Our final project for the class was an action figure with at least 9 working joints, with at least two different types of joints, one being printed in place. We were also required to use the sculpting environment in Fusion360 as well as utilize dual extrusion on at least one of the final parts of the action figure.
In the sculpt environment, sketch a spline on a work plane that begins and ends on the same axis, creating a face that you then revolve around the axis the spline starts and begins on.
After revolving the body around the axis while still in the sculpt environment, I modified the body using a combination of soft sculpting and flattening.
For the sake of simplicity, I designed only one arm and one leg, then mirroring them onto the other side of the action figure. It is important to note I could only do this because the action figure is bisected by an axis and a work plane. First, I designed the ball and socket joints that would be located at the shoulders, hips, and neck of the figure. To start, sketch a 6 mm diameter circle outside of a 5.45 mm circle. Bisect the two and trim one side, leaving two half circles. Then, sketch a line from the middle of the circles to the outside circle at an angle of 120°. Trim the lines so you only have one face consisting of the two arcs of the circle that have not been trimmed from the horizontal axis to the line from the center of the circle as so.
Revolve this shape around the horizontal axis. Construct an offset plain parallel to the opening of the socket. Sketch two rectangles to create a plus, with both rectangles having a width of .8 mm, and extrude them so they cut 1.5 mm into the socket.
The balls that will go into the socket must be larger than the distance between the inside walls of the opening of the socket, 3.5 mm.
To fit the sockets onto the body, I sketched a circle where I wanted the joints to go, trimmed it in half, then reflected it over the axis so it would be on both sides of the body. Repeat this process with the arms, and also the head joint. Revolve the half circles around their straight edge, cutting into the body and making new sockets. I then moved the socket made in the previous step to fit in the new socket, then mirror it to the other side. Copy the socket again and move it into the new arm socket and repeat the mirror. Copy the socket one more time and fit it into the new head socket.
First I created the legs. Sketch a 4.5 mm diameter circle in the model environment, trim to a half circle, and revolve around its flat edge to create the ball that will fit into the socket. On an offset plane behind the ball, sketch a circle with a 5 mm diameter and extrude it into the ball at a taper angle of -10°, making sure to join the bodies instead of cut them. Then, on the plane visible in the first image, sketch a 20 mm line perpendicular from the midpoint of the body shown. This will be the length of the thigh, from the hip joints to the knee joints. Then sketch a line at the other end of the line just sketched, parallel to the circular face of the body that is the ball joint.
Below the last line sketched, sketch a 4 x 4 rectangle. Sketch two smaller lines .2 mm from the top left corner and the bottom right corner and connect them with a third line. Offset a new line off of this one .4 mm. Trim the line that separated the two triangular pieces in the rectangle and mirror both faces over the leftmost line on the bigger shape. Then revolve these 3 shapes around the line that they are all touching, creating the basis of the hinge joint.
Extrude the circular faces of the cones of the hinge joint .6 mm each away from the joint. Then project the 3D geometry of the two edges of each cylinder just extruded. On an offset plane sketch two rectangles with the same heigh as the cylinders and a width of .4 mm. Extrude these into the cylinders, joining them. Sketch a rectangle .5 mm wide and the height of the joint on the inside of one of the newly extruded faces, extrude the newly sketched rectangle to join the two sides of the joint together. Then loft the the faces together, finishing the thigh.
Construct an offset plane off of the other side of the hinge joint, sketch a rectangle on the plane and extrude it into the cylinder with a -20° taper angle. Construct another offset plane 20 mm lower than the first one, sketch a 4 mm diameter circle on the plane, and loft the two faces together.
I created the feet in the sculpt environment, using a quadball, flatten, and soft sculpting. I then created an offset plan below the foot, sketched a large rectangle and extruded it into the foot, making it flat. Then extrude the circle at the end of the leg into the foot, finishing the leg. Mirror the leg over the plane that bisects the body of the figure, creating the finished legs.
To create the arms, the process is the same as the legs, so follow alone with steps 4-7 to create the arms. One tricky part about the arms is they are at an angle from the body as opposed to the legs. To counter this, when sketching the line from the socket in step 4 make sure the line is not perpendicular to the face. The only other different aspect of the arms is the hands. At the end of the arms, create a 5 mm diameter sphere. Construct an offset plane directly above the sphere and sketch a 3 mm diameter circle centered offset from the center of the hand and extrude it completely through the hand. Fillet the edges with a fillet radius of .2 mm.
Then mirror the arm just as you did the leg, finishing the limbs of the figure.
I created the head in the sculpt environment using a quadball. I flattened the face (probably too much) and slightly flattened the back of the head, using the flatten and soft sculpting tools. Once finished shaping the head, create a 4.5 mm diameter ball to fit in the socket at the neck. Construct an offset plane in between the head and the ball, sketching a 4.5 mm diameter circle on the new plane. Extrude the circle both into the head and into the ball, joining them to make one body. Make the taper angle -10° going into the ball and 10° going into the head.
The last step is creating the face. Start by lowering the opacity of the head to sketch directly onto the plane underneath. Sketch one 5 mm diameter circle on the work plane, bisect it, and trim it to a half circle. Above that sketch an arc with a width of 4.5 mm. Offset this arc .75 mm above that and connect the two shapes with two more arcs on the open ends. Then mirror the half circle and eyebrow onto the other side of the axis that bisects the face.
Below the eyes, sketch an arc with a width of 25 mm, making the axis the midpoint. offset this arc by .5 mm. Close off the two open ends with two more arcs.
Revolve each of the eyes around its flat side, extrude the smile 1.75 mm and extrude each eyebrow .5 mm. Fillet all of the edges of each eyebrow with a fillet radius of .25 mm. Do the same to the mouth with the same radius. Select all of the bodies (both eyes, both eyebrows, and the smile) and move them above the head, then move each component into the head. Do not make the face components join the head, they need to be separate bodies for dual extrusion to make the face a different color.
Slicer: Cura 3.0
Layer Height: 0.2 mm
Infill Density: 20%
Support: Yes, touching build plate
Nozzle Size: 0.4 mm
Estimated Material: ~ 34 g
Estimated Print Time: 4.25 hours
Files for this print can be found here.