topic Re: Hard Case for Product in Fusion Design, Validate & Document Forum

Hard Case for Product

kontakt_kowalskiw — Fri, 09 May 2025 16:41:15 GMT

Hey everyone,

I've been trying to design a hard case for a controller like the one in the image below for several days now, but I'm stuck. I want the case to have a very thin gap between the model of the controller and the case itself (something like 0.2-0.5 mm), followed by a solid 2-3 mm layer of material for the case on all sides.

I've tried several methods:

Shell – geometry errors keep appearing.
Offset Face – again, errors, especially with more complex shapes.
Manually creating surfaces – very time-consuming and difficult to do accurately.

Additionally, my model is not a hollow solid; it has an interior. The only method I've managed to use to remove the interior is converting it to a mesh and then using the "Repaire Type - Warp" option .

But I wonder if there is a better way to do this directly on the solid model.

I'm attaching my STEP file for reference.

Is there a way I can achieve this properly? Maybe another tool, trick, or a different modeling method? I would really appreciate any help.

Thanks in advance for your responses!

Re: Hard Case for Product

TheCADWhisperer — Fri, 09 May 2025 17:04:22 GMT

@kontakt_kowalskiw wrote:

I'm attaching my STEP file for reference.

@kontakt_kowalskiw

Can you File>Export your *.f3d file to your local drive and then Attach it here to a Reply?

Or did you not model this in Fusion?

The geometry appears very rough.

One example...

I would boundary fill the interior, remove the text and all other extraneous external detail first.

Are you a student? (If so, might be able to simplify this with "Shrinkwrap" in Autodesk Inventor Professional.)

Re: Hard Case for Product

kontakt_kowalskiw — Fri, 09 May 2025 17:00:31 GMT

To be honest, there's not much there. Just the original STEP file for the model I want to make a case for.

Re: Hard Case for Product

TheCADWhisperer — Fri, 09 May 2025 17:07:09 GMT

@kontakt_kowalskiw

What is the source of the geometry?

Did you create it or did you get from some other source?

Re: Hard Case for Product

kontakt_kowalskiw — Fri, 09 May 2025 19:09:44 GMT

I found it somewhere. Im sending the original file. Is there something wrong with this?

Yes, I am a student. I am already working on verifying the university and downloading Autodesk Inventor Software.

Re: Hard Case for Product

TheCADWhisperer — Fri, 09 May 2025 19:49:01 GMT

@kontakt_kowalskiw

This is a better model to start with.

Look for the Simplify tools.

Edit: Well, I worked with this for a bit, but it looks like it would be easier to design the core tool from scratch using this only as reference.

Re: Hard Case for Product

kontakt_kowalskiw — Fri, 09 May 2025 20:20:26 GMT

when you say core tool, do you mean a simplified model? Do you think it's better to do it in fusion itself or use the tool you mentioned from Autodesk Inventor?