Requesting help to solidify complex surface for printing

[stdubeck]

I am trying to make a 3D printable tiltrotor from surfaces.  I have watched many how to videos which have gotten me to a very good point where I have stitched surfaces together and patched up holes.  It will be printed in sections.  But I am stumped with the complex geometry of a faring at the tip of the wing.  It is the juncture between the wing and engine nacelle that covers the actuators that move the nacelle.  I am trying to make it solid so that I can put a hole in the end for a post that the engine nacelle will rotate about.

Picture 1 shows a good part of the aircraft left side.

Picture 2 - 4 show various views of the wing and fairing without the engine nacelle

Picture 5 shows just the engine nacelle with the post that will insert into the wing (once I figure this out).

[jeff_strater]

Thanks for the details, @stdubeck.  Yes, I can reproduce the Patch failure.  The problem appears to be specific to the parametric part of Fusion.  In cases where the preview looks OK, but it fails when you click OK, that is often the problem.  That is a bug, and I will log it.  There is a workaround that is pretty non-obvious.  Because the failure relates to the parametric part of Fusion, you can sometimes get around it by creating a Base Feature.  The Base Feature is a little-used capability of Fusion that lets you create an "island of direct modeling in a parametric design", so sometimes you can use that to work around problems like this.  Here is a screencast:

Regarding screencast tools, I like the Autodesk Screencast utility: screencast.  And, I'm not saying that just because it's an Autodesk thing.  Really, this is one of the more useful tools I've found, I use it all the time.

So, this will get you past your current stumbling block.  But, the root of a lot of your problems, I suspect, is that you are starting from a mesh (STL) model.  Fusion has very limited mesh capabilities, and the method of converting a mesh to a BRep is one that has issues, as you've discovered.  You can sometimes make it work, but between Fusion's limited mesh and limited surface capabilities, you might struggle a lot.  I might be tempted to use TSplines with the "Snap Object" feature to use the mesh as an input and re-create the design as a TSpline body.

Regarding surface -> TSpline:  Today, you can only convert a single BRep face to a TSpline and edit it.  My guess is that this is not what you want, so I don't think that path is going to be very successful.

[stdubeck]

Over the next day or two I will try your base feature suggestion as well as the snap object feature and post some results.

Thanks.

[stdubeck]

Getting closer but still not there yet.  I have thickened up some of the fairing overhang parts and made progress on the aft part of the fairing but I just can't close all the small gaps to make a solid body and I can't combine a surface body (wing and fairing) with a solid body (other parts of the fairing I made).  I have tried patches, joining, boundary fill.  I have tried things available in both patch mode and model mode.  I have tried with design history on and off.  No luck.  Model attached. 

In the picture the blue (selected) solid body is located in the area of the fairing (surface body) that I can't close up to make a solid body that can then be joined to selected solid body.  Wow that sounds confusing.  Objective is to make everything in the picture one solid body so it can be 3D printed.  Can't figure out how to do that.  Please help.  If I am successful I'll print you out a model.

Thanks

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[Anonymous]

Hi can we have also the other 3d files of the fusolage and empenage?

i am tryng to print it

Thank you