iPhone 7 case from phone model

[chuckmcgee]

OK...i have searched high and low for a relevant tutorial, example, or even explanation of a feature that I could use.  I am no rookie to CAD, but I am new to Fusion 360 and learn best by doing.  But I have to admit - I need help.

I have an iPhone 7 Plus that I want to design and print my own case for.  I know there are COUNTLESS models of cases I can download and manipulate, but none as rewarding as designing it on my own.

The complication for me is that the phone has rounded sides...unlike the iPhone 5 and older which has flat sides (note - there are many tutorials of how to design a case for that phone - all of which I get quite well).

I am trying to design a case for my phone using a very specific model of my phone (which i have in both IGES and STEP format).  

here is what I have tried so far:

From the phone body, I have tried to select the round sides and choose - THICKEN - in model.  That works well to form the sides, but because the model of the phone I am using has every detail, including the APPLE logo on the back, I can't get the thicken command to ignore those details and I don't know how to model those out after I have the extrusion. 

After the thicken on each of the sides and back, I tried the PROJECT and (in MESH) the ERASE AND FILL command to get rid of the features that didn't need to be part of the thicken (like the APPLE logo and speaker holes in the bottom of the phone).

I have seen examples (of the square-sided iPhone 5 and older) using the SHELL command, and with the round sides and body composition, this attempt throws errors each time

I have tried to create a brand new sketch of the sides using the curves of the lines made at the extents of the bodies, but I can't get the curve to match the existing body and I can't figure out how to highlight the edge line of the body shape and create a line from that.

I would be grateful for some direction here.  I don't necessarily need step-by-step instructions (unless they exist)...but I would do fine if someone would simply tell me what tools I should be using.

I assume my major steps are as follows:

1. Create a 1 to 1.5mm shell or thickness around the sides and back of the phone
2. Remove the design features that aren't relevant to the case (like the Apple logo in the back of the phone or the door for the SIM card)
3. Cut out the shapes where the camera and buttons should be usable with the phone with the case on

Thank you for any help any of you can provide.  I am stuck.

[etfrench]

1. Start with a rectangular box that is wider and longer and thicker than the phone, with the difference equal to the desired thickness of the case. 
2. Either fillet the outer edges of the box or use a pattern on path to create the rounded sides. 
3. Locate your phone model in the rectangular box.
4. Use Extrude|Cut with Keep tools option to create the cavity for the phone. 
5. Make cutouts for the camera lens and other buttons.  You may be able to Push/Pull or extrude a face if the features create faces in the case model.

[chuckmcgee]

I will give this a try!!  Thank you.  I knew about this as an option, but was both stuck on how to get the outside edges to match the curviture of the phone model...and (shamelessly)...was exploring other options where I could somehow either "expand" on the phone model at the desired thickness or "cutting" or "subtracting" the phone from a rectangular cube - both options for retaining the same side curves.

[TrippyLighting]

Does that phone model import as a solid, or as a surfaces ?

[chuckmcgee]

Two versions of the same model...the IGES, which is a collection of about 400 unstitched faces, and the STEP, which is a single body.

Is it easier one way vs the other?

I attached the STEP...(got an error when attempting to attach the IGS).  Neither are my model...I did go through the process of actually creating the phone, and I was happy with the effort, but not as accurate as the attached...so this is what I am using to create the case.

[chuckmcgee]

One thing that might help a lot is to determine if it's possible to create a sketch outline from the outline of a face?  Take, for example, the surface glass of the iPhone...Is it possible to highlight the outside perimieter of that modeled glass and define that as a sketch line?

In Photoshop, that would have been the equivalent of converting a selection to a vector path (and yes...I know Fusion 360 isn't Photoshop...I am just drawing a comparison for what I trying to do).

I think if I can get these curves and shapes to sketches, I can do what I am trying to do.

[chuckmcgee]

Another update - I figured out how to create a sketch from the outline of a face or component...

Project > Include 3D Geometry

I am getting close now...making progress.

[TrippyLighting]

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@chuckmcgee wrote:

From the phone body, I have tried to select the round sides and choose - THICKEN - in model.  That works well to form the sides, but because the model of the phone I am using has every detail, including the APPLE logo on the back, I can't get the thicken command to ignore those details and I don't know how to model those out after I have the extrusion. 

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You can de-feature the phone almost completely. This took 15 minutes off work. With a little work in the patch environment I could also eliminate the raised area for the camera. Might not with the next industrial design contest in terms of surface quality but will be fine for a phone case.

[chuckmcgee]

OK...that is impressive.  Could I trouble you to ask how you did that?  Even if you point me to a specific topic or training doc to read.  I tend to learn better by jumping into a project and then diving into a specific set of features to solve a problem.

[TrippyLighting]

This is actually not all that difficult to do. Just applying some of the practices that this Autodesk University course taught.

The trick to this model was to do it in steps. First the fillet or chamfer, then maybe the rest of the button, or opening. It takes a little experimentation sometimes.

As opposed to what some misguided tutorials teach I never enable the timeline by default as the first step on imported models. This is all done in direct modeling mode so I don't litter my timeline with all that deleted face junk. I just copied and pasted the body so I still have the original in my design and the de-featured copy.

[chuckmcgee]

That was a fantastic video.  Thank you.  I completely de-featured that model and am now in a place where I think I can easily model this case.  When I work on it later, I plan to create a copy of the de-featured model, thicken the walls, build a modest tolerance, and cut out holes.  That should do the trick.

[blacktip]

Wow. Terrific video about direct modeling, Just along the line of what I personally are looking for (i.e. creating models that doesn't need to be referenced through sketches, but rather be something I can make nice renderings out of. Thanks for sharing!

[chuckmcgee]

OK...checking back in.  I am ready (visually) to print my draft of the case to verify fit and measurements (before I do any more customization).

The only issue now is that I can't combine my model as a single element for export as STL.  I get errors due to consistency and other anomalies when I try.

I have attached my progress as a Fusion file, but would be curious if there is a way I can better analyze my model to see why to objects can't form as one.  Visually (and magnifying to a ridiculous degree) reveals obvious

As a summary, the attached was created from de-featuring an accurate iPhone 7 plus model, performing thicken on the sides, creating the buttons from patch extrudes and stitching, and carving out the holes and gaps using shape cuts.

Thanks again all...you have been a wonderful help.

[chuckmcgee]

Actually figured the whole thing out on my own...ended up starting over and doing an offset path and patching...MUCH cleaner blends.  Came out exactly as I wanted.

Thank you all for your help.

[TrippyLighting]

Very cool! Please post a picture once you have it printed.

[cekuhnen]

@chuckmcgee

The iPhone 6 or 7 are pretty easy to model today.

you best friend will be dowanloading the Apple technical drawings for all Apple products so you know the dimensions and details and then make use

of sketches Smooth constraints for blend spline curves and sweep command to create the rounded edge design.

the iPhone 1 that one was a beast to build well - 5 6 7 are pretty simple.

just created a 6 and 7 dummy (body camera buttons audio) for a client smart phone case

missing in the screenshot are the profile images I made from the PDFs and loaded into canvases!