For my parametric design exercise, I created a tolerance test joint using Fusion 360 to help determine the best fit for wood joints in future projects. I defined key parameters, including the material thickness (3 mm) and a user-defined tolerance (±0.05 mm). I then modeled 11 slots—five with increasing positive tolerance, one center slot with exact thickness, and five with decreasing negative tolerance. This setup allows me to physically test and identify the ideal joint fit to apply in future laser-cut designs.
Work Process Detail
Open Fusion 360 and start a new design file.
Go to Modify → Change Parameters, then:
Add a user parameter for material thickness (e.g., Thickness = 3 mm).
Add a tolerance parameter (e.g., Tolerance = 0.05 mm).
Start a 2D sketch on a base plane.
Draw a rectangle and begin designing the test slots:
Create a center slot using the exact Thickness parameter.
On one side, draw five slots, each increasing by +Tolerance, +2*Tolerance, etc.
On the other side, draw five slots, each decreasing by Tolerance, 2*Tolerance, etc.
Finish the sketch and extrude it to a testable piece.
Physically test each slot to determine which tolerance fits best for your material.
Learning Outcome
Through this task, I learned how to use Fusion 360’s parametric design tools to efficiently experiment with material tolerances. This approach not only saves time but also ensures a more precise and adaptable workflow for creating tight-fitting joints, which is especially useful in wood-based fabrication projects like construction kits.
