Assignment:
This week's assignment is to make a design of a pen & pencil holder on Fusion 360 software and prepare it for 3D Printing.
Inspiration:
I'm in love with all DISNEY movies
I browsed google.com and Pinterest website to get inspired, Then I decided to make a Wall-E character as my pen holder.
Software:
We previously used Fusion 360 in 2.5D designing but This time we'll be using Fusion 360 in 3D designing to create more complex shapes.
We used Ultimaker Cura in week 1 to slice a chosen model and generate the gcode required by the 3D printer. This time we'll be using the program for the same function but we'll upload our own model.
Machines: 3D printer: Prusa i3 mk2
Material: PLA generic White filament
The Design Process: I've used Fusion 360 software to create a Wall-E model, I found These Pics references so I followed up them to get some help, but I've changed and skipped some steps.
The main Body Design process
First: I sketched the body and extruded it -two sides-, Then I changed its color using the Appearance menu.
Second: I started to sketch the details like Y-shape on the sides surfaces, after I drew the Y-shape, I extruded it -as a new body-, mirror it on the left side through the ZY plan, then joined the two bodies, and then I cut them out the main body cube.
Finally I started to sketch more details
I drew this line sketch and extruded it -as a new body-, mirror it on the left side through the ZY plan, joined the two bodies then extruded it -as cut from the main body-.
I drew a circle, extruded it, champer its edge then mirror it on the left side through the ZY plan.
I drew this line sketch and extruded it, then mirror it on the left side through the ZY plan.
Front side Design process
On the front side: I sketched a rectangle, then extruded it -as cut-, then I changed tis side appearance to a grey color.
To make these groves: I drew a rectangle and then I create a rectangular pattern to make 3 groves. Then I extruded them -as cut-.
Panel Design process
For the main Panel part: I drew a rectangle shape on the front side and extruded it -as a new body.
Then I drew some small rectangles for the buttons panels.
To make the rectangles buttons: I draw a small rectangle and create a rectangular pattern to repeat the buttons then I extruded them -as cut- to make the buttons grove.
I created two PIPES using the rectangles' lines as a path, and then I cut them out to make a grove.
After that I extruded -as cut- the left rectangle.
To make the round buttons part: first, I extruded the rectangle area, then I drew a circle, extrude it, then filt it. Finally changed its color to red using the Appearance menu.
TADAA! ...... The panel is finished!
D-shape Design process
To make the D-shape: I drew a rectangle on the left side, then extruded it, then sketched the D-shape line, after that, I used the SPLIT feature to remove the excess part that I don't need. Don't just delete it, go to the dropdown list from the body and select remove.
After that, I offset the line and extruded it -as a new body-, mirror it on the left side through the ZY plan, and then joined the two bodies and cut them out of the D-shape body.
The back side Design process
First: I drew a rectangle on the back side of the D-shape surface, then extruded it and cut it out of the D-shape body.
Second: I divided the back surface into two parts, then extruded the below one.
Then I offset the rectangle line, and extruded it -as cut-.
Third: I drew a rectangle and then I create a rectangular pattern to repeat it into 4 rectangles. Then I extruded them.
Finally, I drew some detail on its side, extruded it, mirror it on the left side through the ZY plan, joined the two parts.
To make the diagonal part: I drew a line using the 3D sketch feature, Then I extruded it
then started to sketch on its surface a rectangle, then Copy/Paste that rectangle to make it 4.
I used the edge line as a path to make a pipe, then I split the pipe through the rectangles' edges, then Copied/pasted these parts.
The back pipe Design process
To make the back pipe part: First, I sketched the half of the middle pipe, then I used REVOLVE feature to make it rounded 360,
for the top pipe, also, I sketched half of it then extruded it, champer the edges.
Then REVOLVE the middle top pipe to make it rounded 360, then I copy/paste the top part,
finally, mirrored the whole part through ZY plan.
The Top Design process
To make the top:
first: I draw the rectangle sketch on the back surface, then I extruded it -two sides-.
second: on the top surface, I offset the rectangle sketch line and extruded it -as cut- to the top body surface.
Third: I drew some rectangles on the bulk body's edges and, extruded them -as a new body-, then cut them out.
To make the top rail:
After I've finished cutting the bulk body, I started to fillet the edges, the inner, and the outer.
Then, I used the rectangle line as a path and create a PIPE to make it looks like a rail around the top.
The Base Design process
To make the base: first, I used the CHAMPER feature to champer the edge, then I draw a rectangle on the backside, extruded it
Then, I drew a rectangle on that surface, extruded it -as a new body- then cut it out of the base body.
I drew the line sketch on the left side, extruded it -as a new body- then cut it out of the base body.
I used the CHAMPER feature to champer the front edge, then I used FILLET features in the base's other edges.
I made the pen holder hole, I drew a rectangle then extruded it - as cut-.
some Aesthetic parts
I drew a rectangle, then extruded it
After that, I drew a double lines, repeat them using rectangular pattern, extruded them -as cut-.
finally mirror the whole part to the right side through the ZY plane.
I used the Text tool to write WALL.E and the circle around E letter, then I extruded them -as cut-.
WOOOH! ...... The WHOLE body is finished!
One Part is left!
The Eye Design process
To make the Eye main body:
First: I drew the wing line, then extruded it, after that, I offset it, and then I extruded the offset -as cut-.
Second: I drew a big circle and extruded it, then offset it and extruded it -as cut-.
also, I drew a small circle -as an aesthetic part-, extruded it, then offset it and extruded it -as cut-, finally Copy/Paste it to get 3 circles.
Third: I drew 2 small circles, extruded -as cut- the face between the 2 circles and the offset circle. Then extruded the face between the 2 small circles
I used the DRAFT feature to make the eye hole from two circles, and I changed the angle to get a narrower hole.
the Eye's back: I offset the wing line, then extruded it -as cut-.
After I finished the eye model I mirrored it and joined them together to make two eyes.
YAAAAY! .... The WHOLE model is done!
It was EXHAUSTING but WORTH IT!
I import Wall-E (.stl) file into Ultimaker Cura software. I set up my model in the software. Then I start adjusting the scale of the model (I scaled it 250%) and position it on the virtual printer bed. Then specify my printing preferences for the object. The last step would be exporting the GCode for the 3D printer.
Material: PLA
Printing temperature: 215.0
Profile: Draft - 0.3 mm
Infill: 10%
Support Placement: yes (shown in pics)
Adhesion: No (the surface area touching the plate is wide enough)
Time: 1h,11 min.
Grams: 17gm
I exported my design file as (.stl) file, then I imported it in cura software, set my parameters then exported the gcode for D printing, after that, I put them on the printer's SD card, I followed all the fabrication steps (which are unloading the filament, loading the filament color I like, pre-heating the printer bed, then choose my file to be printed).
The FabLab specialist helped me a little with the steps, also he recommended heightened the fabrication speed up, so he heightened it up 150%, so it took 56 min rather than 1h 11 min.
sadly, I couldn't record the whole process 'cause I was in a rush
The FabLab specialist recommended heightened the fabrication speed up, so he heightened it up 150%, so it took 56 min rather than 1h 11 min.
While slicing my model in cura, when I scaled it down below 250% some parts in the eye model didn't appear so they wouldn't be printed, the fablab specialist recommended editing these parts in Fusion 360, or keeping the 250% scale parameters.
The aim of this assignment covers some important points that will help me in the final project:
Being able to use 3D modeling tools in Fusion 360.
Exploring and utilizing Fusion 360's features to make a complex 3D model.
Make sure that the thickness of the offset parts, more than the printer's nozel thickness, so that if you scaled your model down, you don't miss some parts in the printing fabrication.