1. Diagnose (when something is wrong)

2. Power off, unplug and clean

3. Frame and fasteners

4. V-wheels and eccentric nuts

Loose or worn wheels are the most common cause of Kobra problems.

5. Belts

6. Z-axis lead screws

7. Extruder and hotend

8. Fans and wiring

9. Bed surface

10. Firmware

11. Calibration

Per the Anycubic leveling calibration guide:

12. If it still will not level or print

Afterwards

Record anything you found, what you did about it, and whether follow-up is needed. If the printer is not safe to use, tag it out of service: see Shop Safety: Tagging a Tool Out of Service and Reporting It.

Materials

Which materials are safe for the laser and other machines, and which are prohibited.

Materials

Laser-Safe and Prohibited Materials

Some materials are perfectly safe to laser. Others release toxic or corrosive gases, damage the machine, or catch fire easily. If you cannot identify a material, do not put it in the laser.

To be confirmed: the approved materials list for WMI's laser. What a laser can cut depends on its type and power, so check with a trainer before cutting anything not on that list.

Never laser these

Material Why
PVC and vinyl (including vinyl sheet, many faux leathers, some foam boards and records) Releases chlorine gas, which is toxic and corrodes the machine.
Anything containing chlorine Same reason as PVC.
Polycarbonate (Lexan) Catches fire and discolors rather than cutting cleanly.
ABS Melts rather than cuts and gives off harmful fumes.
Fiberglass and carbon fiber The resins give off harmful fumes.
Coated or mirrored materials you cannot identify Coatings may contain any of the above.

Usually safe, if the machine is set up for it

These are commonly laser-cut or engraved. Ask your trainer which ones apply to our machine and what settings to use.

Whatever the material