How to Model a Sheet Metal Buck for Car Fenders | How To in

[@daveliberato]

You should check the Slicer plugin for Fusion 360. If the model is modified to be more of a volume instead of a surface, it will automate the whole process. I've done it in other parts

[@LearnEverythingAboutDesign]

Thanks Dave, does it still work? I know Autodesk dropped support for it in 2020. knowledge.autodesk.com/support/fusion-360/troubleshooting/caas/downloads/content/slicer-for-fusion-360.html

[@somedutchdude]

@@LearnEverythingAboutDesign It still works yes. Tested it today. Both Windows and Mac.

[@LearnEverythingAboutDesign]

@@somedutchdude Thanks for letting us know!

[@kkkk-ud9ll]

@@somedutchdude Is there a way to use the slicer plugin in a way that would allow it to automatically divide the big parts into a bunch of A4 papers instead of just one?

[@sabda.saratustra]

@@kkkk-ud9ll yes, what you need is SlicerforFusion360 app.. you dont need to have fusion 360 program, this slicer can be opened as stand alone..

[@scottwatrous]

So for me the key is to start the design with the intent of having a master 'plug' volume that you can later simply boolean intersect your shapes from. And from which you would drive your finished sheet metal geometry and so-on. Even if I was provided a thin "skin" model or a surface geometry, if the dedign was set I would just direct model up w solid plug from the provided geometry and slice that up. One upside is that this will actually provide contoured slices so if you are, for example, carving MDF on a router table, you could do a little bit of 3D milling to get closer to net shape. In fact I've used methods like this to create plugs for fiberglass parts where we totally 3D carved the layers and then stacked them to create a complete shape. Same concept really. Of course if cutting basic 2D shapes then just taking a cross section slice and extending it is indeed the simple way to go. Either way if the designer starts out with a solid volume, making plugs and bucks is almost always a simple affair.

[@LearnEverythingAboutDesign]

I never released a video but did play around with making a custom api to do this where it made planes at a set interval and created an intersection sketch. There is a small amount of automation that could help. I agree if you have the ability to cut each piece to the true shape that would really help. I would imagine a lot of folks would rely on 2d and maybe undersize then fill each void with expandable foam and smooth to the final shape maybe? When you did the 3d plug for fiberglass parts did you actually stack them together without a gap making it essentially a solid plug? I like that idea!

[@scottwatrous]

​@@LearnEverythingAboutDesign Yeah I'm the case of a solid plug for fiberglass you can model it as a single big body with whatever added mold details added and then simply use geometry to split it out into sections that can then be laid out on a sheet of foam and carved. I would often cut alignment holes for some common tubing to make everything stay true, and then use spray mount to stick it all. Can even 3D print some sections and floor them into the bulk shape, like, for our case an aircraft cowling with some intake scoops. With even a cheap hobby router, anytime can basically carve up some foam and build up a big tool. Of course carving 2D sections and building out the grid and then filling with foam and using a hotwire and/or other tools also works. But once you learn 3D CAM, it's nice to just program it all and let the machine give you some really cool shapes.

[@asciimation]

This is very interesting, thank you. I need to do similar for a vintage car where I need to design the body then work out the profiles for the timber framing that goes inside it. It's isn't a buck as such but the actual frame of the car the sheet metal (aluminium) is then shaped over. My current issue is do I use forms or surfaces to make the body?

[@LearnEverythingAboutDesign]

Very nice! The decision for forms or surfaces is tough. Right now the surfaces aren't complete in Fusion for this type of work(noting that car body design is a very specific type of modeling with specific software). So if it can be done with a Form I think the output will be nicer. Some of the issues you will run into with Surfaces though you might get around since you will be hand forming them.

[@aliyubalaahmed9756]

It's easier in. Blender by using a plan on the y, z and x axis then boolean intersect and difference after using the solidify modifier

[@LearnEverythingAboutDesign]

There are tools to do this a bit easier, but there is some manual work that needs to happen as well. In fusion the resulting shape is a true curve and you can send that to be laser cut. I don't think the result in Blender would be. You would end up with a bunch of lines because of the mesh. Curves only exist until it is a mesh and the solidify mod only works on a mesh correct?

[@66customsnj]

Thank you for the video. I found a video from about 10 years ago from a car builder, he used an array function I believe and he was able to even space all the panels so he could perfectly fit foam boards in the negative spaces. Is that possible in fusion 360?

[@LearnEverythingAboutDesign]

yes but in this case with this fender I would do a rectangular pattern with the sketch lines in the sketch, since it ended up being a surface. There is no Array function like that but instead Linear Pattern of a body or feature, or the pattern of the sketch entity. Either will work. Sometimes Fusion(and other CAD programs) get really picky about geometry so you have to try some work arounds like we did in this video...

[@robertoferrari5397]

..i'm just starting Fusion 360 so i don't know much..but is there any way that you can use the section analysis tool and actually save the cross sectional view images as you move the plane along a shape?

[@LearnEverythingAboutDesign]

unfortunately no. The section analysis tool, and the slice option in a sketch are just graphics. When you are in a sketch you can use the intersect tool to get the cross section, but there isn't a quick/automated way.

[@robertoferrari5397]

@@LearnEverythingAboutDesign ....☹☹..curses,.. foiled again!

[@tony22745]

I want to take a section from the buck and print (3D) it separately in a small printer. Then I want to take the next section and print that. When it has all been printed I'll join the sections together. What software will do the export of a section from the buck so I can print it separately?

[@LearnEverythingAboutDesign]

in Fusion if you select the individual Body in the bodies folder, you can right click and "save as mesh" that will let you save each body as its own mesh file.

[@RolandAdje]

How would you scale it and what software will you use

[@LearnEverythingAboutDesign]

in this case the part was modeled to scale, but you can scale it in Fusion. Under the Modify tool drop down there is a scale tool.

[@eackerw85]

Could you do a golf driver series in t splines?

[@LearnEverythingAboutDesign]

Sure, Funny enough I did that years ago for NPower subD add-in for Solidworks. If you have any specific shape in mind send me an email [e-mail]

[@eackerw85]

@@LearnEverythingAboutDesign I don't know how advanced you would want to take this, I'm working on mine and need some guidance. I'm trying to do a multi part driver with frame above face and top crown and bottom pieces. I've had more success with overbuilding with surfaces than I have with the t splines method. But once I've got the basic model I'm locked into a pretty closed workpiece.

[@LearnEverythingAboutDesign]

@@eackerw85 As advanced as the topic needs :) The one i did before had a removable weight section that was split after the form body. With a driver and the way the faces/bodies are built this might be a case where overbuilding works. I am not a golfer so pics or a driver name would really help ;)

[@ShadowScoRpi]

This is a parametric model, if not, what is it called?

[@LearnEverythingAboutDesign]

Generally Parametric means the design is controlled by parameters like dimensions. So this could be since there are values like the thickness that are controlled.

[@ryanholmes5364]

Wow, this looks like an absolutely tedious task. Shame it couldn't get milled at home out of XPS foam or something similar.

[@LearnEverythingAboutDesign]

I am sure you could build or get a 2x router that would do it :) But yes the task is time consuming (based on geometry). For a simple shape it could be quick, but then why bother with CAD ;)