Introduction         

Over the past decade, 3D printing has experienced rapid growth, transitioning from a niche technology reserved for industrial use to a practice accessible to the general public. There was a time when a basic 3D printer cost several thousand dollars, making it primarily available to industries and research institutions.

In this article, I would like to share my experience with 3D printing, with the primary objective of providing useful pieces of information to beginners who are interested in starting in the world of 3D printing. Whether you're a boomerang enthusiast looking for an innovative manufacturing method or simply curious about exploring the possibilities offered by this technology, this article will provide you with the necessary basics to start your adventure in the fascinating world of 3D printing.

Overview of 3D printing

3D printing is an additive manufacturing technique, involving the successive addition of layers of material. This technique contrasts with subtractive methods (cutting, drilling, etc.), which are the most commonly used methods in boomerang manufacturing. There are several 3D printing processes, but I will only detail the one I use.

The printing method I use is called Fused Deposition Modeling (FDM), also known as Fused Filament Fabrication (FFF). This method involves melting a material and extruding it through a nozzle. The extruded material is deposited onto a build plate generally called a print bed, where it solidifies. During material extrusion, the coordinated movement of the nozzle and the print bed allows the material to adopt the desired geometry. I chose a printer using the FDM method for its ease of use, its relative safety*, and the affordability of the printer and consumables.

*Note: I would like to emphasize that the gases produced during the melting of certain polymers are not harmless. Therefore, I strongly recommend carefully following the printer and material usage instructions. Generally, these instructions include working in a well-ventilated space and using of a respiratory protection mask equipped with a gas/vapor filter for prolonged exposure.

material

To get started with 3D printing, you'll need the following essentials:

• A 3D printer
• Plastic filament
• A computer
• Slicing software, commonly referred to as a slicer

For those interested to deep dive into 3D design and creation, you'll also need computer-aided design (CAD) software.

The 3D printer

In 2020, I opted for a Creality Ender 3 printer, a model that cost less than 200 dollars at the time and received highly positive reviews for a printer in this price range.

Pros:

• The assembly of the printer is simple and well-documented.
• Easy to handle.
• Easy setup.

Cons:

• Odors generated while melting plastic.
• Noise generated by the printer.
• Manual calibration of the print bed.

When I decided to acquire this printer, my priority was to have a simple and versatile tool to start 3D printing, and so far, it has perfectly fulfilled this function. Additionally, it offers the possibility to print boomerangs, which is an added advantage. However, the size of the boomerangs printable in one piece is limited by the dimensions of the print bed, which is 22 cm in diameter. Nevertheless, it is still possible to print boomerangs in multiple parts and glue them together afterward.

Examples of boomerangs printed or printable with an Ender 3 printer. All boomerangs have a 100% infill density and fly perfectly, except for the yellow MTA, which is too soft. The red boomerang was made by Collin de Graag, also known as ScottW. It is a cleverly designed boomerang incorporating LEDs and all the necessary embedded electronics for night use. 

The dimensions of the print bed of the Ender 3 compared to the dimensions of Denis Suprana's JetSpeed boomerang.

The Plastic

It’s fantastic!

(For the people not familiar with French culture, "Le plastique c'est fantastique" is a French song by Elmer Food Beat, a French rock band known for their humorous and catchy songs.)

There is an abundance of choice regarding materials, manufacturers, and colors. The median price of a one-kilogram spool of 1.75 mm diameter PLA is about 25 dollars.

A small sample of polylactic acid (PLA) spools. There is an abundance of choice regarding materials, manufacturers, and colors. The median price of a one-kilogram spool of 1.75 mm diameter PLA is about 25 dollars.

The Ender 3 printer theoretically allows the possibility of printing the following materials: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), and polyurethane (TPU). However, so far, I have only experimented with PLA. My decision to prioritize PLA is based on my desire to choose a printing material that is as safe as possible. Indeed, PLA is recognized as the safest rigid plastic, while TPU is an elastomer and ABS is considered potentially hazardous to health under printing conditions. In summary, as the safety of my family is my priority, I have opted for PLA so that my new hobby presents no risk to their health.

The computer

The computer plays a central role in the 3D printing process, enabling the operation of software and manipulation of necessary files. However, you don't need a high-end computer setup.

Personally, I use a relatively modest computer, equipped with an AMD quad-core processor clocked at 2 GHz, an integrated Radeon R4 graphics card, and 8 GB of RAM, running Windows 10 64-bit. Previously, I used an even older computer with a single-core processor running Linux, and all the software worked perfectly.

The slicer

The slicer is an essential software in 3D printing, necessary for converting 3D models into instructions interpretable by the printer. It manages various printing parameters such as print speed, nozzle temperature, and object infill.

Personally, I exclusively use Cura. It's user-friendly software that offers several levels of settings, allowing users to quickly handle the software while also providing the opportunity to explore advanced settings later on.

Master the art of slicing with Cura.

Conclusion

We are reaching the end of this first article where we have explored the basics of 3D printing, from its fundamental principles to practical hardware and software choices. I hope this article has provided you with the necessary information to start your adventure in the exciting world of 3D printing, whether it's for making boomerangs or exploring other creative horizons. In any case, one thing is certain: with the right knowledge and tools, the possibilities are endless. I wish you a lot of success in your creative journey!

Useful links

Creality Ender 3 printer: https://www.creality.com/products/ender-3-3d-printer?spm=..page_2437713.products_display_1.1&spm_prev=..index.header_1.1

Cura software: https://ultimaker.com/software/ultimaker-cura/

About the toxicity of ABS in 3D printing:  https://clevercreations.org/is-abs-toxic-safe-material-print-fumes

Comparison of the mechanical and physical properties of various polymers in 3D printing: https://www.youtube.com/watch?v=ycGDR752fT0

Websites dedicated to the sharing of user-created 3D files:

• https://www.thingiverse.com/
• https://www.printables.com/
• https://cults3d.com/

3D boomerang models from ScottW: https://ww2.scottw.nl/index.php/3d-models/