WEEK 02 Computer-Aided Design

INTRO:

Throughout my educational and professional career, I have worked with a wide range of design and modelling software, covering graphic design, vector illustration, and 3D modelling. Each of these tools serves a different purpose, and I have had varying experiences with them. Below are my reflections on some of the most recent ones I have used:

IcemSurf

IcemSurf is a highly specialized tool used in the automotive industry for precise surface modelling. It is extremely powerful, but also incredibly difficult to learn due to its outdated interface, lack of online resources, and very high cost.

Alias

Alias, I also used for automotive (surface) design, is a more user-friendly alternative from Autodesk. It offers extensive learning materials, making it easier to get started compared to IcemSurf.

Revit

Revit is an engineering and architectural tool widely used for BIM (Building Information Modelling). It is excellent for version control and collaboration across multiple disciplines. With abundant online courses and resources, it has become the standard in modern architectural and civil engineering projects.

Rhino + Grasshopper

Rhino, especially with its Grasshopper extension, is an incredibly powerful tool for parametric and organic design. I used it in the past but haven’t worked with it in the last decade. The good thing about Rhino is that once you purchase a license, it is yours forever, making it more accessible compared to Autodesk’s subscription-based software.

3ds Max

During my architecture studies, I used 3ds Max extensively for modelling and rendering. While it has plenty of online tutorials, the learning curve is steep, and rendering times were often painfully long—sometimes taking over 24 hours. In recent years, I found Corona Render to be a more user-friendly alternative to V-Ray. However, like most Autodesk products, 3ds Max is expensive and requires a subscription.

SketchUp

SketchUp has evolved from a standalone software to an online-based tool. It remains an intuitive program where you "draw" in 3D, making it excellent for quick visualizations. It’s a great tool for conceptual modelling or communicating ideas to clients and fabricators. However, its simplicity comes with limitations, and navigation can sometimes be frustrating (I remember getting stuck between the walls all the time).

AutoCAD

I mastered AutoCAD early in my career, but I now find it increasingly obsolete. It essentially mimics traditional drafting on a computer, with minimal automation. Furthermore, Autodesk’s expensive subscription model makes it less appealing as alternative tools become more advanced and accessible.

Adobe Suite (Photoshop, Illustrator, InDesign, etc.)

Adobe’s subscription model provides access to powerful tools with limitless creative possibilities. With a vast library of tutorials, almost anything can be achieved in terms of image editing, vector design, and layout creation.

Photoshop is a powerful raster-based tool for editing, retouching, and manipulating images.
InDesign is a layout design software used for creating print and digital publications like magazines and brochures.
Illustrator is a vector-based design tool for creating logos, icons, illustrations, and scalable graphics.

CorelDraw

Is basically Illustrator but from another company, often praised for its user-friendly interface and flexibility in layout design,

MY APPROACH THIS WEEK

One of the biggest challenges with many of these software tools is accessibility. Many of them have expensive licensing fees, and I have lost access to several programs after my student licenses expired.

For this reason, I have decided to focus on learning free and open-access tools moving forward. This week, I started with Fusion 360 for modelling and basic rendering. Later, I plan to explore Blender for animation and simulation.

Additionally, I downloaded FreeCAD, but I will revisit it later as I progress in my learning.

By shifting towards free and accessible software, I aim to develop skills that are not dependent on expensive licenses while still maintaining high-quality design capabilities.

2D & 3D:

FREECAD

SREP-BY-STEP GUIDE TO DRAW THE FABACADEMY LOGO IN FreeCAD

1. Start a New Project and Set Up the Workspace

Open FreeCAD and create a New Project.
Select Create a Draft from the upper menu.
Drag and drop the image of the logo into the workspace to use as a background.
Open Appearance settings and adjust the Transparency for better visibility.
Switch to Top View for easier drawing.

2. Create the Base Shapes

Use the Circle tool from the upper menu to draw a circle.
Apply the Downgrade option to convert it into a wireframe.

3. Draw and Trim Lines

Use the Polyline tool to draw straight lines continuously. (Press Escape to stop.)
If any lines extend outside the circle, trim them:
- Select the part of the line you want to keep.
- Press Trimex, then select the cutting object (in this case, the circle).

4. Add Other Shapes

Use the B-Spline tool to trace around the contour of the logo. (Click to create points, press Escape to stop.)

5. Define the Center and Create Arcs

Draw a centerline:
- Enable the Snapping tool for centers.
- Select the Line tool and hover over the circle until the snapping symbol appears.
- Click to place the centerline.
Remove the circle and use the Arc function:
- Select the middle point marked by the centerline and two other points to define the arc.

6. Final Adjustments

Select all objects and use the Upgrade function to group them into a block.
Rotate the block around the center point using Copy.
Delete the guide line.

7. Your FABACADEMY logo is now complete!

FUSION360

YOUTUBE TUTORIALS:

Product Design Online @ProductDesignOnline

https://www.youtube.com/@ProductDesignOnline

Lars Christensen @cadcamstuff

https://www.youtube.com/@cadcamstuff

FabLab Benfica @fablabbenfica9815

https://www.youtube.com/@fablabbenfica9815

SOME OF THE PROBLEMS:

Learning a new 3D program is not an easy process. Even with the best tutorials, there will always be things you miss: important details that beginners might overlook or changes in updated versions that make certain steps unnecessary.

Here are some problems I encountered while following Lars’ tutorials and solve them thanks to FabAcademy Global Open Time:

When creating this object, I wasn’t paying attention. While extruding, I accidentally chose New Body instead of Join. Because of this, I couldn’t create a fillet between the two separate bodies. To fix this, I used the Combine tool to merge them, and then I was able to apply the fillet I wanted.

After mirroring this object, Lars moved the Extrude feature in the timeline after the Mirror, and it worked for him.

However, I had to edit the Extrude operation and manually add the new mirrored object that it passed through.

MY 3D DESIGN PROCESS

SREP-BY-STEP GUIDE TO MODEL A REWARD MACHINE:

1. Start a New Project and Create a Sketch

Open Fusion 360 and start a New Project.
Click on Create Sketch and select the plane you want to draw on.
Tip: If you hover your cursor over a tool, Fusion 360 will display an explanation of its function.

2. Draw the Base Shape for Revolving

Use sketching tools from the top toolbar (e.g., Line, Arc, Circle) to create your desired shape.
Ensure all lines are black, meaning they are fully defined and won’t move by accident.

3. Use the Revolve Feature

Click Revolve from the Create menu.
Select the profile (your sketch) and define the axis around which the shape will rotate.

4. Add a New Component

Click Create > New Component.
Pay attention to the browser on the left, as components can be nested within others or created as separate components.

5. Create an Offset Plane for the LED Panel

Click Construct > Offset Plane and set the distance from the main body.
This will create a new sketching surface for the LED panel.

6. Sketch and Extrude the LED Panel

Draw the shape of the LED panel on the offset plane.
Use the Extrude tool to extend the shape and attach it to the main body.

7. Add Fillets for Smoother Edges

Click Modify > Fillet and select the edges you want to smooth.
Enter the desired fillet radius to round the edges.

8. Create a Hole Using Another Component

Create a new sketch and draw the shape of the hole.
Use the Extrude tool to cut into the main body.

9. Use the Combine Feature for Cutting

Click Modify > Combine.
Select two bodies and use the Cut operation to subtract one from the other.

10. Render the Model

Switch to Render Mode (upper-left corner).
Apply materials and adjust render settings for a realistic finish.

BLENDER

YOUTUBE TUTORIALS:

ANIMATION

FILES

The .FCStd file extension is the native project file format for FreeCAD. It stores a complete 3D model, including parametric history, parts, sketches, and assemblies, allowing users to modify designs efficiently.

FAB_ACADEMY_LOGO.FCStd

The .dxf (Drawing Exchange Format) is a file format developed by Autodesk for enabling data interoperability between different CAD software. It contains 2D or 3D design data and is widely supported by most CAD applications as well as vector (like Illustrator) Neil mentioned to stay away from this format if possible, and I think that was why:

Inconsistent Formatting Across Versions: DXF has many versions (e.g., R12, R14, etc.), and not all software supports every version equally well. This can lead to incompatibilities, causing data to be misinterpreted or lost when opening or exporting between different programs.
Complexity of Data Structure: The format is quite verbose and text-based, with lots of metadata and parameters embedded in the file. As a result, when exporting complex drawings, the DXF file can become cluttered with extra data or unnecessary layers, which makes it harder to cleanly transfer the data between applications.

Despite these challenges, DXF is still widely used because it serves as a standard for 2D vector data exchange. The best way to avoid the "messy" side of DXF is to use a specific version that's supported by your target software and avoid exporting unnecessary elements.

FAB_ACADEMY_LOGO.dxf

The .f3d file extension is a Fusion 360 archive file format. It stores 3D design data, including parametric history, components, sketches, and assemblies, allowing for advanced editing and collaboration.

RewardMachine.f3d

The .stl (stereolithography) file extension is a widely used format for 3D models, primarily for 3D printing and computer-aided design (CAD). It represents the surface geometry of an object using a mesh of triangles but does not include color, texture, or other attributes.

RewardMachine.stl

PHOTO & VIDEO COMPRESSION

To convert images I used few programs programs:

IMAGE MARGIC

You can download it from here: https://imagemagick.org/script/download.php
ImageMagick is a powerful command-line tool for editing, converting, and processing images in bulk (all in once). I use PowerShell terminal with this command:

mogrify -path output/ -resize 1200x1200 -quality 85 -define jpeg:extent=200kb *.jpg

*run this command from the folder with images

mogrify command is used for bulk processing images in-place (modifying the original files).
resize 1200x1200: Resizes images while maintaining aspect ratio (adjust as needed).
quality 85: Adjusts JPEG compression quality for optimization.
define jpeg:extent=200kb: Ensures images stay under 200kB.

XNCONVERT

You can download NConvert from: https://www.xnview.com/en/nconvert/
XnConvert is a fast, powerful and free cross-platform batch image converter like ImageMagic, but also has its GUI (Graphical User Inerface)
Here’s an example of conversion:
1. You simply drag&drop a photo
2. Press ACTION and you can choose many edition options
3. In OUTPUT you choose final format, name, where to save and more options
4. Press CONVER and it’s ready
Here’s an example for PowerShell Command for Batch Conversion

Run the following command in PowerShell inside the folder containing the images:

C:\XnConvert\nconvert.exe -out jpeg -resize 1200 1200 -ratio -q 85 -o output\%%.jpg -size 200000 *.jpg

out jpeg → Converts to JPEG format.
resize 1200 1200 → Resizes image to max 1200px width/height.
ratio → Maintains aspect ratio.
q 85 → Sets JPEG quality to 85% (adjustable).
o output\%%.jpg → Saves to output folder (you must create it first).
size 200000 → Ensures files are under 200kB.
.jpg → Processes all JPG files in the folder.

VIDEO

CHECKLIST:

Computer-Aided Design

Model (raster, vector, 2D, 3D, render, animate, simulate, ...) a possible final project
Compress your images and videos, and post it on your class page

Learning outcomes

Evaluate and select 2D and 3D software
Demonstrate and describe processes used in modelling with 2D and 3D softwares
Demonstrate image and video compression

Have you answered these questions?

Modelled experimental objects/part of a possible project in 2D and 3D software
Shown how you did it with words/images/screenshots
Included your original design files