Week 3 - Journal

This week contains 3 main milestone activities:

• practice a 3D model of pen holder through Fusion 360 to discover the 3D features of the program.

• Then we go through a lecture to talk more details about the fabrication using laser machines and the software used to identify the ideas Fusion 360.

• on the other hand, the Midweek and Eoweek Self-Practice helped me to understand well the software programs which have been used to guides below to understand how to manage 3D components in Fusion 360 as Extrude, sweep, loft, revolve and perform different types of joints, 3D features, and sub-features to create 3D objects.

• Also, to practise these tools I made a model of two objects: Design a Pen and Pencil holder to be placed on a desk or a table, a Fidget/Stress relieving Object , and a LEGO minifigure using Fusion 360.

• Then, I discussed my chosen files with the instructor in the Eoweek session to show up the thoughts and difficulties that could be faced during the week. last but not least I will enter the Fab lab to cut it in the next week.

For the software:

• All the models are sketched using Fusion 360.

• Using ultimaker cura 4.10 to manipulate and set printing properties.

For the Machine:

• Using 3D PRUSA printing machine to fabricate a 3D object.

For the Materials:

• Using the 2mm Silvar pla filament.

1. For Fidget/Stress relieving Object Drawing Steps:

it contains 4 parts, I draw the ball cover base part as follows:

a. beginning with a sphere with R55.

b. then from construct panel >>offset plane>>with height=87.64,, in order to make it as a cutter plane by choosing then a modifier of split the body.

C. press modifier shell with R=4.5

I draw the ball connect part as follows:

a. a sphere with R=50 , then from construct panel >>offset plane>>with height=49.

b.open the skecth on this constructed plane and draw a rectangle 30 *30 with height=39.72.

c.then make another planes inside this rectangle to draw the holes inside.

I draw the Hook connector part as follows:

a. I draw the half profile of the pillar in this shape with Revolve.

b. then from construct panel >>offset plane> and choose the end plane height =15.

c. draw a rectangle sketch on it >>30*30 with H=45.

d. then by choosing the side of this object to draw a rectangle 15*20 to make them as holes in object. by opening a sketch on the faces of it make a center line down to 5.36.

e. above this holed rectangle, by pressing the upper face of the shape and draw a sketch of a cylinder down with a height 5.36.

I draw the Hook part as follows:

a. I draw the base as a box and for the pillar, i draw half profile of the pillar in this shape with Revolve.

b. to make the arc part, I choosed the front sketch on the shape, then from the center of the arc with a H=44.52+5+14.2/2, from this point I draw a half arc to the lower point of the shape.

c. then I draw a profile tangent to this arc with a profile rectangle 14.2*20, then with Sweep i choosed the profile of rec. and the arc as a path then I made a mirror of this shape, to be constructed.

2. For the LEGO minifigure Drawing Steps:

a. for the Head part: i draw the half profile of the head and an axis to construct this part with a revolve feature.

b. for the Torso part: I draw three plans, on 0.00, 1 and 13.7. to use the loft along the higher two planes and the extrude for the lowest two planes. then I choose the modifier shell with R= 1.6 to make the shape empty ,, by choosing to sketch the triangles inside the shapes to make the supports with Dim 0.8 and 1.2. then I chosethe sided faces to make the circular holes with H=9, at the end i made a fillet to all the sides of the shape with R=1.6.

c.For the pants part: I draw the side profile shapes the two cylinders and the base parts, then by using extruding them with Distance =14.1. then choosing to draw on this part above face sketch XY and tracing the shape mentioned in the worksheets, finally extrude it with H=4.8 and make a cutter offset plane to make the sloped angle.

D. for the Legs part: first choosing the side sketch to draw the leg profile the circles and rectangle shapes, then extrude it with 7.38. i made the holes in that object by choosing the faces and draw sketches on the same direction of the face. then I draw a circle and a small square to make the fixation parts in that shape.

E. the Hat part: I draw a spline with a half profile then Revolve it to make the hat part.

F.For the Arm part: with using sweep and Pipe features I draw the profile of a circle and a spline as a path of the hand. then making a cylinder connector and a hand part by using extrude.

3. For the pen/pencil (Proposal 1) Drawing Steps:

a. for the bolt part : I draw a front sketch the profile of the half shape with line and an axis in order to use them to make a Revolve feature. (H=45mm,W=30mm, L=40mm, holes=5,7mm)

b.Then i choosed the plane of the bottom bolt then I draw a Box in the XY sketch on this plane with Dim 40*40 then with the Extrude Sub Features (CuT method) i draw a circle R= 2.5 mm on the drawn rectangle face and cut this part.

C. After that I draw 3 main planes one on the bottom face of the drawn rectangle and then I made a construct plane down to 6 and 10 mm from it with construct panel >>offset plane. then with using the Loft feature I choose the first two planes then the others to make it.

D.then to make the base I draw a box 30*40 mm from the plane base of the nozzle of the shape, then Champered it. and draw spline on its face then using pipe R =0.2mm to make its thick.

E. then I convereted all to be components and make an appearance metal effects for them.

F. press right click on the final object and save it as .STL binary to be prepared the cura program.

4. For the pen/pencil (Proposal 2) Drawing Steps:

a. for the main body of the holder, i used the loft option to connect a two planes but in a different dimensions (33*30mm),(40*35mm) and positions , to make it as a twisted output object. With drawing a plane offset from the base 0.00 plane H=15mm. then with using Shell option to make a thick R=0.2mm. i Repeated this step with using the shape second plane sketch and add another one above it with distance 16 mm. then using the champer option to cut from the body on one side.

b. for the holder hand I used a sweep feature with a circle profile R=0.2mm and I draw the path spline on the face of the main holder body.

c. then I draw on each body planes some polygon sketches and i used Extrude Cut option to make holes in the object.

Yes, through the midweek and Eoweek sessions; we discussed the video tutorials and address the problems i faced with my instructor.

While practising the midweek Videos:

I faced some problems through the Sweep Features as the object output gives me some errors in its construction. Also the output is full of holes.

the solution was to modify the points of the rail spline and the dimensions of the profile too. Also the position of the profile whether perpendicular or parallel.

Also to make a subtracted pattern in the revolve Vase model. i faced some problems to circular pattern the cut parts. As the program couldn't make this action and put me in the error command. the solution was that checking the number of the repeated parts to not be intersected in the output.

While practising the EOweek Videos:

The animation theme in objects when moving them is locked. The solution was to make any part as a ground to be fixed around it.

While visiting the Lab for printing:

I got a problem with my model, the attached pictures captured it. i did not put any infill in the STL file, as I did not want the machine to make a bridging lines between model but this results in weaken the base of the model. so the instructor Amany that was in my slot advised me to the following solution.

Solution was to raise the infill to 20% and it goes well , but I had to minimize the model and raise the profile up to 0.3 to track my slot.

After printing the thing I thought about happened as the machine put some bridging lines between the circle (Stringing), so the specialist Noha advised me to cut it and use a sand paper to clean it up. Also she learned me more about Stringing issues and the solutions of it by adjusting the Retraction distance and speed.

Practicing the Tutorials through making the Lego parts as showed in the video.

Personalizing my minifigure and give it a character.

I also watched some videos about another 3D Features and how could we use it.

i tried some trials about how to make the model lighter in weight and time during printing. i made three options: Default Shape no holes and big thick 18 Hrs, With holes 8 Hrs, and With small Shell thick 11 Hrs.