Goal: Use CAD to model the wearable sensor's electronics and case
Software: Fusion 360
Prior Experience: essentially none
New Methods:
sketching,
construction lines,
constraints (horizontal/vertical, midpoint, coincident, midpoint, distance),
parametric design,
extrusion,
bodies,
constructions,
import (step file),
rigid group,
joint,
scale,
import (insert derived),
cut (using "extrude" tool)
shell,
fillet,
split,
animate (exploded view),
export (animation video)
Details:
- Doing my best approximation of final product (currently know very little about PCB design)
- Consider this an "artist's rendering"
- For CAD software, went with Fusion 360 for now
- Start by doing some basic experiments with sketching
- Successfully constrain a rectangle and construction lines
- Use 'extrude', to form a rectangular prism to represent the PCB
- Experiment with importing .step files (3D CAD Models) from the internet
- To add wireless capability, import a 3D model of an ESP32 (WiFi/Bluetooth)
- Use 'measure' to get ESP32 model dimensions and use those to parameterize the PCB
- Use 'rigid group' to constrain the ESP32's parts relative locations
- Use 'joint' to constrain ESP32 to location on PCB
- To approximate an IMU (accelerometer/gyroscope), import a 3D model of an Adafruit BNO055 development board
- Remove the PCB, such that only non-PCB BNO055 components remain
- Again, 'rigid group' and 'joint' to constrain BNO055 location to PCB
- Do the same for a USB-C port and a battery
- Scale battery to fit the PCB
- The case is built around the electronics
- It is a rectangular prism with a hole for the USB-C port and a lid
- Critically, the case is parameterized to adjust if the electronics change
- The electronics and case were done in separate design files
- The case file links to the electronics file, updating when changes are made there
- Look up Fusion 360 "insert derived" to learn more about that
- Process for making the case is as follows
- Import electronics design ("insert derived")
- Make a sketch from the top face of the PCB
- Double-sided extrude to make a rectangular prism flush with outer extent of the electronics
- 'Shell' to the outside, leaving a hollow case with a perfectly sized cavity
- Create sketch from USB-C port shape, then "Extrude" to cut port hole in the case
- Use 'fillet' to round the edges of the case
- Use 'split' to separate the case into two bodies (lid and case)
- Convert the case lid and bottom into components (required to animate)
- Create animation of exploded view (in Fusion 360 - see tutorials)
Resources:
- Imported .step files: Espressif, GrabCAD
- HTML templates: HTMAA, OpenAI GPT4
- Fusion 360 tutorials: Autodesk
Files:
[next week]