Using a BRep to Cut a Model Body

[adamVUUNK]

I'm having a heck of a time here and I'm hoping one of you gurus can help me get over this hurdle.

I'm trying to build a stand for my AirPods. I got a, supposedly, dimensionally accurate STL model file of the AirPods from thingiverse. I brought the STL into 360, I reduced the number of faces so it was manageable and then converted it to a BRep. From there, I tried just doing a simple cut operation on a cube. I was left with the cut and an outline of the BRep in it.

I think part of the problem is that the model has an opening for where the speaker is. I tried deleting faces so I could patch the opening, but I couldn't get it to work. Could someone give me some pointers please?

[GRSnyder]

I don't see any of the steps you describe in the file that you posted. It's just a Fusion 360 file with an imported pair of meshes and a sketch of a square.

It's easier for other people to review your design if you turn on Capture Design History. Right-click on the root object of the browser ("AirPods Pro Model STL...") and select Capture Design History down at the bottom of the context menu. Do this first before any other steps, because only steps that are done subsequently to this will be captured.

Having Capture Design History on does complicated the conversion of meshes to breps. Before you convert, choose Create -> Create Base Feature. Then do the Mesh to BRep conversion, then click Finish Base Feature.

[adamVUUNK]

You're right, I should have included more detail in the uploaded file.

I unfortunately didn't save where I was and had to remake it. I'm getting a new issue now that there isn't an overlap, even though I took the same steps as I did last time. Here's a new file with history turned back on from the point where I did the BRep conversion.

My steps:

1. Remesh STL

2. Reduce faces

3. Convert to BRep

4. Turn history back on

5. Draw cube and attempt to do a join

[TrippyLighting]

That workflow makes almost no sense to me. Can you post the original high rez mesh?

[adamVUUNK]

Sure, here's the original STL.

[TrippyLighting]

This will take a little while to clean up, Blender just crashed and I had not saved my work 😕

In Blender I separated the mesh into separate objects. The goal is to get back to the clan subdivided quad mesh this one was.

That can then be converted into a T-spline an Brep/NURBS. More work, but much better result.

[adamVUUNK]

Ugh! Thanks for doing that. I tried Blender, but I just could not for the life of me figure it out. I saw a YouTube video that described the process, but it just didn't work for me.

[TrippyLighting]

Not sure what process you saw but it likely is very different from what I am trying 😉

Blender is not easy to digest for beginners! But it is a very powerful software.

[TrippyLighting · Accepted solution]

Attached is part of it.

[adamVUUNK]

This is amazing! Thank you!