How to Perform 3D Printing Using xCAD

xCAD can be used to take a design from an initial 3D concept all the way to a file that can be processed by a 3D printer. The typical workflow is:

Create 3D Model → Verify Dimensions → Check Solid → Run 3D Print Check → Export STL/3MF → Slice → Generate G-code → Print

xCAD supports STL export, including mesh/facet controls, and its documentation describes a 3D Print Check for detecting common topology problems. Supported versions also provide 3MF export.

Step 1: Start a New xCAD Drawing

Open xCAD and create a new drawing.

In xCAD:

File → New

Then configure the drawing units.

For 3D printing, millimeters (mm) are commonly used.

You can configure English or Metric units through the Page Setup Wizard.

Example

Suppose you want to print a small mechanical bracket.

Set your design units to:

Millimeters

Then create the model using the actual dimensions you want to manufacture.

Step 2: Create Your 3D Model

Now create the object you want to print.

xCAD provides a range of 3D modeling tools that can be used for printable geometry.

Common tools include:

• Box
• Cylinder
• Sphere
• Cone
• Torus
• Wedge
• Extrude
• Revolve
• Sweep
• Loft
• Boolean Union
• Boolean Subtract
• Boolean Intersect
• Fillet
• Chamfer
• Shell
• Hole
• 3D editing tools

xCAD's standard 3D objects include boxes, cones, cylinders, hemispheres, polygonal prisms, spheres, toruses and wedges. 

Step 3: Create a Simple Example

Let's create a 100 mm × 60 mm × 20 mm mounting plate with two holes.

Step 3.1 — Create the Base

Choose:

Draw → 3D Object → 3D Primitives → Box

Create the box.

Enter:

• Length: 100 mm
• Width: 60 mm
• Height: 20 mm

xCAD allows dimensions such as length, width and height to be entered through the Inspector Bar when creating a box. 

You now have your basic printable solid.

Step 4: Add Holes

Next, create holes through the mounting plate.

Create a cylinder with the required diameter.

For example:

Hole diameter = 10 mm

Position the cylinder so it passes completely through the plate.

Then use:

Boolean → Subtract

Select:

Main Plate − Cylinder

The cylinder is removed from the plate, creating the hole.

Repeat the process for the second hole.

Step 5: Add Fillets or Chamfers

Sharp edges may not always be desirable.

You can use:

Fillet Edge

to create rounded edges.

Or:

Chamfer Edge

to create beveled edges.

xCAD's 3D editing tools include dedicated operations for chamfering edges, filleting edges and shelling solids.

For example:

Select Edge → Fillet → Enter Radius → Apply

You might use a:

2 mm fillet

for a particular edge.

Step 6: Check Your Dimensions

Before exporting, verify that your model has the correct physical dimensions.

Check:

• Length
• Width
• Height
• Hole diameter
• Wall thickness
• Overall size
• Clearances

For example:

This step is extremely important because the slicer can only work with the geometry you provide.

Step 7: Check the 3D Solid

Your model should ideally be a closed, valid solid.

Look carefully for:

• Open surfaces
• Unconnected geometry
• Duplicate faces
• Overlapping geometry
• Incorrect normals
• Non-manifold edges
• Unwanted shells

xCAD's current user documentation also lists tools for 3D Boolean operations, solid/surface conversion, shelling, holes, fillets, chamfers and a 3D Print Check tool.

Step 8: Use 3D Print Check

This is one of the most useful steps before exporting.

When exporting an STL, xCAD provides a 3D Print Check option in supported versions.

It checks for common problems including:

• Non-manifold edges
• Duplicate facets
• Collapsed facets
• Inconsistent normal orientation
• Open edges
• Shells

It can also report:

• Model extents
• Number of facets
• Number of vertices
• Surface area
• Volume

Real-time workflow

File → Export / Save As → STL

↓

Enable the available 3D Print Check

↓

Review the diagnostic information

↓

If errors are reported, return to the model and repair the geometry.

Step 9: Repair the Model if Necessary

If the print check identifies a problem, don't immediately send the file to your slicer.

Go back to the 3D model.

For example:

Problem: Open Edge

Check whether two surfaces actually meet.

Problem: Duplicate Geometry

Delete unnecessary overlapping objects.

Problem: Non-Manifold Geometry

Inspect intersecting solids and rebuild the problematic region.

Problem: Incorrect Solid

Rebuild the geometry using:

Extrude → Boolean → Fillet/Chamfer → Solid

Then run the print check again.

Step 10: Prepare the STL Export

Once the model passes your checks, export it.

Use:

File → Export

and select:

STL

xCAD's STL exporter converts precise CAD geometry into a faceted representation suitable for stereolithography/3D-printing workflows. 

Step 11: Select STL Format

xCAD can provide different STL storage options depending on the version/configuration, including:

• Binary STL
• ASCII STL
• Color Binary STL where supported

For ordinary FDM printing, Binary STL is generally a practical choice because it is compact.

Step 12: Configure the STL Mesh

This is an important step.

xCAD's STL export provides mesh parameters controlling how accurately the original CAD geometry is converted into triangular facets.

The documented controls include:

• Surface Deviation
• Normal Deviation
• Edge Length
• Aspect Ratio
• STL Facets

Why does this matter?

Your CAD model may contain a mathematically perfect circle.

STL doesn't store that perfect CAD surface directly. Instead, it approximates the surface using triangles.

So:

Coarse mesh → fewer triangles → lower file size → less accurate curved surfaces

Fine mesh → more triangles → larger file → closer approximation

Step 13: Update the Mesh Preview

xCAD's mesh parameters dialog allows you to update the generated mesh and review the number of facets and vertices. 

For a curved model:

1. Adjust the mesh settings.
2. Click Update.
3. Check the resulting facet count.
4. Inspect the model.
5. Increase resolution if the curved surfaces look too faceted.

Don't simply use extremely fine settings for every model. Excessively dense meshes can create unnecessarily large files.

Step 14: Save the STL

Choose a filename such as:

Mounting_Bracket.stl

Save it somewhere easy to find, such as your Desktop or a dedicated 3D Printing folder.

Your workflow is now:

xCAD Model → 3D Print Check → STL

Step 15: Alternative — Export 3MF

If your xCAD version supports it, you can also export:

3MF – 3D Manufacturing Format

xCAD documentation describes 3MF export as a 3D-printing format and notes support for information such as units, colors, textures and UV coordinates. 

So you have two common workflows:

Option A

TurboCAD → STL → Slicer

Option B

TurboCAD → 3MF → Slicer

For a simple single-color model, STL is often sufficient.

Step 16: Open Your Slicing Software

xCAD creates the 3D model.

You normally use separate slicing software to prepare that model for your particular printer.

The overall workflow is:

xCAD

↓

STL / 3MF

↓

Slicer

↓

G-code

↓

3D Printer

The slicer translates your model into the layer-by-layer instructions needed by the printer.

Step 17: Import Your STL

Open your slicer.

Choose:

Import Model / Add Model

Then select:

Mounting_Bracket.stl

The model should appear on the virtual print bed.

Step 18: Check the Model Size

This is a very important real-world check.

Confirm that the slicer reports approximately:

100 × 60 × 20 mm

If it shows something dramatically different, check your units and export/import settings before continuing.

Step 19: Position the Model

Place the model on the print bed.

Usually, you want the largest appropriate flat surface touching the build plate.

For our mounting plate:

100 × 60 mm face → Print Bed

This can provide:

• Better bed adhesion
• Fewer supports
• Better stability
• Faster printing

Step 20: Choose Your Material

Select the material you intend to print.

For example:

PLA

Good general-purpose choice for many prototypes.

PETG

Useful when greater toughness or temperature resistance is desired.

ABS/ASA

Useful for applications requiring different mechanical/environmental properties, provided your printer supports them.

TPU

Used for flexible parts.

Always use settings recommended for your specific printer and filament.

Step 21: Set Layer Height

Choose an appropriate layer height.

For example:

0.20 mm

is a common general-purpose starting point for many FDM printers.

For finer detail:

0.12 mm

For faster/coarser printing:

0.28 mm

The actual usable values depend on your printer and nozzle.

Step 22: Set Infill

Infill controls how much internal material is used.

For example:

15–20%

can be suitable for many general prototypes.

For stronger functional parts, you may choose a higher percentage.

Remember that wall/perimeter count and print orientation can be just as important as infill percentage for mechanical strength.

Step 23: Configure Walls

Set the number of walls/perimeters appropriate for the part.

For a functional mechanical component, you may want more walls than for a decorative model.

For example:

3–4 walls

can be a reasonable starting point, but the correct value depends on the application and printer.

Step 24: Configure Supports

Look at your model.

Ask:

Does any geometry extend significantly over empty space?

If yes, support structures may be necessary.

If the mounting plate is completely flat and has simple vertical holes, you may be able to print it with little or no support.

Step 25: Set Bed Adhesion

If the model has a large flat bottom surface, adhesion is generally easier.

Depending on your slicer/printer, you may choose:

• Skirt
• Brim
• Raft

For a stable flat plate, a skirt or no additional adhesion structure may be sufficient depending on the printer and material.

Step 26: Slice the Model

Now click:

Slice

The slicer converts the CAD model into individual printing layers.

For example:

Layer 1
Layer 2
Layer 3
Layer 4
...
Layer 100

The slicer then generates the printer-specific toolpath.

Step 27: Preview the Layers

Don't immediately start printing.

Open the slicer's preview.

Move through the layers and inspect:

• Outer walls
• Holes
• Infill
• Supports
• Bridges
• First layer
• Top layers

Look for anything unexpected.

Step 28: Check Estimated Print Time and Material

The slicer should provide estimates such as:

Print Time: 2 hr 15 min

Material: 38 g

These are estimates and vary according to printer settings.

If the print time is excessive, consider:

• Increasing layer height
• Reducing infill
• Reducing unnecessary supports
• Optimizing orientation

Step 29: Generate G-code

Once everything looks correct:

Click → Slice / Export G-code

The slicer creates the printer-specific instructions.

For example:

Mounting_Bracket.gcode

The G-code contains instructions controlling things such as:

• Movement
• Extrusion
• Temperature
• Speed
• Layer changes

Step 30: Transfer G-code to the Printer

Depending on your printer, transfer the G-code using the supported method, such as:

• SD card
• USB
• Network
• Manufacturer's cloud/software system

Select the correct file on the printer.

Step 31: Prepare the Printer

Before starting:

1. Install the correct filament.
2. Check the build plate.
3. Clean the print surface.
4. Confirm nozzle condition.
5. Check bed leveling/calibration.
6. Confirm the correct material profile.
7. Confirm the correct nozzle size.

Step 32: Start the Print

Start the print.

Do not walk away immediately.

Watch the first few layers.

Check that:

• The first layer adheres correctly.
• The nozzle isn't dragging through the model.
• Material is extruding properly.
• The model isn't lifting from the bed.
• The dimensions appear correct.

Step 33: Monitor the Print

During printing, monitor for:

• Warping
• Layer shifting
• Stringing
• Under-extrusion
• Over-extrusion
• Poor bridging
• Support failures
• Nozzle blockage

If a serious problem appears, stop the print and investigate before wasting additional material.

Step 34: Remove the Finished Part

After printing is complete:

1. Allow the part to cool if appropriate.
2. Remove it carefully from the build plate.
3. Remove supports if present.
4. Remove any brim/raft.
5. Clean up the part.

Step 35: Inspect the Final Part

Compare the physical print with your xCAD design.

Check:

• Overall dimensions
• Hole diameter
• Wall thickness
• Surface finish
• Fit
• Assembly clearance
• Functional performance

For precision parts, use appropriate measuring equipment such as calipers.

Step 36: Make Corrections in xCAD

If the physical part isn't correct, return to xCAD.

For example:

Hole too small

→ Increase hole diameter.

Part too large

→ Correct the relevant dimension.

Wall too thin

→ Increase wall thickness.

Parts don't fit

→ Adjust clearance.

Then:

Modify CAD → Export STL/3MF → Slice Again → Reprint

This is the normal iterative 3D-printing workflow.

Real-World Example: Printing a Phone Stand

Here's a complete practical example.

Step 1 — Create Base

Create a:

100 × 80 × 10 mm

base.

Step 2 — Create Back Support

Draw a profile for the phone support.

Step 3 — Extrude

Extrude the support to create a 3D solid.

Step 4 — Boolean Union

Combine the support and base.

Step 5 — Create Cable Opening

Draw a slot or circle.

Step 6 — Boolean Subtract

Subtract it from the solid.

Step 7 — Add Fillets

Round appropriate edges.

Step 8 — Check Dimensions

Confirm:

100 × 80 × required height

Step 9 — 3D Print Check

Run the available print check during STL export.

Step 10 — Export

Save as:

Phone_Stand.stl

Step 11 — Open Slicer

Import the STL.

Step 12 — Orient

Place the flat base on the print bed.

Step 13 — Set Material

Select your chosen filament profile.

Step 14 — Set Layer Height

Start with:

0.20 mm

Step 15 — Set Infill

For example:

15–20%

Step 16 — Configure Supports

Enable them only where the geometry requires them.

Step 17 — Slice

Generate the layers.

Step 18 — Preview

Inspect the entire model.

Step 19 — Generate G-code

Export the printer file.

Step 20 — Print

Start the printer and monitor the first layers.

xCAD 3D Printing Tools at a Glance

xCAD's documentation specifically lists workplanes, 3D primitives, Boolean operations, chamfer/fillet, shelling, holes and 3D Print Check among its 3D tools.

Complete Real-Time Workflow

PHASE 1 — DESIGN

Open xCAD
↓
Set mm/inch units
↓
Create workplane
↓
Draw 2D profile
↓
Extrude / Revolve / Sweep
↓
Create 3D solid

PHASE 2 — PREPARE

Add holes
↓
Add fillets/chamfers
↓
Check dimensions
↓
Check wall thickness
↓
Verify closed solid

PHASE 3 — PRINT CHECK

Export → STL
↓
Run 3D Print Check
↓
Review topology
↓
Repair errors if necessary
↓
Recheck

PHASE 4 — EXPORT

STL or 3MF
↓
Save the file

PHASE 5 — SLICE

Open slicer
↓
Import STL/3MF
↓
Check scale
↓
Orient model
↓
Select printer
↓
Select material
↓
Set layer height
↓
Set walls/infill
↓
Add supports if required
↓
Slice

PHASE 6 — PRINT

Preview layers
↓
Generate G-code
↓
Transfer to printer
↓
Prepare print bed
↓
Start print
↓
Monitor first layers
↓
Complete print

PHASE 7 — INSPECT

Remove part
↓
Measure part
↓
Test fit/function
↓
Modify xCAD model if necessary
↓
Reprint

The Most Important Rule

Don't think of 3D printing as simply "Save as STL and Print."

The reliable workflow is:

Accurate CAD Model → Valid Solid → 3D Print Check → Appropriate STL/3MF Mesh → Correct Slicer Settings → Layer Preview → G-code → First-Layer Inspection → Finished Part

That workflow helps minimize failed prints and makes xCAD a useful design and preparation stage in a complete 3D-printing process.