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Closing the loop by completing all stages in the design process is an important experience for every engineer. There is significant experiential merit, for example, in providing first year students with a design challenge that starts with a blank sheet of paper and ends with reflective observation of their fabricated model. The advent of 3D printing has “game changer” potential as a vehicle for this experience, but it has limitations, especially for large class sizes. An activity was devised to complete the design loop using 3D printing. This initiative effectively overcame the limited throughput rates and high material costs associated with 3D printing for 427 students. Activity outcomes were assessed via an exit survey, including whether students perceived differences between their CAD and 3D physical models. Students enjoyed the experience, and grew from it. The outcomes from this initiative along with the lessons learned may be of use to other instructors considering a similar experiential path.

Closing the Loop: Integrating 3D Printing with Engineering Design Graphics for Large Class Sizes