By the end of week 3, you will be able to:
Manage 3D components in Fusion 360 and perform different types of joints
Design T-slot and angled bracket joints to assemble two 2.5D parts using M3 screws and nuts
Select the proper joint (T-slot or Bracket with captive nut) based on form
Design and assemble free form enclosures (3 faces or more) for a desired propose or function
Design x-slot guides to assemble boxy enclosures
Type: Individual Activity
Description: Build a cardboard model of a simple mobile phone holder
Materials & Tools:
Cardboard: Any Cartoon from nearby mini-market will be more than enough
Pencil and paper: to design the parts of your phone holder
Cutter or scissors
Glue or sellotape
Requirements:
The mobile holder should be designed to rest on a flat surface (Table Top)
Cardboard is the only construction material allowed to build the model
You may use Google Search to find reference models
Reflect & Share:
What are the parts of your model? How did you design them?
Did you design your model for laser cutting? 3D printing? or Both?
How did you assemble and fasten the parts together?
What are the challenges/problems that you faced?
How could you potentially improve the model?
Follow the video tutorials below (in order) to learn how to model, manage, and joint multi-component objects in Fusion 360
Assembly in Fusion 360
Multi-Part Jointing
Deadline: Before Midweek Session
Session Mode: Online via Google Meet
Session Outcomes
Discuss video tutorials and address challenges or problems with the instructor
Participate in a pair learning activity to practice joints modelling and assembly in Fusion 360
Take a walkthrough week assignment description and requirements
Group A1
Group A2
Group U1
Group U2
Group U3
Group U4
Group Z1
Group Z2
Session Exercise
Model & Assemble a Photo Frame in Fusion 360 (View Reference)
(Expand to view Description & Requirements)
Requirements:
Design a photo frame that holds a photo with a size of: 125*80mm, and the frame is inclined by 70 degrees from the desk base (View Reference)
The photo frame is assembled using T-slot technique “2 tabs and 1 screw”, the T-slot dimensions are the same we used in the Midweek self-practice (View Reference)
[Hint 1]: Consider using 3-point rectangle while drawing tabs on the inclined line on the side parts]
[Hint 2]: Use project tool in drawing the frame part, to project side part tabs and screw places for quicker sketching
All your sketches should be fully defined!
Assemble all your pieces using rigid joints in Fusion 360
[Extra] Add patterns on the front frame part!
Complete the exercise and follow the video tutorials below (in order) to learn how to model free form enclosures in Fusion 360
Jointing Best Practices
Project: Make a Mobile Stand with Two Jointing Techniques
Deadline: Before EOweek Session
Mode: Face-to-face @ Fab Lab
Session Outcomes
Discuss video tutorials and address challenges or problems with the instructor
Participate in a pair learning activity to practice modelling multi-face enclosure in Fusion 360
Discuss assignment progress: concept and execution
Session Exercise
Design, fabricate, and assemble a Lantern that has 4 sides, top, and bottom. (View Reference)
(Expand to view Description & Requirements)
Lantern Assembly
Requirements (View Reference)
Use T-slot joint to assemble 4 sides with bottom part
Use X-slot to assemble 4 sides with each other
Use a bracket with captive nut to assemble top part with 1 side
Lantern Body (Laser Cut)
Requirements:
Sketch sides, top, and bottom parts (View Dimensions). All sketches must be fully defined.
HINT: you can copy one side from the other using the "Copy-Paste New" technique.
Create a pattern on the side parts so that the candle light can travel through (View reference for minimum required pattern). For this purpose, use basic shapes: rectangle, circle.. etc then use rectangular or circular pattern tools.
(NO free-form drawings, just basic shapes repeated with patterns)
T-slot dimensions are the same we used in the self-practice videos (View Reference)
Extrude your sketches into a 2.5D parts and assemble all your components using rigid joints in Fusion 360
Export your lantern faces in *.DXF format (USE KERF -0.15)
Finally, prepare your *.DXF files in Laser Cutter software and fabricate using Laser Cutting
Bracket Joint (3D Printed)
Requirements:
Create a 3D model in Fusion 360 for the a bracket with captive nut (You may follow the video tutorial in the EoWeek Self-practice)
[Hint] You may need to resize the bracket length based on the pattern you choose in the laser cut sides (the holes may show the bracket so you may need to make it a bit smaller)
Assemble the bracket with 1 side and top part
Export your singular part in *.STL format
Finally, prepare your *.STL file in Cura Software and fabricate using 3D Printer
Design a model of a pen and pencil holder that may rest on a flat surface (Table Top). Be creative and come up with the coolest pen and pencil holder!
Description:
Using Fusion 360, design the pen and pencil holder so that it consists of multiple 2.5D parts (at least three) and assemble them using proper joints. Fabricate the 2.5D parts using Laser Cutting
Your pen and pencil holder should contain at least 2 compartments on one base, with at least one of them closed with 4 faces, to hold different stationary items (For example, a compartment for pens and the other for sticky notes or paper clips)
Select the proper joints that fit your form (T-slot, and/or Bracket with captive nut). Design the joints using Fusion 360 and fabricate it using 3D Printing (Only if you decide to use a bracket with captive nut)
For inspiration, conduct Google search using the keywords: Laser Cut + Pencil Holder
Technical Requirements:
The model is designed and assembled using Fusion 360
The model contains at least 2 compartments on one base, with at least one of them closed with 4 faces
The model utilized at least one jointing technique (T-slot and/or Bracket with Captive Nut)
The model is fully designed for fabrication using Laser Cutting (except of brackets using 3D Printing)
The parts of the model are prepared for fabrication by applying proper fabrication parameters
The parts are fabricated and assembled using M3 screws and nuts
Make sure to document your Assignment for Week 3 in the Maker Journal covering the following requirements:
Process Documentation:
Ideation: Describe how you came up with the idea for the model. Were you inspired by a certain reference? or did you custom design it to fulfil a certain personal need?
Tools: Describe software tools and machines that you used in your assignment
Design: Describe how you designed your pen and pencil holder. Which types of joints did you use? How did you change the appearance of the model?
Implementation/Fabrication: Describe how you exported the design files from Fusion 360, prepared the files for fabrication, and produced the design using Laser Cutting and 3D printing. And most importantly, show us the final outcome of the assignment
Media: Provide supporting images and videos to demonstrate the design and implementation processes
Learning Documentation:
Learning from Mistakes: Describe problems and challenges that you faced, and briefly describe solutions
Community of Learning: Highlight an advice or idea provided by a peer or an instructor that helped in solving a problem or a challenge. Or an advice that YOU provided to help your peer(s)
Progress Review Deadlines:
Jan 13th, 2025 @4:00 PM for Design Documentation
Jan 20th, 2025 @4:00 PM for Fabrication Documentation