Engineering concept
Separate 3D-printed meshes and laser-ready planar cut profiles are different manufacturing outputs and must match one approved CAD revision.
IED Unit 3 • Lesson 3.9
Manufacturing & Fabrication Preparation
Focus question: How can one Fusion assembly be translated into accurate files for two different manufacturing processes?
Your lesson guide
Objective
Export individual printed components without losing scale or identity. Create laser-ready fin geometry from the approved fin component. Preserve revision control across multiple manufacturing files.
Materials
For the online work: a browser and your engineering notebook. Follow the activity’s materials list for any physical build, and get teacher approval before using equipment.
Plan your time
Suggested work block: 45–60 minutes. Physical builds and projects may span several classes; follow your teacher’s schedule.
IED Unit 3 • Lesson 3.9 • Learning Studio
Learn the concepts before completing the assignment
Today's engineering work
Freeze the approved revision; export each module as its own STL; create a clean 1:1 millimeter fin DXF; verify scale, actual 1/8 in stock thickness, quantity and total print estimate.
Worked example
Example package: Nose_R1.stl, Body_R1.stl, Lower_R1.stl, Fin_R1.dxf. Remove dimension lines and title blocks from cut geometry.
01 / Illustrated concept
Manufacturing Exports
What the diagram means: Separate 3D-printed meshes and laser-ready planar cut profiles are different manufacturing outputs and must match one approved CAD revision. The example values illustrate the principle and do not replace actual teacher-assigned dimensions.
02 / Watch and research
Instructional video and technical resources
Fusion export for 3D printing
Use the relevant modeling or assembly technique; the demonstration project may differ from the rocket assignment.
Watch directly on YouTube ↗Expert references
Use these official Autodesk or NASA guides when the video alone does not explain the underlying workflow.
Primary technical reference ↗Additional learning resource ↗Self-study: identify a key technique, pause the tutorial, apply the operation and verify the result before continuing.
03 / Step-by-step guide
From theory to your own project
Guided task sequence
- Freeze the approved revision
- export each module as its own STL
- create a clean 1:1 millimeter fin DXF
- verify scale, actual 1/8 in stock thickness, quantity and total print estimate.
Worked example and verification
Example package: Nose_R1.stl, Body_R1.stl, Lower_R1.stl, Fin_R1.dxf. Remove dimension lines and title blocks from cut geometry.
Important: Do not substitute illustrative numbers for actual CAD dimensions, real measurements or instructor approvals.
04 / Independent practice
Explore one key parameter
Interactive concept explorer
Illustrative values only; not a completed engineering inspection or teacher authorization.
Check your reasoning
Why not export the entire rocket as one STL?
The modules must be manufactured and inspected separately.
Is a drawing-sheet DXF automatically laser-ready?
No. Use closed, planar, scale-verified profiles only.
Use the lesson's original assignment and “What to Submit” sections below for exact deliverable requirements.
Lesson Overview
What You Are Learning
Learning Targets
- Export individual printed components without losing scale or identity.
- Create laser-ready fin geometry from the approved fin component.
- Preserve revision control across multiple manufacturing files.
- Verify that printed parts and fin geometry match the final assembly.
Unit 3 Progression
Unit 2 taught basic STL export. Unit 3 adds mixed manufacturing and configuration control across an assembly.
ComponentsAssembleVerifyFabricateReviseFlight Test
Compressed-Air Rocket Challenge
Project Requirements
These requirements apply throughout Lessons 3.6–3.14.
1/2 in PVC Reference Tube
- The launcher tube outside diameter is 0.840 in (21.34 mm).
- Model the launch tube as a separate grounded Fusion reference component.
- You choose the rocket's internal launch clearance, but the finished rocket must slide freely over the actual PVC tube without binding.
- Before choosing the rocket's internal bore dimension, measure the actual unpressurized classroom launch tube. The 0.840 in (21.34 mm) diameter is the nominal outside-diameter reference, not the target bore size.
- The launcher itself is teacher equipment and is not modified as part of this project.
Modular 3D-Printed Rocket
- The structural rocket body is 3D printed in classroom-approved filament.
- Use at least 3 major printed modules: a lower launch/fin module, a main body module, and a nose/upper module.
- The rocket must have at least 2 removable printed-to-printed interfaces.
- Major printed modules must be disassembled without damaging the parts; permanent adhesive is not allowed between major modules.
Connection Method
- You choose how major modules connect.
- Examples include keyed/slip couplers with retention, twist-lock/bayonet features, screws/inserts, snap-fit features, or another approved method.
- The connection must keep the rocket aligned and secure during handling and flight-readiness checks.
- If a connection uses hardware or a tool, it must still be serviceable without damaging the printed parts.
Laser-Cut Fin Assembly
- Use 3 or 4 identical fins, equally spaced at 120° or 90°.
- Fins are laser-cut from 1/8 in acrylic or plywood.
- Use 3.175 mm as the nominal CAD thickness, then measure the actual stock and use that measurement for the final fin interface.
- Fins must use a repeatable locating feature such as slots, tabs, keyed pockets, or another approved feature. Surface gluing alone is not an acceptable locating method.
- Adhesive may be used to retain the fins after the fit/alignment check is approved.
Lightweight by Design
- Primary body walls should generally be 1.2–2.0 mm thick; 1.6 mm is the recommended target.
- Geometry thicker than 2.5 mm should be limited to local interfaces, couplers, fin mounts, fastener features, or other justified reinforcement.
- Total predicted 3D-printed material should be 100 g or less.
- The finished rocket should have a total mass of 125 g or less before the flight-readiness review.
Build for the Classroom Process
- Every printed component must fit the classroom printer build volume and be designed to print without support material.
- No support material may be required inside the launch bore or any mating interface.
- The nose must be rounded/blunt, and exposed fin corners/edges must be made safe before flight.
- Only the instructor operates, pressurizes, or changes settings on the compressed-air launcher.
Assignment
Create the Rocket Manufacturing Package
Export only the approved components from the Lesson 3.8 design review. The instructor controls the manufacturing schedule and equipment use.
Step-by-Step Instructions
- Freeze the approved revision: Save a final pre-manufacturing version before exporting files.
- Export each printed module: Create one STL per printed rocket component. Do not export the whole rocket as one mesh.
- Check STL scale: Re-open or inspect the mesh export and verify millimeter scale and expected dimensions.
- Create the fin profile: Produce a clean 2D outline for the approved fin and export it as DXF for laser cutting.
- Use actual stock thickness: Confirm the Fusion fin component and fin slot geometry use the measured thickness of the selected 1/8 in acrylic or plywood stock.
- Name every file: Include student name, component name, and revision/version when required.
- Check print orientation: Identify the intended support-free orientation for every printed part.
- Check material estimate: Confirm the manufacturing set remains within the 100 g predicted printed-material limit.
- Submit for fabrication: Upload the files to the assigned location and wait for instructor approval before manufacturing.
Before You Submit
- Each printed module has its own STL.
- The fin has a laser-ready DXF.
- Files match the approved assembly revision.
- Fin thickness matches the measured stock.
- Print orientation is support-free.
- File names clearly identify each component.
Submission
What to Submit
Submit only the following assignment-specific deliverables in Google Classroom:
Resources
Lesson Resources
IED Unit 3
Return to the Unit 3 lesson map and project sequence.
Introduction to Engineering Design
Return to the IED course hub.
Build your lesson report
Checkpoint: is your evidence ready?
- Check calculations, units, labels, and measurements against the activity requirements.
- Record what actually happened, including unexpected results.
- Explain what you changed and why; attach required drawings, photos, CAD, or code in your classroom assignment.
Submit only the following assignment-specific deliverables in Google Classroom: 3D-print files: separate, clearly named .stl file for every distinct printed module (not one combined rocket mesh). Include revision labels if any parts changed. Laser file: one .dxf containing the flat profile of the chosen fin for approved 1/8 in stock; state whether 3 or 4 copies are needed.
A PDF download is not a submission. Review it, then upload it and any required attachments through your classroom assignment system.