Looking to create a 3d wood carving of a wavy flag

[rockaukum]

First attempt:  drew it all out, extrude it up, create a plane above model, edit it for "wavy" look.  Would not work until I removed the stars from the extrude.  but could not get the stars to cut properly.  I think due to the wavy pattern, on some of the stars (v-bit, engrave) the bit plunged through to the bottom.

Second attempt: Drew rectangle, extrude up. create plane above model, edit for "wavy" look, replace face to the original rectangle. Then tried to draw the stars and striped onto the "new" face (top).  Can't seem to get it to work as the sketch is placed onto the original top of the rectangle (at least where the old top was)

I have been trying various ways with no luck and am finally turning to the pros for guidance.  I have searched for tutorials which do this but only find ones for vetric, so any guidance would be great!

I have a friend who is taking command of his own squadron (helicopters) and I am flying back for the ceremony and would like to present the flag carving to him.

(could not get the past to put the file here so I manually entered it, hope that works)

http://a360.co/3JncXPf

Thanks,

Steve

Rockaukum

[hamid.sh.]

Have you seen this post? It's about an identical deign.

[rockaukum]

Hamidsh,

Yes, I did see that post and you were involved in it.  I read through it yesterday while muddling my way through my project.  I did not have issues with replace face, I even tried the whole process with split face with no luck as to the stars.  The main difference between the two is that the other one is extruded up while I am cutting the stars into the flag.  creating the problem of the cutter diving way too deep causing collisions.

Perhaps there is a way to sketch the stars onto the wavy plane that I made to replace the face with?  I have tried several ways with no luck.

Thanks,

Steve

[hamid.sh. · Accepted solution]

I know only one way to mimic this but it's tedious and not very accurate.

For the start: If you want your stars to follow the waviness correctly you need to be able to deform a sketch from its 2D form to the 3D surface. To Fusion does not do this for sketch of DXF, but it can map an image to any 3D surface via Decal function.

You can follow these steps:

1. Apply a decal of the flag to the wavy surface (disable chain faces).

2. In a sketch (on a plane above the surface) draw stars as seen from top view. This step is the "tedious and not very accurate" part, because you draw stars just visually from its image, and you can't use pattern because each stars is deformed differently according to the local curvature.

3. In a new sketch use Project/Include > Project to Surface, select lines of previous sketch and project them along Z axis onto the surface. They will match the decal.

Here is a link to screencast (I get error trying to insert it here).

I know this is not a good solution, but it works. I'll be happy to hear from others about a better solution.

[rockaukum]

Hamidsh,

Again, thanks for the insight.  I will give this a go tomorrow.  ( we are out of power here, two days now and no relief in sight!). I will post a follow up once I give it a try.  You say tedious, but I have Been trying to get this to work for two day now so tedious is not a big concern at this point.  Fortunately I have a couple of months to get this cut.

Again, Thank you very much!

Steve

[rockaukum]

Hamidsh,

I finally got internet service back, Still waiting for power so I can do a sample cut.  I completed the process with just a few setbacks.  It looks like it will work just fine.  It was a tedious process but Not too bad at all. Thanks for the help on this.  I hope to post a picture once I get it cut, may be a while though....

As a follow up question, I will want to scale this out to about two feet in length,  I am under the assumption that once I scale the original sketch, all else will adjust accordingly.  It this correct or do you think  I will need to redraw the whole project?

Again, Thank you for taking the time to help out.

Steve

[hamid.sh.]

Happy to hear that it helped. Please do share a picture once you made it!

About the scaling I am not sure without seeing your workflow, especially I am not sure which sketch do you refer to as "the original sketch". Nevertheless, if you had followed what I suggested, in the 2nd step since you draw starts only visually, their are not associated with anything and they won't update if something prior to them changes in timeline. However, once you have done the design scaling the body naturally keeps every part of the body relative together.

[rockaukum]

Hamidsh,

Finally got power back so I gave it a go.  This is the sample cut.  there are some thing I'll change for the final.  One think I stoppr=ed the cut prior to the last few stars and cheated the Z down to see what the stars would look like.  Complete blow-out!  When I cheated the z down, I did not raise it back up so when I started the cut again, it rapid across the work and cut those lines.

I do not like how deep I went on the lines for the union and striped so I'll go shallow there.

Anyway, thank you for your time and effort.  I appears to work jus fine.

Steve