MASTERING FUSION 360 Copyright ©2023 by Jake O Sugden and Joshua Manley/SliceForm
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1st Edition June 2023
ISBN-13: 979-8-9881894-0-4 (Paperback)
ISBN-13: 979-8-9881894-1-1 (Hardcover)
Library of Congress Control Number: 2023907750
Publisher: SiceForm [Link]
Written By: Jake O Sugden & Joshua Manley
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Ring_inscription.svg). Involute [Link] was created by Claudio Roccichini and is licensed under Creative
Commons Attribution 2.5 Generic CC BY 2.5 ([Link]
File:Involute_wheel.gif). Sugden, Jake O. “Low Poly Skull by Sliceform.” Thingiverse, Jake O Sugden, 6
Apr. 2023, ([Link] Weatherly, Isaac. “Electric Guitar.” Pexels, 3
Feb. 2019, ([Link] Accessed 6 Apr. 2023.
“Clear Light Bulb.” Pexels, LED Supermarket, 2 Aug. 2017, ([Link]
bulb-577528/). Accessed 6 Apr. 2023. Chapter Pages Image was created by fanjianhua on Freepik and is
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PREFACE vii
PREFACE
In the early 2010’s I was a first-year engineering student taking my first Computer Assisted Design
(CAD) class. On the first day the professor walked in, handed us the syllabus, said, “this is going to be
difficult,” and walked out. I shot a confused look at my classmates, whose expressions resembled mine.
I wondered what I had gotten myself into and if this was what university was really like.
She was right; it was difficult. For the next 12 weeks, I read textbooks, attended office hours, asked
questions, and generally felt lost. I googled questions with complex answers I couldn’t understand. I
searched for courses and how-tos. I tried to find mentors or peers who could help but to no avail. I was
on my own.
I struggled through the course, using willpower and a hefty dose of caffeine, but it was not easy. When it
was over, all I felt was relief. If it weren’t for people insisting on the importance of CAD, I’m sure I would
have sworn it off forever.
And now, years later, I love to make CAD models and use the software nearly every day. As I type this,
my 3D printers are working on autopilot, replicating custom 3D models I’ve designed for my clients,
literally making money as I sleep.
The truth is, the course did not work well for me, but the professor was right. CAD is difficult to learn.
However, I also now know that learning CAD does not have to be like this. With the right training
program and the proper guidance, learning CAD is like learning how to ride a bike. It’s fun and
rewarding and gets even better as you practice. Making a CAD model helps you visualize what could
be.
So, I set out to build the CAD class I wished I had when I first learned. I wanted:
• To build models I found exciting and could make in the real world.
• To feel the real sense of progress from practice exercises that are not too hard but not too easy
either but build up from the foundation.
• A community of peers and mentors who understood where I was and when I was struggling and
could help when I ran into problems.
• To build my dream projects and feel confident doing them.
This is that CAD Class!
viii PREFACE
Does any of this sound familiar to you?
• You’ve spent months or years imagining what you could do if only you knew how to make a 3D
model and share your ideas with the world.
• You’ve endlessly searched for free tutorials on YouTube, LinkedIn, and Google, watched them and
tried to follow along but didn’t get what you needed and still don’t feel like you truly “get it.”
• You tend to get excited to start learning, progress through a few tutorials and make some progress,
but then give up a few weeks later.
• You have questions but aren’t sure how to ask them due to your limited knowledge.
• You watch a tutorial, get stuck, and Google solutions but cannot find a suitable answer to your
question.
• You feel demoralized and conclude that learning CAD may be too difficult.
I have good news. The problem is not you, your intelligence, or your learning ability. The problem is the
system, or rather the lack of one, you are trying to follow.
If you have the proper structure and relevant content at the correct time, and you are surrounded by the
right community and mentors, learning feels enjoyable and happens naturally.
Is it impossible to learn online for free? Absolutely not. You can learn for free online. It’s simply going to
take you a great deal of extra time and quite a bit of frustration to do it. You will have to develop your
syllabus, tutorials, learning plan, and troubleshooting help when things get tough. If you persevere, you
will get it, but the path will be anything but straightforward and will likely take much more time than you
anticipated.
What we’re offering you is a well-thought-out plan engineered with your success in mind. Every
project is meticulously thought out and builds on previous knowledge. I’ll give you every tip and trick
I think you’ll need as you work through 27 projects designed to take you from beginner to advanced
modeler. You’ll have access to a community of fellow CAD modelers working through the same projects
simultaneously.
We’re giving you the blueprint; all you need to do is follow it.
WELCOME TO CAD CLASS
We’re glad to have you join an exclusive club of engineers, makers, artists, hobbyists, and
entrepreneurs. Throughout this course, you will learn everything you need to know to go from beginner
to being able to make your dream projects.
You will have a chance to connect with peers, interact with us, and share what you build along the way.
This course is perhaps the best investment you can make in your future self. Good luck!
PREFACE ix
We believe it takes 3 things to be successful with CAD modeling:
1 - Good instruction that starts with the basics and builds up from there.
2 - Access to a community of people working on the same thing.
3 - Practice, practice, and more practice.
If you’re willing to commit two hours per week for the next few months, you will learn CAD. It’s as simple
as that. Do the exercises we’ve meticulously planned for you, and the results will follow.
Imagine being able to take the lead in designing projects, 3D printing custom solutions to problems,
and expanding your skillset to include one of the most powerful 3D design programs ever invented.
Are you committed to doing the work? If so, let’s go!
What this course is and isn’t, how it can help you, and who we are:
Learning computer-aided design (CAD) is a beautiful thing allowing you to communicate your
3-Dimensional ideas to people and machines. Sharing your ideas with people increases your chances of
getting hired, making a sale, or solving a problem.
Sharing your ideas with machines means you can enlist the support of an army of manufacturing
equipment ready to accept your model, diligently follow the instructions about how to make it, and
produce many more copies than you would be able to yourself. This way, your factory is ready when you
have an idea worth reproducing.
Until recently, it was prohibitively expensive to learn CAD, and only a few specialists with access to
the software learned it. Now many programs have free trials or inexpensive subscriptions, making it
possible for anyone to learn. Still, not many people do. Why?
Learning CAD is hard. Not because learning the program is hard but because the resources available
are a mix of boring, outdated, unclear, tailored to the wrong skill level, and simply unhelpful. While
many individual CAD classes can be suitable, almost none consider the learner’s current state and take
them through the journey from beginner to competent modeler. We aim to change that.
This course covers 28 projects spanning 12 different topic areas. Each is engineered to introduce a
few new ideas and gradually become more complex and challenging. These projects will combine the
tangible art of making with the digital confidence of CAD.
WHO THIS COURSE IS FOR
Makers and future makers who do not know how to CAD model but know they should. It is for anyone
new to CAD modeling or who has had experience trying to learn CAD but is still struggling to get it.
x PREFACE
It is also for people who use or have used TinkerCAD, FreeCAD, Google SketchUp, or other 3D design
software. Many of these programs have limited functionality, and if you feel constrained by them, this
program is for you.
Here are a few examples of professionals who will benefit:
• 3D printing hobbyists can use CAD to make custom parts from scratch instead of downloading pre-
made models online.
• Woodworkers can use CAD to sketch out concepts before making anything, saving time and money
and getting a clear picture of what the design will look like before making it.
• Almost all makers, machine operators, tinkerers, and dreamers will benefit from knowing CAD.
• If you’ve ever thought - I should learn CAD - this course is for you.
WHO THIS COURSE IS NOT FOR
This course is not for experienced CAD modelers unless you want a quick recap or to transition to
Fusion 360 from another CAD program. Even then, a more advanced program may be more suitable
for you. While we touch on many subject areas and do so at a reasonable depth, our target audience is
beginners.
It is not for 3D animators or digital artists unless you are an artist or animator looking to make some of
your creations physically. Still, Fusion 360 may not be the best tool for the job.
It is not for architectural or civil engineering or any other specialized professional who requires tools
more closely suited to their work.
HERE’S WHAT YOU’LL NEED TO GET STARTED
Internet + Laptop or Computer (most iPads, tablets, and Chromebooks will not work). Fusion 360 is a
cloud-based software and requires an internet connection to function fully. Ensure you also check the
latest computer specifications on the Fusion website for information about whether your machine will
work. 3D design software tends to be processor intensive.
A mouse with a clickable scroll wheel and two buttons. Some programmable mice may not work. You
can use a simple and inexpensive mouse to navigate around our projects.
Fusion360 CAD software (Make sure you sign up for the free Hobbyist or Education version)
Join the Discord community: [Link]/5hbt6xDPqf
PREFACE xi
This is where you will Discuss projects and progress with your fellow students. Please do join and
Discuss! If you need help with this, email create@[Link], and we’ll set you up.
And here are some things that are nice to have but not necessary:
• An inexpensive second monitor can be a game changer. If you can afford a second monitor, buy it.
• Calipers - These are great for making and modeling Dimensionally accurate practical objects.
WHAT IS FUSION 360?
Fusion 360 is the Swiss army knife of design and manufacturing tools. As the name implies, it is a fusion
of several different types of software.
With Fusion 360, you can design parts, make blueprints, create photo-realistic images, animate
assemblies, render objects, simulate CNC manufacturing, create Exploded Diagrams, and more.
You can build various practical CAD skills by combining a visually helpful toolset with complex and
powerful Workspaces.
HOW TO USE THIS BOOK
This is a workbook. The best way to use it is to open Fusion 360, work through the steps to make the
suggested models, and then experiment with the new functionality you’ve learned by creating something
custom.
While it is possible to binge this content, we don’t recommend it. The best way to get better at CAD
modeling, really everything in life, is to practice. We encourage you to experiment each week before
moving on to the next week’s lesson. The more models you make, the better you’ll get.
If you get stuck, have a question, or want to share something you’ve created, we encourage you to
do so on the Discord server. The QR code for the Discord channel corresponding to each project is at
the beginning of each project. It’s easier to learn with the support of a community. You can join the
community here:
[Link]/5hbt6xDPqf
Some lessons require you to download additional information or files. You can find these files by
navigating to [Link]/freedownloads or by signing up for the free preview at:
[Link].
The free preview also contains a full-color PDF if you would like a digital color copy. If you have trouble
downloading or signing up for the preview, email us at Create@[Link].
xii PREFACE
We also offer an online video course, working through these same projects on video. Some people
prefer video, some prefer written lessons, and some prefer a combination. You can sign up for a free
sample of the introductory videos at [Link].
WHEN YOU’RE STUCK
You will inevitably face challenges. When you do, here are a couple of suggestions.
Ask for help on the Discord server channel corresponding to the project you are working on
[Link]/5hbt6xDPqf
Use the Fusion 360 website Discussion forum.
FRUSTRATION WITH LEARNING CAD
“No great thing is created suddenly, any more than a bunch of grapes or a fig. If you tell me that you
desire a fig, I answer you that there must be time. Let it first blossom, then bear fruit, then ripen.” -
Epictetus.
ACKNOWLEDGMENTS xiii
ACKNOWLEDGMENTS
We want to acknowledge those who helped us establish a love for building and design, the
worldwide communities of helpful and enthusiastic makers, and those friendships built on sawdust,
sweat, and pints.
A special thanks to our large group of beta testers who helped polish, advise, and edit, and who
affirmed our belief that the best way forward in CAD education is alongside a friendly community
of like-minded tinkerers and manufacturers. Their months of help and assistance improved this
book, our courses, and the future of CAD Class and Sliceform.
And finally, thanks to our editor Robert Henry from Right Hand Publishing, whose wealth of
knowledge and unwavering support profoundly impacted this book.
ABOUT THE AUTHORS
Jake O Sugden is a mechanical engineer and lifelong maker passionate about engineering and
design. He taught many making Disciplines at one of the nation’s premier makerspaces, testing
many of the concepts found in this book over the last six years with thousands of students. He is
co-owner of Sliceform, an additive manufacturing company focused on product development and
education. He’s a Fusion 360 expert who works with the program daily.
Professor Joshua Manley is an entrepreneur and educator with a passion for making. He is a
published scientist who ran a science tutoring business in New York City, teaching Math, Chemistry,
Biology, Physics, and SAT/ACT prep. He then led the education department of one of the nation’s
largest and most successful makerspaces. He’s taught thousands of students, educators, and
administrators worldwide. His TED-Ed talk about bicycle physics has millions of views.
DEDICATED TO
This book is dedicated to our families and loved ones. Thanks to you, we kept our heads high
and our minds clear as we wrote this book and continue to build our business. Without Kasey and
Ilana’s unwavering confidence, Wayne, Jane and Holly’s unending support, Libby’s unquestioned
positivity, and the many words of encouragement from those closest to us, we would not have
succeeded.
TABLE OF CONTENTS
PREFACE............................................................................................. VII
ACKNOWLEDGMENTS......................................................................XIII
CHAPTER 0 BASICS..............................................................................16
INTRODUCTION OF CAD MODELING WITH FUSION 360
FUNDAMENTALS........................................................................................ 18
SATURN V ROCKET..................................................................................... 32
CHAPTER 1 SINGLE PARTS..................................................................40
HOW TO DESIGN INDIVIDUAL 3D MODELS
MOBIUS STRIP............................................................................................ 42
SURFBOARD............................................................................................... 48
FANTASY RING........................................................................................... 56
FILAMENT GUIDE....................................................................................... 62
CHAPTER 2 MECHANICAL DESIGN......................................................70
THE BASICS OF DESIGN USING MANUFACTURING PRINCIPLES
PLASTIC BUILDING BRICK........................................................................... 72
INVOLUTE GEAR........................................................................................ 80
GEOCACHE HIDE...................................................................................... 88
CHAPTER 3 PARAMETRIC DESIGN.......................................................98
HOW TO CUSTOMIZE YOUR DESIGNS WITH DIMENSIONS AND PARAMETERS
METRIC BOLT........................................................................................... 100
SILICONE MOLD...................................................................................... 106
CHAPTER 4 ENGINEERING DRAWINGS............................................114
HOW TO MAKE YOUR OWN BLUEPRINTS
DRUMSTICKS........................................................................................... 116
SPACE PROP EMITTER............................................................................... 124
CHAPTER 5 APPEARANCES................................................................134
HOW TO GIVE YOUR 3D MODELS COLOR, TEXTURE, AND DECALS
AMERICAN FOOTBALL.............................................................................. 136
PHONE CASE AND HOLDER..................................................................... 146
CHAPTER 6 ASSEMBLIES...................................................................158
HOW TO BUILD YOUR PROJECT WITH MULTIPLE PARTS
FIRE PISTON............................................................................................. 160
3DP HOT END.......................................................................................... 172
CHAPTER 7 JOINTS...........................................................................194
HOW TO JOIN PARTS FOR REALISTIC MOVEMENT
PIZZA CUTTER.......................................................................................... 196
TESLA TURBINE........................................................................................ 208
CHAPTER 8 CAM................................................................................234
HOW TO MANUFACTURE PARTS ON A CNC WITH COMPUTER-AIDED
MANUFACTURING
LONGBOARD........................................................................................... 236
ELECTRIC GUITAR..................................................................................... 248
CHAPTER 9 RENDERING...................................................................266
HOW TO MAKE YOUR PARTS LOOK PHOTO-REALISTIC
EDISON BULB.......................................................................................... 268
A.I. VILLAIN.............................................................................................. 282
CHAPTER 10 MOTION ANIMATION..................................................298
HOW TO MAKE YOUR MODEL MOVE AND COME ALIVE
STRANDBEEST.......................................................................................... 300
GEAR TRAIN............................................................................................. 306
ROBOTIC HAND...................................................................................... 314
CHAPTER 11 EXPLODED DIAGRAMS.................................................328
HOW TO EXPLODE YOUR PROJECT AND REBUILD THEM
JAPANESE PULL SAW................................................................................ 330
MACHINIST HAMMER............................................................................... 342
CHAPTER 12 FULL ARC......................................................................356
BRING EVERYTHING YOU’VE LEARNED TOGETHER IN A FINAL PROJECT
SPACE PROP HILT..................................................................................... 358
TOOL REFERENCES / INDEX..............................................................389
CHAPTER ANSWERS..........................................................................396
RESOURCES.......................................................................................398