1. Creating the CAD Model:

• First, I took the measurements from an iPhone 15 Plus and sketched them in Fusion 360.

• I then designed the borders where the edges of the case would bend up. To achieve this in CAD, I used the Flange tool, followed by the Bend tool to bend the borders into place, creating the basic shape of the phone case.

2. Creating the CAM Process:

• Once the design was complete, I needed to set up the CAM process for the waterjet to cut the metal sheet.

• I selected the 2D cutting waterjet program and highlighted the necessary holes and borders for the cuts. After this, I simulated the cut to ensure everything was aligned and would be processed correctly once the waterjet was ready.

3. Simulating the Process with Paper:

• Since the waterjet machine was unavailable, we decided to simulate the process using paper to understand how the cutting and bending would work.

• I started by cutting out a larger version of the iPhone case shape from a piece of paper, ensuring it was bigger than the actual measurements.

4. Cutting and Shaping the Paper Model:

• I then carefully cut out the holes for the power button, volume buttons, action button, charging port, and speaker holes using a box cutter.

• Using a ruler and pencil, I drew the bend lines on the inside of the paper where the borders would fold.

• I used the ruler to guide the folds and simulated the brake forming process, bending the paper along the lines.

5. Final Assembly:

• Once the paper was bent, I taped the corners together to keep the shape from unbending, simulating the final form of the iPhone case.