112.1.3 - CAD/DFM

Design Software

What is "CAD"?

CAD stands for Computer-Aided Design, and typically refers to a piece of software (program/app) where you create digital models or representations of physical objects/systems
For this course and many courses continuing into your program, you will primarily be using Mechanical CAD software, but it may make sense at various points in your education/career to learn and adapt to new & different types of CAD software. The best practices you will learn in this course are relatively universal, so transitioning or learning new CAD/other software should be viewed as a regular occurrence and not something to dread, prolong, or avoid.
For this course, the CAD software we will use is called Fusion 360, which is a product from the company Autodesk, a software company based in the US. There are several reasons we will be using Fusion 360:
- FREE for students & educators, including all advanced features/options (ex: generative design), without limits
- Cloud Data Management, meaning you can log-in to Fusion 360 account on any computer at any time and have access to all your files (exporting files to "local" storage is still possible, but cloud is default)
- Collaborative Workspace, meaning you can easily work on & share files with anyone else who uses Fusion 360
- Unified CAD/CAM/CAE/PCB, meaning you can use one piece of software to perform a wide variety of CAD, Computer Aided Manufacturing (CAM) & Computer Aided Engineering (CAE) functions, as well as Electronics/Printed Circuit Board (PCB) design & manufacturing
- Greater Accessibility for those who do not have high-end computers at home, as Fusion 360 can run in a browser on even a Chromebook

Why use CAD?

CAD more than anything is a visual communication tool that allows you to very precisely illustrate what you are trying to do or make to yourself or your customer, before you make it. Additionally, using CAD to design 2D & 3D objects has many advantages over both traditional, hand-drawn designs, as well as not drawing anything at all:
- Improved Quality & Efficiency
  - Computers draw perfect lines, curves, & geometric shapes & objects to exact specifications effortlessly
  - You can quickly & easily adjust any & all dimensions and features of a CAD model
- Easier & Clearer Communication
  - Allows you to show someone in exact detail what you are designing, as well as illustrate potential problems with your design in relation to other objects/environments
- Easier Manufacturing
  - You can directly use the geometry within your design to create required commands for computer-controlled machines using "CAM" (Computer Aided Manufacturing) software

The History of CAD

Early Roots (1950s–1960s):
- CAD began from numerical control and computer graphics research, with milestones like Hanratty’s PRONTO and Sutherland’s Sketchpad laying the foundation for interactive digital design.
Commercial Emergence & 2D CAD (late 1960s–1970s):
- Early commercial systems such as DAC-1, Applicon, and Computervision digitized drafting, making computers practical tools for 2D design and engineering documentation.
Move toward 3D, Solid Modeling, and Parametric Design (1980s):
- The 1980s introduced 3D modeling, solid geometry, and parametric design through systems like CATIA, Unigraphics, and Pro/ENGINEER, while AutoCAD made CAD affordable on personal computers.
Consolidation, Mid-range CAD, and Desktop 3D (1990s–2000s):
- Affordable 3D systems such as SolidWorks, Solid Edge, and Autodesk Inventor emerged, integrating CAD with simulation, PDM, and CAM while legacy firms consolidated.
Modern CAD & Today:
- Modern CAD combines cloud, AI, and collaborative technologies, with AutoCAD expanding into web/mobile platforms and Unigraphics evolving into Siemens NX as a high-end design suite.

Types of CAD

Architectural CAD

- Used primarily in floor design for architecture and building engineering.
- Split into 2d line modeling and 3d large modeling subsets.
- Examples include:
  - Autodesk AutoCAD
  - Autodesk Revit

Mechanical CAD

- Used primarily in the design, engineering, and manufacturing of precision hardware for many industries
- CAD models are typically solid body models, which are easily usable with most Computer Aided Manufacturing (CAM) software for most manufacturing processes
- Examples include:
  - Siemens NX & Solid Edge
  - Dassault Systems SolidWorks
  - Autodesk Fusion

Graphical CAD

- Used primarily in entertainment, marketing, and graphic design industries and applications
- Oftentimes models are strictly digital assets, and are not easily manufacturable in physical formats without redesign, significant modification, and/or conversion
- Examples include:
  - Autodesk Maya
  - Autodesk 3DS Max
  - Blender

Other CAD Types

- In total, there are over a hundred different CAD software solutions in existence/use today, and more are being created/developed on a daily basis
- Hyper-Specialized CAD Types:
  - PCB
  - Electrical
  - Civil

CAX = Computer Aided Everything

Autodesk Fusion

FAQ, Tips, & Tricks with CAD (Fusion 360):

Fusion 360 uses cloud-based file storage, meaning all your files are automatically stored on a remote server. The benefit with this is that if you log in to your Fusion 360 account from any computer, you will be able to access and use all your files without the need of a Flash Drive or other physical file storage device.
- If you need to "download" any of your files from your Fusion 360 account to a local computer/device, click on "File", then "Export" and follow the window instructions
Currently, you must have internet access in order to log in to the downloaded version of Fusion 360. After logging in, you can lose internet access and still be able to work in Fusion, your files will just not be uploaded immediately. So if you're going somewhere that doesn't have internet access, log-in before you go there, keep the program open, and you'll be able to use Fusion in "offline mode".
If you have you used other CAD software in the past, and are unsure about Fusion and how they are different, then consider checking out the following transition guides from Autodesk, for previous SolidWorks and MasterCAM users:
- SolidWorks Transition Guide
- MasterCAM Transition Guide
- If you a self-learner and want direction towards some resources to practice on your own and "get ahead", check out these options:
  - YouTube Video Playlist: "Learn Autodesk Fusion 360 in 30 Days for Complete Beginners!", by Product Design Online [34 Videos]
  - Tutorials for Fusion 360 (by Autodesk): Fusion 360 Fundamentals
  - CAD/CAM/CNC Projects, Tutorials, and Resources: Titans of CNC Academy

There are many computer stations within the various buildings and rooms on campus that you have access to use as a student. We recommend primarily using the Computer Lab in Room 120 in B24, as that is where your instructors will be the majority of time for this course. That being said, it is highly encouraged to also use Fusion 360 outside of available class/lab hours for additional practice & experience.
There are two main ways you can use Fusion 360 outside of class:
1. 1. Download & Install Fusion 360
    - If you have a relatively new computer (> 5 years old) with decent processing power, this is the option we would recommend
    - Autodesk lists Fusion 360's minimum & recommended computer specifications here: System Requirements for Autodesk Fusion 360
    - If you are looking to get a new computer, aside from the laptop listed in the syllabus tool list, there are some decent recommendations here: "What Computer to Buy for CAD & CAM", by NYC CNC
  2. Run Browser-Based Fusion 360
    - If you have an older (> 5 years) or less powerful computer (ex: a Chromebook or other cheap laptop), this would be your best bet to use Fusion 360 effectively outside of class. The reason for this is that the "heavy lifting" processing power of using Fusion is done on the cloud (Autodesk's servers), and the only processing power your computer needs is to be able to run a web browser (ex: Chrome, Firefox, Edge, etc.)

Creating & Verifying your Autodesk Educational Account

The most-used piece of software for this course will be Autodesk Fusion 360, a integrated CAD/CAM/CAE software. In order to use Fusion 360 to its full capability, you will first need to create an Autodesk Educational Account. The following steps outline how to do so:

Go to this link: "Get Educational Access", Autodesk.com
Fill in the on-screen information prompts to create an Autodesk account, using your student email (ex: lastname1234@students.cptc.edu)
- After filling-out the prompts, you will likely be require to go to your student e-mail to confirm/verify
- When it asks for an expected Graduation Date, enter in a date as far into the future as it allows you (ex: December, 6 years from now)
You will likely be asked to verify/prove you are a student in order to be eligible for educational use of the software (free, fully-featured, 1-year, renewable license) - follow the process and ask for help if you get stuck

PrusaSlicer

The next most-used piece of technical software you will utilize for this course is called "PrusaSlicer", a free Computer Aided Manufacturing (CAM) software designed for programming 3D Printers.
Just like Fusion 360, PrusaSlicer is or can be installed on all computers available to you as a student at school, but our recommendation is to utilize the Computer in the MET Lab spaces in B24, as that is where your instructors will be the majority of time for this course. Also just like Fusion 360, the more you use and practice with PrusaSlicer, the better you will be with 3D Printing
PrusaSlicer has much less computer processing constraints than Fusion 360, and should be able to run on most any computer.
- - To install on your computer, click on the appropriate download link for your computer/OS at this webpage: Download PrusaSlicer
If you run into any issues when using PrusaSlicer or want to dive deep into its various features, check out the resources here: Prusa Knowledge Base: PrusaSlicer

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