Can't convert Form to BREP due to T-Spline Topology (Star-Points)

[DavidJ.Wood5706]

Hello,

I could really use some help. I am trying to make a replacement door to go on the glove box of my SKi-Doo Snowmobile, to eventually hold my phone in view, but safely out of the cold.

I'm relatively new to Fusion and am having diffuclty Converting my FORM design to BREP so I can turn it into a solid object. When I use the Repair Body feature, it returns the following error...

   Conversion error for: Door Skin (Form)

         T-Splin topology problem. Use Modify - Utilitites - Repair Body to remove error.

However, when I did this, it clean up a few T-Points, but has not been able to repair enough Star-points I guess to allow this to be converted. 

I know you need to minimize the number of T-Points and Star-Points as possible, but I can't think of a way to do this without distroying the shape. 

Note: The form was placed over the (still attached) 3D scan of the original dash. So you can see what I am trying to replicate. My goal is to add thinkness (or Shell) to this shape once it has been converted so I can 3D print it. The most important dimensions will be on the hinge at the bottom and the back side where the door will meet up with the mating glovebox. Once this is confirmed to mate up I plan to design a phone holder to place this geometry. 

Many thanks as I have been killing night trying to find a solution.

[TrippyLighting]

First, as a beginner you should not be working with the timeline disabled! THe design does not include the scan, so we cannot see what this is supposed to resemble 😉

Avoiding triangles and n-gons is more important than reducing star points and and T-junctions. I'll see what I can do ...

edit: I found the scan. This is much easier to design NOT using T-Splines. 

[DavidJ.Wood5706]

Thanks for taking a look at this. 

Somewhere along the design process I noticed that I had not re-enabled the Design History, so I turned it back on. But noticed that when I did this, the Form body I had spent all this time creating, had disappeared. So yes, I have been working without a timeline. So I have had to use Cntl-Z to catch design mistakes (doh!)

 You should still see the original Component scan called "Scan Wireframe" but it s visibiulity was turned off. Please let me know if you still can;t find it and I'll try another way.

Thank you so much for your input.

[DavidJ.Wood5706]

@TrippyLighting

I realize the 3D scan is not perfect, so I have attached a photo of the actual part. ThanksOriginal Dash Door

[DavidJ.Wood5706]

@TrippyLighting 

I saw your comment...

    edit: I found the scan. This is much easier to design NOT using T-Splines. 

Do you think this should be designed in Surface mode, not Forms due to the hard edges, etc.?

[TrippyLighting]

---

@DavidJ.Wood5706 wrote:

Do you think this should be designed in Surface mode, not Forms due to the hard edges, etc.?

---

Yes. Can you post the scanned model before conversion into a solid ?

Converting it into a solid wasn't needed and only makes the model slow 😉

[DavidJ.Wood5706]

@TrippyLighting 

Here's the original scan in OBJ as exported from the scanner. Is that what you want?

[DavidJ.Wood5706]

Worth noting, the object did not come into Fusion 360 at the right scale despite being done in mm. So I had to scale the object by ~56.2180786 to measure correctly. That's a whole 'nother topic!

[HughesTooling]

---

@DavidJ.Wood5706 wrote:
Worth noting, the object did not come into Fusion 360 at the right scale despite being done in mm. So I had to scale the object by ~56.2180786 to measure correctly. That's a whole 'nother topic!

---

That's an odd scale. When I open your OBJ file in Rhino I get this so not sure the problem's with Fusion.

[DavidJ.Wood5706]

Agreed. The scale must be wrong in the 3D scanner, which makes everything so much fun. Right!

Thanks for confirming it's not just me though.  😉

[TrippyLighting]

Can you provide a dimension of the actual physical artifact so we might scale the scan properly ?

I created a shape that fits the interior cavity. Do these dimensions look reasonable?

[DavidJ.Wood5706]

Sorry for the delay @TrippyLighting 

Please see the dimensions of the FRONT edge of the interior section. my calibers could not accurately reach the back wall as I suspect your polygon was based on.

THANK YOU!

[DavidJ.Wood5706]

Hi @TrippyLighting,
Did the dimensions below help you?
Thank you for your assistance

[TrippyLighting · Accepted solution]

My apologies for the late reply. I don't have a lot of time these days as I need to make progress on my own projects 😉

The attached file contains what can be seen in the screenshot. Unfortunately I don't have time for more. Hopefully it can serve as a guideline on how to approach this. IMHO, this is NOT a beginner or even intermediate level project. This part has very complex geometry, something that in my experience not many people have an eye for.

First I would focus on getting those parts of the geometry correct where this part interfaces with existing parts. Assuming this this will be 3D printed, I would make simple geometry and then do test prints to see how it fits and adjust as needed.

Once you have a good fit/function, you can focus on making the rest of the geometry.

[DavidJ.Wood5706]

Thank you @TrippyLighting 

I'm glad I'm not the only one scratching their head on this one. I keep trying to stretch my mind how to create surfaces or solids from 2D flat sketches.

I'm curious how you were able to create the ornage line outline shown in the image below? Was this done using a section analysis or or some tool I don;t have in the Personal license version?

I went back and scanned the glovebox that I need to mate this door with, I think I'll avoid replicating the exact curves of this door and make it my own design, as you said, once I've got the parts to meet up.

Thank you very much for your insight and help!

[TrippyLighting]

The orange sketch is a mesh section sketch I used only as a visual guideline.

This isn't so much of a head scratcher. I've done this a number of times, it is simply a lot of work I currently don't have the time for.

Personally I would probably mostly work with surfaces instead of solid bodies.