Fusion Fundamentals Workbook Instructor 1st Edition
Fusion Fundamentals Workbook Instructor 1st Edition
2024-2025
FUSION
FUNDAMENTALS
WORKBOOK
INSTRUCTOR
ED CHARLWOOD
JAKE O SUGDEN
JOSHUA MANLEY
Fusion Fundamentals Workbook Copyright ©2024 by CADclass. Authors Jake
O Sugden, Joshua Manley, & Ed Charlwood.
Disclaimer: The information in this book is true and complete to the best of the
author’s knowledge. Any advice or recommendations are made without
guarantee on the part of the author or publisher. The author and publisher
disclaim any liability in connection with the use of this information.
Other product and company names mentioned herein may be the trademarks of
their respective owners. Rather than use a trademark symbol with every
occurrence of a trademarked name, we are using the names only in an editorial
fashion and to the benefit of the trademark owner, with no intention of
infringement of the trademark.
Publisher: CADclass
His approach to teaching has earned him prestigious accolades and recognition,
including the honor of being a Google Certified Innovator, an Apple Distinguished
Educator, and an Autodesk Academic Partner. He also serves as a Fellow of the Royal
Society, which recognizes people who make a "substantial contribution to the
improvement of natural knowledge, including mathematics, engineering science, and
medical science."
What is CAD 6
User Interface 10
Classic Donut 17
Brick Ring 30
3D Printing 36
Emoji Face 43
Laser Cutting 48
Saturn V Rocket 54
Artificial Reality (AR) 60
2D > 3D Design Intent 66
Carabiner 69
Finger Surfboard 81
Pizza Cutter 90
TinkerCAD 104
Rendering Workspace 105
Animation Workspace 107
Manufacturing Workspace 108
Drawings Workspace 109
End of Book Test 113
Glossary 115
Certificate 120
How To Use This Book
Welcome to the multi-tool of parametric CAD software, Autodesk Fusion! Get
ready to combine powerful tools and fun challenges to master transformational
new design skills.
This workbook is your blueprint to augment live instruction. Students should fill in
the blanks, check the boxes, do the projects, and think. Learning the fundamentals
takes about 12 hours. Mastery takes a lifetime. Your journey starts here!
Now this page is complete, check this off, to keep track of progress >>>
How To Use This Book
Welcome to the fantastic world of Fusion! We are delighted that you are
empowering your students with this powerful tool.
All the pages with a grey background like this one are for instructors and self-
learners. They provide answers, links, QR codes for further reading, and
valuable background knowledge to add depth and richness.
You may find that some students grasp the fundamentals quickly, in this case
we encourage you to seek out our book Mastering Autodesk Fusion Edt.2
which has 27 amazing, challenging step-by-step practice projects:
CADclass.org/pages/books
Excel
Garageband
PowerPoint
Types of CAD
2D (Autocad)
3D (Tinkercad)
Parametric (Fusion)
Textiles and clothing (Clo3d.com)
Forms, surfaces and characters (Blender.org)
6
What is CAD?
CAD stands for:
A: Aided
D:
The first 747 “jumbo jet” flown in 1969 was designed using 75,000 paper
drawings of 4.5 million parts, 136 miles of electrical wiring, 5 landing gear legs,
4 hydraulic systems, and 10 million labor hours: t.ly/6SRqJ
CAD revolutionized the design process. Designs are now created digitally,
allowing for easy modifications and precise measurements. Virtual prototyping
enables rapid testing and iteration without physical production. Collaboration is
enhanced through digital file sharing and simultaneous work on designs. 3D
visualization provides photo realistic representations, while integrated simulation
tools allow for comprehensive analysis before manufacturing. CAD also
facilitates integration with other technologies like 3D printing and CNC
machining, enabling mass customization, and reducing material waste. These
advancements have made design faster, more accurate, and more innovative.
7
What is Autodesk Fusion?
Designers and Engineers are human superheroes with unique skills to improve
the world. They created everything you see, hear, touch, and feel.
CAD is like having a superpower that lets you design and create anything you
can imagine. So, let's master the fundamentals of Fusion a powerful tool that
real architects, engineers, and designers use daily to bring their ideas to life.
8
Why Learn CAD?
Reasons to Teach CAD
CAD skills are in high demand across
various industries (engineering, architecture,
product design, etc.)
Fusion is widely used in professional settings,
giving students relevant experience
Integrates multiple disciplines: design,
engineering, mathematics, and technology
Provides practical application of theoretical
concepts
Allows students to bring their ideas to life in
a digital space
CAD challenges students to think critically
about design and functionality
Teaches iterative problem-solving through
design revisions
Prepares students for a digitally-driven future
Now you have read this page, check this off >>>
Discord Community
We all have experiences of asking questions on a forum and receiving unhelpful
or overly advanced responses that leave us feeling more confused and frustrated
than before.
Discord.gg/5hbt6xDPqf >>
9
UI (User Interface)
These are the buttons for This is where you’ll find
the Data Panel, File, all your account details
Save, Undo & Redo. and preferences.
10
UI (User Interface)
This is the Data Panel. Click the 3x3
square to see your folders and files.
11
Folders & Files
Your Data Panel is where all of your files are
stored and organized. When you first open this
page, you will see a series of Projects. These are
the top-level organization structures that house
your folders. Think of projects like your Desktop,
Documents, Downloads, Pictures, etc.
......................................................
12
Number The UI Features
1 2 3 4
Navigation Bar Toolbar Layout grid Account
5 6 7 8
Timeline Browser ViewCube Data Panel
13
Solutions
1 2 3 4
Navigation Bar Toolbar Layout grid Account
8 4
2 7
6
3
5
1
5 6 7 8
Timeline Browser ViewCube Data Panel
Mouse Controls
Click on your Profile icon in the top right corner and select Preferences.
Verify the Default Modeling Orientation is set to Z Up and change your Pan,
Zoom, Orbit Shortcut to Tinkercad.
Select:
Zoom:
Pan:
Orbit:
14
ViewCube
Label the axes (X, Y & Z):
15
Solutions
.....................................................................................................
YZ
In general, it is best practice to choose the plane that logically makes your
project appear like it would in real life. Designing a coffee mug standing up, not
on its side or upside down, makes the most sense.
This skill may be confusing now, but it will improve as you design more projects
in this book.
16
Active Engagement
U.I. (User Interface)
Mastering Fusion UI is crucial because it directly
impacts design efficiency and creativity. UI mastery
matters because it reduces time spent hunting for
commands, keyboard shortcuts speed up repetitive
tasks, and quick navigation means more time for actual
design. You can try:
A UI Scavenger Hunt: give students features to find
(timed)
Try “speed modeling” using only shortcuts
Celebrate finding multiple ways to access the same
command
Encourage sharing of “productivity tips” with
classmates
Mouse
We strongly encourage everyone to use a 3-button
mouse (with a clickable scroll wheel).
ViewCube
Mastering the ViewCube matters! Quick orientation
saves time and improves spatial understanding.
Encourage students to click on all the edges, faces,
and corners, and encourage them to use these
terms when discussing their 3D designs with you.
Our Pedagogy
This chapter in the Fusion Fundamentals Workbook is designed to teach 3D
modeling concepts to beginners using Autodesk Fusion. The goal is to build
foundational knowledge and practical skills through a simple, engaging project
everyone is familiar with. By focusing on intentional practice and play, students
will develop the mindset of a CAD designer and can take these basic building
blocks as far as their imagination goes.
The donut in the section ahead is a tangible, relatable object. It provides a clear
goal, making the abstract concepts of 3D modeling concrete. It’s easy to
visualize, reducing cognitive load and freeing up space to complete other taxing
tasks.
There are many technical terms and tools (like Revolve, Extrude, and Spline)
within the context of creating the donut. This helps students understand not just
what these tools do, but when and why they would use them in a real modeling
scenario.
The donut project strategically introduces new skills and concepts, starting with
basic operations like sketching and revolving, then progressing to more
advanced techniques like splitting faces and creating custom appearances. This
progression helps build a foundation of fundamental workflows and will be used
throughout the book. For now, these steps are written in detail. However, the
level of detail (the scaffolding) is gradually removed throughout this book.
After the project, key concepts and vocabulary are reinforced. This helps solidify
learning and encourages students to reflect.
Pedagogy
The chapter mentions additional resources, like CADclass.org, for more detailed
walkthroughs, encouraging students to seek more information and continue their
learning journey.
Sources:
Tangible, relatable object approach:
Situated Learning Theory (Lave & Wenger, 1991)
Constructivism (Piaget, 1936; Vygotsky, 1978)
Hands-on experimentation:
Experiential Learning Theory (Kolb, 1984)
Active Learning (Bonwell & Eison, 1991)
Other ideas:
Bring in donuts / 3D print a sliced donut
Bring in a bagel & bread knife and slice
Intro: Classic Donut
Imagine everyday objects around you, not as finished products, but as simple
2D shapes waiting to be transformed into 3D forms. With a few creative tweaks,
a basic rectangle becomes a sturdy tabletop, and four elongated squares stretch
into legs, giving rise to a table.
In this project, you will explore one of the most fundamental but powerful
workflows in Fusion - turning a 2D flat sketch into a 3D object. With one basic
shape, a couple clicks -- and a few simple tricks -- you will create a mouth-
watering Classic Donut!
Key learning:
17
Classic Donut
.............................................................................
This gray dot is the Origin and is the only fixed point in
the Fusion universe. Most of your sketches will reference it.
18
Classic Donut
Press [ C ] for Circle, click to the right
of the Origin near the X-axis, move
your cursor up, and click again to
define the circle's diameter - don’t
worry exactly how big it is, for now.
To make the Donut shape, you will rotate the circle about a vertical
axis.
Because the vertical line is assisting you in making the donut shape,
you can turn it into a Construction line. Click the line and press [ X ].
It should now be dashed.
Q? What happens if you do not press Esc after using a sketch tool?
...............................................................................................
...........................................................
The order of operation doesn’t matter with this tool. You could
also click the two points in reverse order or hold down
Ctrl/Cmd, select both points, and then select the Horizontal /
Vertical constraint.
19
Classic Donut
Type [ D ] for Dimension, click on the
Origin, then the circle’s center, move your
cursor up, click, type 40, and press Enter.
This has defined the location of the circle,
but not its size.
.......................................................................
Click Finish Sketch in the top right corner and click the
house icon on the ViewCube to get an Isometric view of
your sketch. When transitioning from a 2D Sketch to the 3D
Workspace, always have a 3 dimensional view.
.......................................................................
20
Classic Donut
The default appearance and material in Fusion is
grey steel.
.........................................................................
Navigate to Create >> Spline >> Fit Point Spline, click above and below the X-
axis 6 times (so the first and last points are outside the donut), and press Enter.
Unlike other tools, pressing Esc will delete the spline, so you must press Enter.
.....................................
21
Classic Donut
..................................................
......................................................
22
Classic Donut
To make the top half of the Donut look like dripping colorful icing, you need to
add an appearance to the top face. Unfortunately, there is no premade Pink
paint in the Fusion Appearances Library...so let’s make a custom one!
.....................................................................
Review:
23
Reinforce & Stretch
Try to re-do the Donut project in the same file with these changes:
Make the diameter of the circle 60 mm instead of 40 mm.
Change the distance from the Origin to 35 mm not 40 mm.
Explore these questions and try the prompts to find out what's possible:
1. Try to make the curves on the 5. As you click more using the
spline used to split the donut more spline tool, what happens to the
‘extreme’. curvature of the line you are
creating?
2. Try to take a “bite” out of each
side of the donut, as if it had been 6. What happens when you
shared. Extrude (cut) if you don’t select all
the circle’s faces?
3. Try to make the donut have a
chocolate icing topping, exploring 7. Can you enter #RGB codes
the Appearances. when editing colors?
Sketch a storyboard of
how you would design,
constrain, and dimension
the profile of a plate to
place the donut on using
Sketch and Revolve.
24
Rubric
Confidently Navigates
Can navigate
navigates the basic UI Has difficulty
most of the UI
UI Navigation UI, utilizing all elements but navigating the
and use
major tools and struggles with interface
common tools
features some features
Can apply
and modify a Can apply a
Can apply an
range of range of Has difficulty
appearance to
Apperances appropriate appearances applying an
a body
appearances to to bodies appearance
and/or faces
bodies and and/or faces
faces
Can ask
insightful Tries to solve
Asks for help Is often stuck
Problem questions and problems but
and tries to and cannot get
solving solve issues often gets
solve issues un-stuck
independently stuck
and creatively
Tool Review: Revolve
25
Tool Review: Dimenions
Dimensions are used for 2 main purposes, setting the exact sizes of
individual parts, and defining the placement and spacing of geometry.
While dimensions are essential, there are some potential pitfalls.
Applying too many dimensions can lead to sketches that are visually
busy and hard to read, but also almost impossible to edit effectively.
26
True or False?
27
Solutions
Dimension D
Construction ?
A ?
? De-select
? E
Appearance ?
28
Solutions
Dimension D
Construction X
A Appearance
Escape De-select
Extrude E
Appearance A
Split Face
Revolve
Challenge
Challenge 1:
29
Active Engagement
In this project, your students will explore the process of making a ring that can
clip a toy building brick onto it. This project facilitates the repetition of the 2D to
3D workflow (Sketch to Extrude) to create the ring’s basic shape and then again
by sketching on a face, not a plane as before.
Most students love building bricks, making this lesson relatable and
expandable. Play, build, print, and have fun!
With a few creative modifications, a basic circular shape turns into a practical
platform, designed to securely carry a small figure and bring a playful element
into everyday wear.
In this section, you'll dive into the process of transforming flat 2D sketches into a
functional 3D object using Fusion's essential tools.
Starting with a classic ring design, you'll learn how to create a unique, 3D-
printable holder that can comfortably grip a small plastic brick or figurine with a
few simple steps.
Key learning:
Sketch and Extrude the basic shape of the Ring Body on an Origin Plane.
Make Sketches on Faces, not just Origin Planes.
Add Dimensions and Constraints to Sketches to keep them organized.
Extrude cut away a cavity that can be sized to fit perfectly on your finger.
Extrude enclosed profiles with taper angles for tight fits with plastic parts.
30
Brick Ring
Start by clicking the ( + ) symbol at the top of your screen to start a new file.
This opens a new tab, like in an internet browser.
..................................................
31
Brick Ring
.............................................................
32
Brick Ring
Notice that the circle and rectangle were blue before adding dimensions and
black after. Blue lines are Undefined, meaning the size and location of the
geometry is unknown. Black lines are Defined, meaning size and location are
known.
..................................................
33
Brick Ring
.........................................................
Click and hold your right mouse button to orbit to the flat face. You
can also click and drag the ViewCube to orbit but the mouse is
easier.
Select the Horizontal / Vertical Constraint tool and click both circle’s centers.
Select the Equal Constraint tool and click both circles circumferences to make
them the same size. Notice the new Constraint icons on the two circles.
34
Brick Ring
Press [ D ] for Dimension and
add all of the following
dimensions.
..................................................
Click Finish Sketch press [ E ] for Extrude,
select the 2 circles, set the Distance to 2.25 mm,
the Taper to -2 deg, and click OK.
..........................................................
Type [ A ] for Appearance, search for your
favorite color, and click and drag the icon
onto the Body.
35
3D Printing
3D Printing (a form of Additive Manufacturing) is a process where a three-
dimensional object is created by adding layer upon layer of material. This is
done using a computer-controlled machine that can print objects from a digital
design file.
The most common type is called Fused Deposition Modeling (FDM) where a
plastic filament is melted and Extruded, building up the object 1 layer at a time.
...which can be
...becomes a 3D
A 2D sketch... exported and then
design...
3D printed!
36
3D Printing
3D printing, like paper printing, is seemingly simple. However, there are many
steps to get your machine set up properly and many things that can go wrong!
Here’s a basic 3D printing workflow overview:
Import the STL: Open the slicing software and import the STL file. To customize
the print, you can adjust settings like layer height, infill density, and print speed.
Slice the Model: Once you're happy with the settings, click Slice to generate the
G-code. This set of instructions tells the printer how to move and Extrude the
filament to create the object.
Save the G-code: Save the G-code file to an SD card or USB drive, which you'll
use to transfer the file to the printer.
Load Filament: Before you start the print, you'll need to load the filament into the
printer. This involves feeding the filament through the Extruder and into the hot
end, where it will melt and be deposited onto the print bed.
Start the Print: Insert the SD card or USB drive into the printer and select the G-
code file you want to print. The printer will then start the print, following the
instructions in the G-code file to create the object layer by layer.
Remove the Object: After finishing the print, remove the object from the print
bed. Be careful, as it may still be hot.
Learn more from our good friends at Printlab: Designing for 3D Printing:
t.ly/R-MYe.
Reinforce & Stretch
Try to re-do the ring exercise from scratch but with these variations:
Make the outer diameter circle 35mm instead of 24mm.
Increase the wall thickness to match the original inner
diameter.
Explore these questions and try the prompts to find out what's possible:
37
Rubric
Sketch on
Has difficulty
Create sketches faces and
Only sketch on sketching on
Sketch Tools on faces and planes but
faces or planes faces and
planes sometimes has
planes
trouble
Has difficulty
Apply and edit Apply and edit Apply a limited
Dimensions applying any
a range of some range of
and dimensions
dimensions and dimensions dimensions
Constraints and/or
constraints and constraints and constraints
constraints
Export a 3D Export a 3D
Export a 3D Is unable to
printable .STL printable .STL
3D Printing printable .STL export a 3D
file with some file with some
file printable file
difficulty help
Explain how to
Has difficulty
create the ring Mostly explain Explain how to
explaining how
Process using the how to create create parts of
to create the
technical CAD the ring the ring
ring
terms above
Tool Review: Extrude
38
Tool Review: Fillet
39
True or False?
40
Solutions
Dimension D
? De-select
? Circle
Appearance ?
41
Solutions
Dimension D
Isometric view
Finish Sketch
Escape De-select
C Circle
Appearance A
Horizontal / Vertical
Create Sketch
Challenge
Challenge 1:
Challenge 2:
Create a block which you can attach your brick figures to accessorize your
computer monitor. You’ll need to think about the dimensions of the section to
remove from a cuboid to slide over the top of your laptop screen.
42
Active Engagement
The chapter uses highly engaging and relatable subject matter that connects
with students' daily digital experiences while teaching fundamental CAD skills.
Here are some practical ways instructors could enhance this activity:
Generally, you’ll aim to use more constraints and fewer dimensions. This makes
Sketches easy to read, easy to edit, and easy to understand if you need to look
at it in the future or give the file to a peer.
In this activity, you will sketch an emoji to practice using a variety of constraints.
You will soon see how these simple foundations turn into rockets headphones,
and more.
Key learning:
43
Emoji Face
Click the Save icon and save the file as “Emoji Face” to
the Fusion Fundamentals folder .
.......................................
Write it here [ ]
Select the Circle tool, click on the Origin, move your cursor away to make a
lager circle that fills up your screen.
When you start a circle at the Origin, its location is Defined but its size is
unknown, meaning the entire circle is still Undefined.
44
Emoji Face
....................................................................
45
Emoji Face
To make the horizontal line down the
middle of the teeth type [ L ] for Line.
...............................................
You can manually add constraints to Sketch features, but Fusion will
also try to work out (infer) what constraints it thinks you want and
suggest them to you with a light blue icon. This can be helpful, but you
can also add them accidentally.
....................................................................
46
Emoji Face
..........................................
47
Laser Cutting
Laser cutting is a sophisticated manufacturing process that utilizes a focused
light beam to cut through materials, providing precision and versatility in
creating intricate shapes.
This technology has widespread use in the automotive and electronics industries
Lower power (20W) machines typically cut or engrave sheet materials like
plywood or acrylic, while industrial versions (1kW +) can cut steel and glass.
You can also use DXF files on other 2D tools like Laser Etchers, Vinyl Cutting
machines, Plasma Cutters, and Embroidery Machines.
...............................................
48
Reinforce & Stretch
Try to re-do the symmetrical Emoji Face exercise with another emoji.
Practice this approach: add your geometries first and fast, then add
constraints, and lastly dimensions. If you need inspiration, try one of
these (easy > hard):
Explore these questions and try the prompts to find out what's possible:
3. Try remove key constraints mod- 7. Can you copy and paste sketch
sketch, for example, to the origin, entities?
and see what happens.
8. Which new terms can you fill
out in the glossary in the back of
the book?
49
Rubric
Understands Understands
Can apply a Has difficulty
and correctly and can apply
Constraints limited number applying
applies all most
of constraints constraints
constraints constraints
Understands
Can apply
and can apply Can mirror with Has difficulty
mirror to
Mirror mirror to limited mirroring
symmetric
symmetric understanding sketches
sketches
sketches
Understands Difficulty
Understands Understands
how to sketch understanding
how to sketch how to sketch
Sketch Mastery and resize how to sketch
and resize and resize 1
various and resize
some shapes shape
shapes shapes
Lacks
Has mastery Has difficulty
Understands understanding
Dimensions over when to applying
when to apply of when to
and apply dimensions
dimensions vs apply
Constraints dimensions vs and
constraints dimensions vs
constraints constraints
constraints
Confidently
explains how Can mostly Can explain Has difficulty
Problem the emoji was explain how to how to create explaining
Solving created using create the parts of the how to create
the CAD terms emoji emoji the emoji
above
Tool Review: Constraints
Constraints that contradict each other can cause the model to become
unstable or fail to update correctly.
Constraints can create complex dependencies between different elements of
the model. Changes to one part may have unintended consequences on
other parts, which can make the design process more challenging.
50
Constraints Review
Name the Constraints and draw the icon
Coincident
51
Solutions
Name the constraints and Sketch the icon
Concentric
Coincident
Midpoint
Tangent
Vertical
Horizontal/Vertical
52
Solutions
Horizontal/Vertical
Coincident
Tangent
Equal
Parallel
Perpendicular
Fix / Unfix
Midpoint
Concentric
Collinear
Symmetry
Curvature
Challenge
Midpoint Constraint
Perpendicular Constraint
53
Active Engagement
This chapter scaffolds learners through a complex CAD project. It breaks down
the iconic Saturn V rocket into segments, teaching important concepts like
Extrusions, tapered angles, patterns, and appearances through a real-world
example. Here are practical ways educators could enhance this activity:
Making these designs real brings CAD to life. When students can
touch, test, and share their creations, CAD class becomes an
engaging experience they'll remember long after graduation.
Intro: Saturn V Rocket
Congratulations on mastering fundamental skills in
Fusion! You've learned how to sketch, apply
constraints and dimensions, add appearances, and
use features like Extrude and revolve—all following
the crucial 2D to 3D workflow.
Key learning:
54
Saturn V Rocket
....................................................................
.................................................................
..............................................................
55
Saturn V Rocket
........................................................
.........................................................
..............................................................
56
Saturn V Rocket
.........................................................
57
Saturn V Rocket
Set the Taper Angle to -11 deg and change the Operation
from Cut to Join.
.........................................................................
58
Saturn V Rocket
................................................
....................................................................
59
Saturn V Rocket
Navigate to Create >> Pattern >> Circular
Pattern, change the Object Type to Features,
and select the two most recent Extrusions and
the Fillet in the Timeline.
...........................................................
Review:
60
Reinforce & Stretch
Explore these questions and try the prompts to find out what's possible:
2 - What does the curved arc with 5 - With Extrude activated, click
the grey circle do that appears and move the blue arrow below
when Extruding? the face it joins. what does it do?
61
Rubric
Understands Understands
how to fully how to Can constrain Has difficulty
Fully Constrain constrain constrain most a single constraining 1
sketches (black simple simple sketch simple sketch
lines) sketches
Can modify
Can modify a Can find and
body and apply Has difficulty
body using use the Split
Split Body appearances using the Split
the Split Body Body tool with
using the Split Body tool
tool instructor help
Body tool
Asks insightful
Tries to solve
questions and Asks for help Is often stuck
Problem problems but
solves issues and tries to and cannot
solving often gets
independently solve issues get un-stuck
stuck
and creatively
Tool Review: Pattern
62
True or False?
63
Solutions
? Extrude
Circle ?
? A
64
Solutions
E Extrude
Circle C
Appearance A
Extrude
Circular Pattern
Challenge
Challenge 1:
Challenge 2:
65
2D > 3D
Storyboard the sketches, features, and tools used to create this (use some, or all
of these boxes, as necessary).
66
2D > 3D
Option 1 Option 2
Both methods are valid approaches for creating a plant pot in Fusion.
The “best” method depends on the specific design requirements and the
designer's preference.
2D > 3D
Storyboard the sketches, features, and tools that could be used to recreate this
toy brick with an open bottom (use some, or all of these boxes, as necessary).
67
Solutions
Option 1 Option 2
This method allows for more Fewer steps are involved, which
variation in the brick's can save time.
dimensions, as you can adjust The Shell function means all
the width and length of the wall need to be the same
rectangle. thickness, unless you add
Option 1 involves more steps another step.
than Option 2, potentially
increasing the risk of errors.
Both methods are valid approaches for creating a toy brick in Fusion. In some
cases, a combination of both might be used to achieve the desired result.
Design Intent
68
Active Engagement
The carabiner scaffolds progression by introducing sweep operations - a more
advanced CAD concept - through a practical, real-world object. It combines
previously learned skills (sketching, constraints) with new concepts (sweeps,
modifications) in a project that students can produce via 3D printing. Here are
some key pedagogical elements and suggestions for enhancement:
Product Analysis:
Timeline Learning:
Product Showcase:
Key Skills:
69
Carabiner
..........................................................
...........................................................
70
Carabiner
Repeat this step on the other side.
...................................................................
..............................................................
There are two ways to fully define this sketch that take the same amount of time.
..........................................................................................
71
Carabiner
Navigate to Create >> Sweep. Select the profile and path and click OK.
................................................................
..............................................
In manufacturing, sharp edges are almost always removed. Fillets (rounded) and
chamfers (angled) are the most common techniques for removing them.
72
Carabiner
New sketch on the Carabiner’s top face.
................................................................
....................................................................
New sketch on the Carabiners Top Face. Make the slots shown. Use the Equal
and the Parallel constraints and add the following dimensions. Fully define the
Sketch.
73
Carabiner
.........................................................
.................................................................
............................................
74
Carabiner
Review:
To create the Carabiner you
Swept a Profile around a
Path
You Extrude-cut to make a
latch and also modified the
Body with a Chamfer and
Fillet
Notice the 2D to 3D to
Modify workflow
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Reinforce & Stretch
Explore these questions and try the prompts to find out what’s possible:
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Rubric
Understands why
it's necessary
Understands Somewhat Has difficulty
Multi-Plane and how to
how or why understands with concept
Sketches create sketches
but not both how or why and execution
on different
planes
Can join
Understands Has difficulty
sketches with the Can join a
the concept but using and
Sweep sweep tool using single profile
has difficulty understanding
different profiles and path
applying it the sweep tool
and paths
Understands
Understands
how and why to Understands
how to use Has difficulty
Chamfer & modify 3D how to use the
either the Fillet using Fillet and
Fillet bodies using Fillet and
or the chamfer chamfer tools
chamfer and chamfer tool
tool
Fillet tools
Understands Understands
Has difficulty
when inferred inferred Understands
Inferred understanding
constraints are constraints but some inferred
Constraints inferred
created and how has trouble constraints
constraints
to delete them removing them
Can ask
insightful
Asks for help Tries to solve Is often stuck
Problem questions and
and tries to problems but and cannot get
solving solve issues
solve issues often gets stuck un-stuck
independently
and creatively
Tool Review: Sweep
Unlike the other Create tools, the distance the Profile is swept is not a dimension,
but a fraction of the length of the Path. If the Body is half the length of the Path,
then the Distance would be set to 0.5 = 50%.
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True or False?
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Solutions
? Line
T ?
Apperance ?
Sweep icon
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Solutions
Show/Hide icon
Tangent
Save
L Line
T Trim
Apperance A
Sweep icon
Fillet
Challenge
Challenge 1:
Challenge 2:
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Active Engagement
This chapter uses the narrative and real-world connection, opening with a
description of surfing that connects technical CAD concepts to tangible
experiences in a fun scaled-down way. This approach helps students understand
the relationship between 2D design and 3D objects in a meaningful context.
Teaching Lofting:
Use transparent materials to show internal profiles
Demonstrate how profile order affects shape
To teach Offset Planes use physical spacing boards
Explore other shapes that could be lofted e.g a banana
In this chapter, you’ll explore how to take multiple flat 2D profiles of a surfboard
and sculpt it into a fully realized 3D object using the Loft tool. You’ll begin with
sketches—outlining the length, width, and board’s curvature. From there, you'll
shape the size, curvature and fin placement, translating ideas into something
you can imagine riding. By the end, you’ll see how moving from 2D to 3D is
more than a technical step—it’s where design starts to feel real, and your
surfboard goes from lines on a screen to a creation capable of slicing through
the waves.
Key Skills:
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Finger Surfboard
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Finger Surfboard
....................................................
.....................................................
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Finger Surfboard
...................................................
Thread some string through the hole, tie a knot, and tie another end around your
ring finger. Have a friend get up to speed, lower your window, and ride your
surfboard in the air!
Q? Ask the Autodesk Assistant (in the bottom right corner): “Are there other
ways to save an STL file?”What does it suggest?
............................................................................
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Reinforce & Stretch
With all these planes and sketches, the browser can become
confusing. Try to right-click on Features in the Timeline and
rename them logically and methodically, e.g., Offset Plane 1
(smallest ellipse).
Explore these questions and try the prompts to find out what's possible:
3 - Can a Loft do a “cut” like you 7 - Does the Pattern tool help
can in Extrude? reduce repetition?
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Rubric
Understands
Understands Has difficulty
how to join 2
how to join 3+ Understands using and
Loft sketches on 2
sketches on 3+ the concept understanding
planes using
planes using loft loft
loft
Able to create
many types of Able to create Able to create Has difficulty
Independent
custom features a few custom 1 custom creating a
Features
such as holes features feature custom feature
and fins
Able to
Able to rename rename and
Able to
Rename and sketches, reorganize Has difficulty
rename at
Organize body's, and some features, renaming
least 1 item
timeline features body's, or
sketches
Can ask
insightful Tries to solve
Asks for help Is often stuck
Problem questions and problems but
and tries to and cannot get
Solving solve issues often gets
solve issues un-stuck
independently stuck
and creatively
Tool Review: Loft
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True or False?
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Solutions
? E
? P
? Circle
Apperance ?
? Ellipse
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Solutions
Extrude E
Project P
Save
C Circle
Apperance A
Loft
Ellipse
Challenge
Challenge 1:
Challenge 2:
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Design Intent
When designing your projects, you followed a
logical approach by starting with the largest
sections and added or subtracted more and more
detail. From there, you proceeded to design and
dimension the smaller parts in a step-by-step
process, working from one element to the next in a
methodical "domino" progression.
There are often multiple ways to achieve your desired outcome, with some
methods taking longer than others. For instance, instead of mirroring a part, you
could create it twice. The strategy you choose when approaching a design at
the conceptual level is known as “Design Intent.”
Make some notes here about how you would approach designing
a simple flashlight:
Active Engagement
All projects in this book can and should be made
in real life. This not only makes the lessons tangible
but also allows you to experiment and play in your
classroom. If you do it well, you can make your
design class something students fondly remember
forever. Here are some ideas:
1 - 3D print pizza cutter handles before class so students see them. Better
yet, have your 3D printer making them as they walk in. This brings the
lesson to life and will add to the enthusiasm. Bonus points if you cut a slice
of pizza with a cutter you made!
2 - Every part of this project can be 3D printed (the handle, blade, and
pin). However, you can also buy 5 mm stainless steel pins, order
inexpensive bulk pizza blades from Amazon or Ikea, and 3D print
handles. This way students gain valuable experience with design, sourcing
parts, tolerances, testing, and more. They’ll have to edit their designs to
get the parts to work correctly.
3 - Use this lesson as an excuse to throw a pizza party where students cut
the pie with their pizza cutters, making it an experience they’ll never
forget.
To create the pizza cutter you’ll make three Components: the handle, the blade,
and the pin connecting the handle and the blade. You’ll model each part
separately using Components, then add Joints, and then motion. By the end,
you’ll have a pizza cutter with a spinning blade.
Assemblies unlock your ability as a CAD designer to take your skills to the next
level!
Key Skills:
All assembly projects that require moving parts must be made from
Components (not Bodies) and connected with Joints. Joints allow for
linear and rotational movement, a combination of both, or no
movement at all.
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Pizza Cutter
Center to Center slot from the Origin to the right center of the previous slot. Add
a 5 mm circle at the Origin. Add the dimensions shown. Finish Sketch .
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Pizza Cutter
Mirror the Body about the Front Plane, highlight the entire Body and add a 1.5
mm Fillet.
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Pizza Cutter
......................................................................
This pin will pass through the hole in the handle holding
the blade in place while allowing it to rotate.
........................................................................
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Pizza Cutter
The Pin component is done! Activate the Root (top)
Component in the Browser. Notice the Anchor icon
next to Handle, the first component, denoting that it is
Grounded or locked in place. Also notice the icons
next to the components and next to the Root
component.
To rigidly join the two components together, add a Rigid Joint. Because the two
parts are already in the correct location, use the As-Built Joint tool found in the
Assemble menu.
...................................................
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Pizza Cutter
..........................................................
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Reinforce & Stretch
Try to design and assemble a pizza cutter starting with the pin,
then the blade, then the handle. Compare and contrast the
approaches - was one "better" than another?
Explore these questions and try the prompts to find out what's possible:
1. Change the type of Joint from 4. What does the icon for the
Revolute to Cylindrical - what is the Rigid Joint look like?
same and what is different?
5. What is the difference between
2. What happens if you press the “Animate Joint” and “Animate Joint
Flip button in the Edit Joint dialogue Relationship”?
box?
6. What does the icon for the
3. What does holding the Revolute Joint look like?
Command key on a Mac or Control
key on a PC do when applying a 7. What happens if you re-order
Joint? features in the Timeline?
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Rubric
Can connect a
Can connect Understands
single Has difficulty
components the concept but
Joints component understanding
using multiple has trouble
using 1 type of and applying
Joint types applying it
Joint
Can describe
design flow Has difficulty
Understands Understands
Put it all from sketch to understanding
most of the full- some of the full-
Together 3D, to modify, any of the full-
arc arc
to Joint, to arc
animate
Can heavily
customize pizza Can Has difficulty
Can make
cutter and substantially using the tools
Explore minor
create new customize the beyond the
modifications
designs from pizza cutter steps provided
scratch
Can ask
insightful
Asks for help Tries to solve Is often stuck
Problem questions and
and tries to problems but and cannot
Solving solve issues
solve issues often gets stuck get un-stuck
independently
and creatively
Tool Review: Joints
Y
The 6 DOFs (Degrees of Freedom) are
along - translational - 3 axes (X, Y, and Z) B
and also around - rotational - each axis.
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Tool Review: Assembly
Components can be thought of as folders that hold all the information about a
part including the 3D Body, the 2D Sketches, Construction geometry to make the
part, and Canvas images.
In Fusion, there are two types of components: Internal and External. Using
Internal components is more common. As the name implies all the data about the
component is held within the assembly file.
External components store all the parts data outside the assembly file in a folder.
This frees up more computing power in the assembly file but can be tricky to
work with.
The Assembly at the top of the Browser
(AKA the root component) holds all
components.
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True or False?
99
Solutions
Allows a Component to
rotate but is confined to only
Planar being able to move in one
plane.
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Solutions
Allows a Component to
rotate but is confined to only
Pin Slot
being able to move in one
plane.
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Students’ Headphones
Welcome to our showcase of four unique student headphone design projects!
Each of these designs reflects the creativity and skill of our students, who have
taken different approaches to achieve distinct results.
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Explore Workspaces
Our books are available on Amazon and other platforms or for a donation/free:
CADclass.org/pages/books
103
Tinkercad to Fusion
Tinkercad is another CAD software also made by Autodesk. One of the Export
links in Tinkercad is called Send to Fusion, which sends your Tinkercad design
straight to Fusion if you already have it installed and open.
a.co/d/fNAF2CX
Our books are available on Amazon and other platforms or for a
donation/free: CADclass.org/pages/books
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Rendering Workspace
Not only can you move your model around this world,
but you can also adjust the environment to suit the mood
or vibe of your project.
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Rendering Workspace
Once your scene is set up to your liking,
you can render the image to be
photorealistic.
There are also many new AI-powered rendering tools (used to make digital
designs more realistic). If you are interested, search for and try one with one of
your Tinkercad creations.
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Animate Workspace
Open the Pizza Cutter design and enter the Scratch Zone
Animation Workspace. The timeline on the
bottom of the screen works similarly to a
timeline in video editing software, but
instead of editing clips, you edit movements
of your view, zoom, linear movement and
rotational movement of parts.
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Simulation Workspace
The Simulation Workspace is locked behind a paywall for the Hobbyist license
of Autodesk Fusion but is available in the Educator license.
The concepts of FEA (Finite Element Analysis) and mechanical engineering can
be intimidating, but this tool can be easy to use if you know the simple process.
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Drawing Pedagogy
Technical drawings are standardized, detailed visual representations of objects,
systems, or structures that communicate precise specifications and technical
information.
...................................
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Drawing Workspace
110
True or False?
111
Solutions
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Solutions
1. What does CAD stand for? CAD stands for Computer-Aided Design, as it
involves using computer software to assist in the design process.
3. What is the name of the navigation tool located in the upper-right corner of
the Fusion interface? The ViewCube provides a visual representation of the
model's orientation and allows for quick view changes.
4. In Fusion, what are the three primary axes representing the three dimensions?
X, Y, and Z represent the standard three-dimensional axes in CAD software and
are used for precise object placement.
6. What is the term for a numerical value that defines the size of a design
element? Dimensions are numerical values used to specify measurements like
length, width, and diameter.
8. Which file format is typically used for exporting designs for laser cutting from
Fusion? DXF (Drawing Exchange Format) is a widely compatible format for 2D
drawings, commonly used in laser cutting applications.
10. Where is the hierarchical structure that organizes parts and sub-assemblies
in Fusion? The Browser in Fusion visually represents the design history and
hierarchical relationships between components and bodies within an assembly.
End of Book Test
1. Name a specific piece of ‘everyday’ design software (not Fusion).
3. Explain the disadvantages of using CAD vs. designing with pencil and paper.
4. Describe 2 ways CAD could contribute to cost or time savings in design and
manufacturing.
7. Name some benefits of designers using CAD that allow for collaboration with
other designers.
8. Name the parts of a piece of clothing Fusion is well suited to design in 3D.
Why is this?
9. State specific examples of types of products that Fusion is not well suited to
designing in 3D. Why is this?
10. Name industries where CAD is commonly used and explain how it benefits
these sectors.
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Solutions
1. Microsoft Word is a widely used desktop publishing software.
4. CAD can contribute to cost savings by reducing the need for physical
prototypes and speeding up the design process, leading to faster time-to-market.
5. Some limitations include its limited compatibility with other CAD software.
8. Fusion is well suited for designing simple 3D shapes, such as buttons and
zippers because they are parts with definite dimensions, unlike clothing.
9. Fusion is not well suited for designing complex and organic 3D shapes and
structures, such as clothing patterns or detailed textures.
12. The Rendering workspace is where you can make your 3D designs look real
by adding colors, lights, and shadows. It's like taking a drawing and making it
look like it's from the real world, with shiny or smooth surfaces!
13. Keyboard shortcuts can help a CAD designer speed up everyday tasks, such
as zooming in and out, rotating objects, or switching between different tools.
14 Q: "Can you recommend any resources or tutorials for learning more about
CAD software and how to use it effectively?" A: Yes, go to CADclass.org!
Glossary
Sketch ..................................................................
Pan .................................................................
Orbit .................................................................
Extrude .................................................................
Mirror .................................................................
Constraint .................................................................
Sweep .................................................................
Loft .................................................................
Parallel .................................................................
Body .................................................................
Fillet .................................................................
Pattern .................................................................
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Glossary
Coincident ..................................................................
Shell .................................................................
Dimension .................................................................
Spline .................................................................
Body .................................................................
Revolve .................................................................
Tangent .................................................................
Fix .................................................................
Workspace .................................................................
Timeline .................................................................
ViewCube .................................................................
Isometric .................................................................
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Glossary
Component ..................................................................
Browser .................................................................
CAD .................................................................
Animation .................................................................
Render .................................................................
2D .................................................................
ViewCube .................................................................
Joint .................................................................
Version .................................................................
3D .................................................................
CAM .................................................................
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Shortcuts
3D Design Workspace
A: Apperance E: Extrude
H: Hole J: Joint
2D Sketch Workspace
L : Line X: Construction
O: Offset P: Project
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Resources
If you want more information on the previous Workspaces and CAD topics then
consider ordering Mastering Autodesk Fusion Edt.2 available on Amazon or at
CADclass.org for free or a donation. This much larger text includes the following:
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Certificate of Completion
CERTIFICATE
OF COMPLETION
Socials:
[email protected]
Youtube.com/@CADclassOfficial | Tiktok.com/@cadclass
Twitter.com/cad_class | Instagram.com/cadclassofficial
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