Modeling a Curved Blade

[apabst]

I've recently been trying to model the batarang prop from Batman V. Superman in Fusion 360, which calls for modeling several blades with a sharp curve and I haven't been able to find a way to make good transitions between the edges. Basically what I've been doing is sketching out the shape, extruding the blades out from the sketch, and then using the fillet tool to round out the edges. This has worked well for individual edges, but it seems to be impossible to get the different sections flush with each other.  I've attached screenshots of what I have before and after the fillet, as well as a reference image I'm using.

Can someone suggest a good way of going about this?

[TrippyLighting]

It would probably be helpful if you could share your design

Please export as .f3d and attach to your next post.

[apabst]

I'm unable to export to a .f3d, but here is a link to download the design directly from Fusion 360.

http://a360.co/29ZjDUA

[TrippyLighting]

Looking at the shape in the attached image and comparing to your design, I don't think you can create the ouster blade shape just by filleting.

I would likely use a number of lofts with rails. Fortunately the sketch yo've drawn contains already a lot of what's needed to do this.

I'll see how far I can get with lofts.

Aslo, as a general rule, apple radii and fillets as a last step.

[TrippyLighting · Accepted solution]

This is how far I've gotten in brutal all-out fight with the loft tool 😉

Not sure yet who's won, it's not over yet!

I deleted the mirrored part of the sketch as that is easier to do with the solid error command. Also only modeled the upper half, so I mirrored twice and then combined the 4 bodies.

Some advice:

• Avoid the evil conic curves. These should be illegal. I deleted the one that defined the leading edge of the wing and used a single spline to define that edge.
• Mind tangency's, otherwise the loft and filleting tools will spit error messages at you.
• Create rail sketches separate from the main sketch. If need project sketch elements from existing sketches.

This shape looks deceptively simple in the photo, but the outside blade geometry is not simple.

Filleting is also going to be the the next challenge. I'll leave that to you.

[apabst]

Awesome! Thanks for the help and the advice. I truly appreciate it.

[TrippyLighting]

Well...don't praise the day before it's over 😉

You'll curse me when starting to fillet this beast!