topic Re: Sweep fail around a Ø 4.4 mm pin, fix? in Fusion Design, Validate & Document Forum

Sweep fail around a Ø 4.4 mm pin, fix?

p_abt15 — Fri, 16 Jan 2026 14:12:43 GMT

I would like to create a custom-defined thread around a pin.

Unfortunately, the sweep is not possible and fails after a short distance.

My procedure:

Extrude the pin
Create a coil with a 0.01 mm pitch for the helix
Create a defined trapezoidal profile
Use the Sweep command

The file is attached.

What is causing this, and how can it be fixed?

Re: Sweep fail around a Ø 4.4 mm pin, fix?

bwalker145 — Fri, 16 Jan 2026 15:13:44 GMT

Edit: Deleted original response, forgot I was messing with your angles.

New file attached. Not the cleanest as I didn't completely restart, but should be what you're trying to accomplish.

Re: Sweep fail around a Ø 4.4 mm pin, fix?

p_abt15 — Fri, 16 Jan 2026 15:47:02 GMT

Thanks for the solution. It seems to all go bad, when I select the wrong edge of the coil.

There are now many seperate surfaces on the tap. Do you know how to unite them?

Re: Sweep fail around a Ø 4.4 mm pin, fix?

p_abt15 — Fri, 16 Jan 2026 18:15:09 GMT

Thank you! Do you know, how to unite the surfaces on the thread? E.g. to use the press/pull tool.

Re: Sweep fail around a Ø 4.4 mm pin, fix?

TheCADWhisperer — Fri, 16 Jan 2026 19:56:19 GMT

@p_abt15

Here is one with lead in and lead out for the thread.

But are you sure you don't want a land at the crest of the thread?

What is the function of this fastener?

Another example...

Re: Sweep fail around a Ø 4.4 mm pin, fix?

p_abt15 — Fri, 16 Jan 2026 20:07:44 GMT

The lead-in and lead-out are, of course, the nicer version of the screw, but I’m not sure how to implement them.

The custom thread is designed for 3D printing. Standard M4 threads with regular pitch and angle are very difficult to print, which is why I made my own custom shape.

I’ve already printed one, and it works really well.

Could you please share a file or example showing how you did the lead-in and lead-out? Also, the chamfer on top looks tricky to model, and I’m having trouble with it (no round edge after the sweep)

Re: Sweep fail around a Ø 4.4 mm pin, fix?

TheCADWhisperer — Fri, 16 Jan 2026 20:19:45 GMT

@p_abt15

Before I attach my example, you didn't answer the question about the land at the crest.

Machine screws do not have pointed crests.

What does the mating hole thread look like?

Re: Sweep fail around a Ø 4.4 mm pin, fix?

p_abt15 — Fri, 16 Jan 2026 20:32:47 GMT

Right now it looks like this:

(the section view is from onshape, because I just couldn't do it in fusion)

The nut and bolt (which is the mating hole) have exactly the same shape as thread.

A better modeling would be a suiting land, as you mentioned.

I should improve this, but i don't know how.

Re: Sweep fail around a Ø 4.4 mm pin, fix?

TheCADWhisperer — Fri, 16 Jan 2026 20:46:56 GMT

@p_abt15 wrote:
I should improve this, but i don't know how.

I will post example when I get a chance.

Re: Sweep fail around a Ø 4.4 mm pin, fix?

p_abt15 — Fri, 16 Jan 2026 20:50:07 GMT

I'm looking forward to it, that would be a huge help!

Re: Sweep fail around a Ø 4.4 mm pin, fix?

TheCADWhisperer — Sun, 18 Jan 2026 02:04:31 GMT

@p_abt15

Looks like you are making progress from your other discussion thread.

Examine the Attached.