3D CAD using Solidworks for Cryptologic Warfare

Course Duration

9 Days

Audience

Employees of federal, state and local governments; and businesses working with the government.

Prerequisites

Basic familiarity with computers and Windows. Prior CAD experience is helpful but not required.

Course Description

This nine-day course trains DoD and law enforcement personnel to design and fabricate custom tools in the field using 3D CAD and 3D printing — no supply chain required. The first four days follow the SOLIDWORKS Essentials curriculum, covering parametric part modeling, assembly design, and engineering drawings. The remaining five days are hands-on 3D printing: students learn to take a design from the CAD environment to a finished physical object, with emphasis on materials, printer operation, troubleshooting, and printing tools purpose-built for operational use. Each student receives a 3D printer and a full toolkit as part of their course kit to keep — ready to deploy when the course ends.

Learning Objectives

• Create parametric 3D part models using SOLIDWORKS sketching and feature tools
• Build assemblies from multiple components using mates and constraints
• Generate 2D engineering drawings with dimensions, tolerances, and annotations
• Apply design intent principles to create models that update predictably
• Operate a desktop FDM 3D printer safely and effectively
• Prepare CAD models for printing using slicing software
• Select appropriate print materials and settings for different applications
• Troubleshoot common print failures and calibration issues
• Understand field fabrication applications and operational use cases for 3D printing

Course Outline

Days 1–4: SOLIDWORKS Essentials

• SOLIDWORKS interface, navigation, and document management
• Sketch tools — lines, arcs, circles, rectangles, and constraints
• Fully defining sketches using geometric and dimensional relations
• Part features — Extrude, Revolve, Sweep, and Loft
• Editing features — Fillet, Chamfer, Shell, Draft, and Rib
• Linear and circular patterns
• Mirror features and bodies
• Creating and editing assemblies
• Mating components — Coincident, Concentric, Distance, Angle
• Interference detection and collision analysis
• Exploded views and animation
• Drawing views — Standard, Section, Detail, and Auxiliary
• Annotations — dimensions, tolerances, notes, and surface finish symbols
• Bill of materials and title block customization

Days 5–9: 3D Printing Fundamentals and Field Applications

• Overview of 3D printing technologies — FDM, SLA, SLS, and when to use each
• Printer components — extruder, build plate, motion system, and firmware
• Printer setup, leveling, and calibration
• Slicing software — importing models, supports, infill, layer height, and print settings
• Filament materials — PLA, PETG, ABS, TPU, and material selection for the mission
• First layer adhesion and print bed preparation
• Monitoring prints and identifying failures in progress
• Post-processing — removing supports, sanding, and finishing
• Designing for printability — tolerances, overhangs, and orientation
• Operational and field use cases — replacement parts, jigs, fixtures, and custom mounts
• Hands-on print projects using student-designed SOLIDWORKS models

Frequently Asked Questions