Hard Case for Product

[kontakt_kowalskiw]

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.
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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!

[TheCADWhisperer]

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@kontakt_kowalskiw wrote:

I'm attaching my STEP file for reference.

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@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.)

[kontakt_kowalskiw]

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

[TheCADWhisperer]

@kontakt_kowalskiw 

What is the source of the geometry?

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

[kontakt_kowalskiw]

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.

[TheCADWhisperer]

@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.

[kontakt_kowalskiw]

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?