This thread, along with a a fair share of experimentation, has helped me to finally understand the differences, advantages and disadvantages of the various assembly methods available. In this post I summarise my understanding, hoping that it will help other users.
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Fusion 360 provides FOUR methods of creating joints: regular joints, as-built joints, rigid groups, and origin joints.
Regular joint:
- Always involves two components.
- Regular joints are used to join two components that are not yet aligned. In other words, regular joints do not require pre-alignment.
- 9 our of 10 times used to establish non-rigid joints.
- Usually references component features such as faces, edges, points, etc. The component origin is a special case of a feature.
- After applying the joint, the selected features of the two components become coplanar, colinear, concentric or coincident. In other words, regular joints usually result in the two components coming into contact.
- Users may then explicitly specify offsets to create separation between two components (to break the 'contact')
- Motion between components is possible, depending on joint type (rigid, revolute, slider, etc)
As-built joints:
- A special case of joint.
- Like regular joints, as-built joints also involve two components.
- Typically used when the two components have been previously aligned, or are loosely aligned (e.g. by hand) and the goal is to preserve their relative positions.
- Unlike regular joints, as-built joints reference component origins only, not faces, edges etc. Because of this, as-built joints can 'break' after re-dimensioning a parametric design.
- 9 out of 10 times used to establish rigid joints, although other joint types are possible.
- With regular joints distance is created by manually setting offsets; with as-built joints, the offsets are implicitly calculated to preserve the initial position of the current position of the components.
Rigid Groups:
- A special case of as-built joint. A rigid group is essentially a rigid joint between more two or more components.
- No kinematic relationships possible: rigid groups are always... rigid. Therefore rigid groups can be thought of as a subset of as-built joints.
- While rigid groups can be emulated identically using as-built joints, the advantage of rigid groups is that they are quicker to establish. As-built joints must be established two components at a time, if you want to join, say, ten components, a rigid group can deal with all ten components in one go, which considerably reduces the amount of work and timeline clutter. It's essentially a workflow shortcut.
- You can think of rigid groups as hair spray to fix freeze components relative positions.
Ground:
- Ground is a special case of rigid joint. It can be emulated using any of the three methods above. In this case the joint is between the selected component and the top-assembly origin. The exact same result can be achieved by explicitly creating a rigid joint between the component and the top-assembly origin or the top-assembly component.
- The main advantage of using 'Ground' is that it requires just one click. Again, it's a workflow shortcut.
There are many situations where any one of these methods can be used, but there's always one method that is quicker/easier, and that's the one you should be using.