Looking for tips on parametric design with conditional elements and automatic slicing into multiple parts

[timderks31]

I've created my own version of a storage solution I first saw in this video by Alexandre Chappel. Since I didn't feel like making custom models for every size of box I wanted, especially since some design choices may change over time, I tried a parametric model. The idea was that I just enter some specs, and Fusion creates the box I need.

I got far enough along to get something that works... kinda. It has some oddities to it, which make me think that I haven't created the model in the optimal way. I've added my model to this post, so you follow along if you want to.

So the general idea is this:

• The base is a grid (separate file). The grid has a certain size, 60x60mm in my case.
• I can create boxes that are sized in increments of the grid size, so (x*60)x(y*60).
• There's a small lip at the top for a label, the lip can be moved.
• Since my printer can only print 150x150mm, anything larger than a 2x2 needs to be printed in multiple sections. To achieve that, I have to:
  • Add extra material at the split location for easier glueing
  • Slice the model at the split location.

In the file I included, things are split up into groups. The first group is about creating the box, that part is working fine.

The second group is about creating the label lip. That kinda works, but strange things happen when I want to suppress that group. I may not want to have that label lip on all boxes, so it would be nice to be able to suppress it in some cases. When I do that however, a lot of things that come after it also get suppressed. I suspect that's because I join the lip to the box, and the things that incorrectly disappear depend on that box somehow. In theory, the label lip shouldn't interfere with anything, but I know that's not how 3D modeling works. What I don't know, is how I can fix this.

The third and fourth group are preparations for splitting in the X and Y direction. They add the extra material (glue lips) near the split location for the glue up. These are causing me the most issues:

• First is removing (hiding, suppressing) the glue lips when there is no split in that direction. If my box =< 2*gridsize, I don't need to glue it in that direction, so I don't need the glue lips. Sadly, I haven't found a way to suppress features conditionally. It's not a huge deal, but it would be nice to have it automated.
• The glue lip that runs along the floor of the box is also causing me issues, but it's an intermittent issue (the best of issues). Sometimes it extends to the other side of the box just fine, sometimes it doesn't extend at all, sometimes it extends beyond the box, and sometimes it extends only partially. I guess it would be better to have a construction plane centered based on the size parameters, and extending it either direction based on parameters too, instead of just extending to the opposing body?
• The glue lips that run along the walls are even worse. I tried creating a 5x5 box once, so I'd have 2 glue lips on all walls. 3 out of 4 walls had 2, but one of the walls only had 1, and I have no clue why, nor can I recreate it at the moment.

The last group handles splitting the model into the different bodies that I can print. I tried the split body functionality, but that caused soooo many issues when the splits cross each other, and thus create new bodies that you can't select automatically. I ended up with creating a massive drawn grid, bigger than any box I'll ever need, where I just use extrude to cut through everything. That works pretty well.

Something I ran into many times while creating this model, is that I really need "combine everything that's touching" functionality. It would have prevented so many issues if I could've created separate bodies, and then join everything together at the very end, and then split everything like I need it. If something like that's possible, please do let me know.

So if you read through this all, you're probably wondering why I posted this. Basically, I'm looking for tips and tricks from those who know way more about Fusion than I do (so most of you reading this). There may be plenty of easier ways of doing things I simply do not know about, of even know how to search for. If you see something you would've done different, or that you know is a bad idea, please let me know. Since I'm only using Fusion 360 for my own projects, I never get any feedback about my modeling methods, but I could really use some feedback.

Thanks for reading, I'm looking forward to seeing what you can teach me.

[davebYYPCU]

I can see what your intent is.  Fusion does not support configurations, so workarounds are required.

First I think it will work in Fusion, with changes and updates to what you have done so far.  

I would need the max size of the drawer, like he did 6 x 6 or are you happy with 6 x 2 as never bigger numbers?

Not a fan of suppression, seems to break stuff.  Apart from the 1 x 1, would you be likely to need modules of odd numbers (3 or 5) or keeping it to modules of 2x ? 

The rest of the parameters make sense, will sort out a way in the next few days, if interested.

[TrippyLighting]

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@davebYYPCU wrote:

...  Fusion does not support configurations, so workarounds are required.

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Yep, STILL does not support configurations. There is a steady stream of users relatively who I assume are new to parametric 3D CAD who are asking for that feature set, not knowing that this is  what they are asking for. Clearly, if new users can imagine and often perfectly verbalize the need for that functionality, then it should have not been a problem for AD to recognize the importance of that feature set and prioritize it over other less needed functionality (I am glad to list a number of things here).

I've experimented with all available workarounds including deriving bodies, components, parameters, entire subassemblies, linked components etc. All of these workarounds have drawbacks.

I am in the fortunate position that I own a perpetual license of another very capable CAD software and once a design concept gets more mature I take it into that software.

I've done this twice now and what a difference it makes being able to work with Configurations even in a design that still is in the concept phase is hard to describe!

Sorry for the rant!

[timderks31]

@davebYYPCU Hi Dave, thanks for the offer. The maximum size of the drawer at this moment is a 12x7 grid, so 720 by 420mm. At the moment, the biggest box I've printed is a 6x2, I don't really expect to go any bigger than 6 units in any direction. I do indeed need uneven numbers, especially since my drawer is 7 units deep.

If you could figure out how to make it work, that would be great. Hopefully it comes with an explanation on how you managed to do it, so I can do it on my own next time.

@TrippyLighting I've done a lot of searching over the last couple of weeks, and it's shocking how many topics I find asking for exactly the thing I'm looking for. Those topics tend to be from the early 2010's, and those features are still not in Fusion. It amazes me from time to time.

[davebYYPCU]

Odd numbers - bugger

How did you want to split those, seeing you can't print a 3 panel?  A middle (yes please) or short end?

Won't be totally automatic, but got my head around the initial geometry.

Later.... 

[timderks31]

I've been splitting them per 2 grid units, since there's already a hump in the floor there. It made sense for me to do it there. You should be able to see the formulas I used in the parameters window.

If it's easier for you to just split them down the middle (although that would still be an issue for a 6 unit long piece), that's fine by me too.

[davebYYPCU]

Doing the 6x2 for now, but a 6x3 would 90 wide matter, and a 3x3 will make it harder to automate, but not so bad otherwise.  Still figuring it out.  Your file is a little harder to figure out, not checked the pattern formulas yet.

Yep will be obvious how it can be done when I send you the file....

[timderks31]

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@davebYYPCU wrote:

...but a 6x3 would 90 wide matter

 Do you mean if the grid size is flexible? Unfortunately not, the grid has already been printed, plus quite a few boxes, so I'm kinda stuck with the 60x60 grid from now on.

[davebYYPCU]

Label holder is a separate component, position as desired and combine join to the receiving component. (Keep Tools.)

Base Component is taken as far it can go, and then you Copy / Paste New - for each type you need.

I have a front for a 2 x ?

a Side for a 2 x 2+ and

a rear corner for a 2+ x 2+

Save out as STL.

With the base or even one of the examples you can further pattern / mirror or change as desired.

Because you are printing at 2 x 2, no need to make an assembly then try and cut it up.

I used the Combine, Shell and Delete faces to clean up the base into the required configuration.

Only thing I would be checking on is the glue faces at floor level if they are wide enough.

Might help...

[timderks31]

I've been looking through your file, and there's quite a few things in there I would have never thought of. Didn't even know you can use sweep to cut. About just having multiple separate bodies instead of trying to create it as one and then cutting them, you're probably right that that's the best way of doing it. I think I wanted to see how far I could push my skills / Fusion 360, but that definitely didn't result in the easiest / most reliable way of doing things. Thanks for the input!