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This paper describes the implementation of a project-based learning course in which students develop skill sets in critical thinking and 3D design and printing. The design and development of the course and the lessons learned from student participation in the course as they developed 3D solutions to authentic real-world problems are discussed. Results indicate that student grouping techniques, in-class work time, and support with 3D design and printing were important to the successful implementation of this course. Moreover, students needed more support thinking about the problem and the importance of their research in the design process.