Step 4: Back Cover Body
Next we’ll make the basic shape of the Back Cover.
- Ensure the Back Cover component is activated.
(Click on the circle next to the component’s name in the Browser)
- First we Extrude the profile created in the previous step.
- Open the Extrude tool and select the profile in the upper half of the circle.
- Pivot the view around (By dragging the View Cube) so you can see the back of the battery holder.
- Change ‘Extent‘ to ‘To Object‘ and select the back face of the battery holder.
(We could have just extruded a fixed distance. It’s better to extrude a distance relative to the battery holder, so that we know there’s enough room)
- …oh no, why was there an error?
When the ‘To Object’ selection is a face, a Chain Faces option appears.
Use ‘Extend Faces’ and the extrusion will work as you expect.
- The back cover needs to be deeper than the battery holder, so set the Offset to 1.8 mm.
- Click OK.
Check that the Body you just created is inside the Back Cover component.
(If not, press Undo and try step 3 again)
- The cover is a very boxy shape, let’s fillet the back edge:
- Ensure you can see the back of the Back Cover. (drag the ViewCube around if needed)
- Open the Fillet tool from the Modify toolbar. (or press f)
- Select the curved back edge of the cover, and drag the arrow in to give it a curve.
10 mm is about right. (This can be changed later. If too large, will interfere with the battery holder)
- The cover is still a solid shape, but it should be hollow!
Fusion 360 has a Shell tool specifically for hollowing solid bodies.
- Open the Shell tool from the Modify toolbar.
- Select the front face of the cover.
- Set ‘Inside Thickness’ to 1.6 mm
(Thick enough to be strong, thin enough to leave room inside)
- Click ‘OK’ to create the Shell feature.
As you can see; the body is hollow, and the front face open.
- Do all the components fit together yet? Let’s run an Interference Check.
- Open the Interference tool from the Inspect toolbar.
- Select the top-level ‘SRL mk1‘ component from the Browser.
- Click on Compute () to see the results.
The results will show that some interference exists;
Rows of the table show names of the components that overlap, and the volume of how much overlap exists.
The switch might overlap with the LED ring, or the battery holder switch might overlap with the back cover.
This was expected, we haven’t finalised the position of everything yet.
- Lastly, let’s give the Back Cover component some colour.
(This is not just for looks, it makes it easier to see what we’re doing)
- Press a to bring up the Appearance tool.
- Navigate in the library and find a plastic colour, (I used Translucent Green)
- Drag that material on to the Back Cover body or component.
- Click ‘Ok’
That was a long step!
Now we know how everything has to fit, so we’ll fix those interferences. We’ll fix them good…