Designing SolidWorks 3D Printing Assignments with Markforged Precision

Before diving into modeling, it’s crucial to interpret the assignment brief properly. Assignments like “Printing & Post Processing of Replica Models with Markforged” usually expect students to demonstrate:

• Proficiency in SolidWorks part and assembly design
• Correct export of STL or 3MF files suitable for 3D printing
• Awareness of 3D printing parameters (layer height, infill, support material, etc.)
• Post-processing knowledge such as sanding, surface finishing, or painting

A good practice is to read the provided instructions multiple times and highlight the key deliverables — design specifications, material type, and printer model (for example, Markforged Onyx One or Mark Two). Understanding what the printer supports (composite materials, continuous fiber reinforcement, etc.) ensures your model design aligns with its capabilities.

Setting Up the SolidWorks Environment

To begin, configure your SolidWorks environment to match the required scale and units. For Markforged printers, metric units (millimeters) are generally preferred. The steps include:

1. Create a new part file and choose the appropriate template.
2. Set Document Properties → Units to MMGS (millimeter, gram, second).
3. Enable visibility of planes and origins for better geometric control.

It’s helpful to organize your design tree neatly. Assign meaningful names to sketches and features — for example, “Base Sketch,” “Fillet Support,” or “Connector Hole.” This not only improves readability but also makes troubleshooting easier if any feature fails during modification.

Modeling the Replica: From Concept to Digital Form

Assignments involving replica models require accurate digital representation of an existing object. Start with reference images or dimensions of the physical model.

The process can typically be divided into the following stages:

Sketching and Constraints

Begin with 2D sketches that define the essential profiles. Always:

• Use fully defined sketches (avoid underdefined geometry).
• Apply geometric relations such as concentricity, perpendicularity, and symmetry.
• Define dimensions precisely using Smart Dimension tools.

A properly constrained sketch ensures parametric flexibility — vital when you need to make design changes later.

Extrusions and Revolutions

Depending on the model’s geometry:

• Use Extrude Boss/Base for prismatic shapes.
• Use Revolve Boss/Base for circular or cylindrical features.
• Combine these with Cut Extrude or Cut Revolve for hollow or complex interiors.

For example, if the replica model has a cylindrical body with internal features, begin with a revolve and then add subtractive cuts.

Fillets, Chamfers, and Detailing

Once the primary body is complete, add fillets, chamfers, and edge refinements to mirror real-world finishing. In Markforged printing, sharp edges can cause stress concentrations or support issues, so soft transitions are preferred.

Use Feature Scope wisely to control which bodies or features the fillet applies to — a technique often overlooked but essential for precise results.

Preparing the Model for 3D Printing

Once the 3D model is finalized, exporting it correctly for 3D printing is a critical step. Follow these best practices:

Checking Model Integrity

Use SolidWorks’ Evaluate tab → Check tool to verify for:

• Gaps or open surfaces
• Interference between bodies
• Thin walls (<1.2 mm for Markforged Onyx material)

Running “Import Diagnostics” helps repair minor geometry errors before export.

Exporting to STL/3MF

• Go to File → Save As → STL (*.stl)
• Under Options, set:
• Output as Binary (smaller file size)
• Resolution: Fine for smooth curves
• Deviation and angle settings for higher accuracy

Alternatively, 3MF files retain color and texture data, beneficial for multi-material printing.

Orientation and Supports

Markforged printers use Eiger software for slicing. The orientation of the model directly affects strength, surface finish, and print time.

Here’s what to consider:

• Load direction: Align layers perpendicular to primary load paths for strength.
• Support minimization: Orient the model to reduce overhangs beyond 45°.
• Surface quality: Face aesthetic surfaces upward to minimize support marks.

Printing Process with Markforged

The Markforged printing ecosystem is known for producing strong, dimensionally stable composite parts. Understanding its workflow helps justify your design decisions in the assignment.

Material Selection

Markforged supports materials such as:

• Onyx: Nylon base with chopped carbon fiber — excellent strength and surface finish.
• Continuous Fiber Reinforcement (CFR): Carbon fiber, Kevlar, or fiberglass for high-strength applications.

When describing material choice in your report, discuss mechanical properties, heat resistance, and surface finish quality as justification.

Print Settings

Use the Eiger interface to configure:

• Layer height (0.1 – 0.25 mm)
• Infill density and pattern
• Shell layers and roof/floor count
• Support structures and raft settings

Assignments often require screenshots of these settings to demonstrate technical understanding.

Monitoring and Troubleshooting

During the print, ensure:

• The nozzle and build plate are clean.
• Filament is dry and properly fed.
• The printer’s environment is dust-free and stable in temperature.

If layer shifting or stringing occurs, mention how it was corrected (recalibration, adjusting retraction settings, etc.) in your report.

Post-Processing the Replica Model

Post-processing is a major focus in such assignments — often accounting for up to 30–40% of the evaluation. It transforms a rough 3D print into a refined, realistic prototype.

Support Removal

Carefully remove supports using tools like pliers or chisels. For Onyx prints, supports are easier to remove due to controlled breakaway points in Eiger.

Sanding and Smoothing

Start with coarse (120-grit) sandpaper and progress to finer grades (400–600). Sand along the layer direction to reduce visible striations.

If necessary, apply:

• Acetone vapor smoothing (for ABS prints)
• Epoxy coating or primer (for Onyx prints)

Surface Finishing

For replica models requiring visual appeal, apply paint or surface coatings:

• Primer → Paint → Clear coat sequence for polished finishes
• Use masking tape to protect functional surfaces

If the part must be dimensionally precise, lightly sand only cosmetic areas.

Assembly and Verification

If your model involves multiple parts, assemble them to ensure proper fit. Use SolidWorks’ Mates to test assembly alignment virtually before physical assembly.

Record measurements using calipers and compare them with your CAD model dimensions. Document deviations (±0.1 mm typical) and justify them due to printer tolerances.

Documenting and Reporting Your Work

Engineering assignments emphasize not only execution but also documentation quality. A well-structured report includes:

1. Introduction: Objectives and scope of the replica model project.
2. Methodology: Steps followed in modeling, slicing, and printing.
3. Design Justification: Material, orientation, and support reasoning.
4. Post-Processing Techniques: Sanding, assembly, and finishing steps.
5. Results and Discussion: Print quality evaluation, dimensional accuracy, and observations.
6. Conclusion: Lessons learned and possible improvements.

Add screenshots from SolidWorks, Eiger, and physical print stages. Highlight problem-solving moments — for instance, “adjusted the infill density to reduce warping.”

Common Challenges and How to Overcome Them

Even experienced students face difficulties in such assignments. Here are some common issues and practical solutions:

Documenting these troubleshooting steps shows analytical thinking and technical maturity.

Tips for Scoring High in SolidWorks 3D Printing Assignments

To make your assignment stand out:

• Focus on design intent: Show how your model serves its purpose effectively.
• Use advanced features: Such as Shell, Loft, Combine, or Split Bodies to demonstrate SolidWorks mastery.
• Include simulations: If time permits, perform Static Analysis in SolidWorks Simulation to justify design strength.
• Show professionalism: Clean report layout, labeled figures, and consistent formatting.

Lastly, if you’re short on time or need expert validation, seek solidworks assignment help from experienced professionals who can ensure your model meets academic and technical standards. Platforms offering SolidWorks 3D Printing Assignment Helper services can also review your STL files and suggest optimizations for printing efficiency.

The Future of 3D Printing Assignments

As educational institutions embrace Industry 4.0, 3D printing-based assignments are evolving rapidly. Students are expected to integrate:

• Topology optimization
• Generative design
• Composite material printing
• Post-print simulations for stress and deformation

Learning to handle advanced tools like Markforged printers now provides a strong foundation for future roles in product design, mechanical engineering, and manufacturing technology.

Conclusion

Completing a SolidWorks 3D printing assignment isn’t just about modeling and printing; it’s about understanding the synergy between digital design and real-world fabrication. From sketching and feature modeling to slicing and post-processing, every step contributes to the precision and quality of the final product.

By mastering the techniques discussed in this blog — and with the occasional guidance of a professional solidworks assignment help expert or SolidWorks 3D Printing Assignment Helper — you can consistently deliver assignments that stand out for their creativity, accuracy, and professional finish.

So, the next time you receive an assignment like “Printing & Post Processing of Replica Models with Markforged,” you’ll not only know what to do but also how to do it the right way.