Reverse Engineer Workflows in

In this video we are going to begin a new series talking about reverse engineering on complex parts using Fusion 360. The part is going to be a KTM Brake Lever that is cast aluminum and was scanned using a Shining 3d Einscan Pro HD.
In Part 1 we will discuss the importance of quality mesh imports, how tolerance affect mesh section sketches, how to create them and ultimately how to loft a body with them.
To follow along you can download the dataset here: a360.co/3GKD3ft

[@MakeTechPtyLtd]

Great work. Lofting more than 2 profiles at once is cool. I've never needed to do that, but it's good to know it's possible. Ken

[@LearnEverythingAboutDesign]

Thanks Ken, lofting between multiple cross sections can get messy. In this case because the shape exists its pretty safe, but it can get out of hand.

[@keal4825]

i alway wait Fusion 360 Tutorial from you, thank you so much , i love fusion 360

[@LearnEverythingAboutDesign]

More to come!

[@dadasut50]

always great technologies, tips and tutorials. you are simply the best

[@LearnEverythingAboutDesign]

Thanks!

[@speway]

The name of the channel intrigued me. 👀

[@mikepedersen2420]

Amazing video! Am very curious if you could create a mesh section sketch along these profiles and use this as a guide rail for easier loft operation? Otherwise the advice using them as construction curves is great!

[@LearnEverythingAboutDesign]

yeah, but the problem you still run into is that it is trying to average out the shape and you need to get pretty loose with the tolerances to get a spline/curve that is 'good" in my opinion. Wrapping a freeform body OR using those guides for a freeform loft will produce a better final surface for sure.

[@warnermcgee8856]

Thanks for the video! You mentioned a few times that “this isn’t the way I’d actually remodel this”. How would you do it? What’s your preferred method and do you have a video demonstrating that method. Thx in advance for your reply. (EDIT) I watched your other 2 videos in this series which more than answered my question about your preferred approach. Extremely informative and helpful. Thank you.

[@LearnEverythingAboutDesign]

You have been busy! Yeah each situation will determine what the preferred method is. Fusion isn't the perfect tool for this but it is certainly possible to get a good result with some patience i think.

[@mic03311]

Great tips! Really appreciate the effort you place in building this material. Thanks a lot!! One question, knowing this object is aluminum cast, cleaning up the mesh and the surface in a tool such as Zbrush could help getting better mesh section in Fusion?

[@LearnEverythingAboutDesign]

Yes it will BUT i still highly doubt that the mesh section sketches would be any better. Using the section sketches that wrap to a mesh, even a highly dense mesh, will never be as "clean" as sketching the curves yourself or using the form.

[@davecoggan9619]

The only reason I use mesh section sketch is to give me the orange outline to trace with splines manually. It's always really janky when trying to thicken surfaces otherwise. I wish Autodesk would update mesh section sketches to allow multiples being generated in a grid if you understand what I mean. Geomagic design x has this feature

[@LearnEverythingAboutDesign]

Yeah as I show here it isn't super great quality. The loft is ok but you are right as soon as you start to offset it those spots would really show. I think right now the best thing you can do is to use the mesh section and make that a construction curve, then snap to it where you wanted to.

[@telemetrycoaching165]

Thank you for the tutorials. I have a qustion about using the perpendicular lines and then extruding them as a surface. Is it neccessary or can I just create mesh section sketch on the body and position it manually? I am getting a hard time achieving a smooth loft surface between the individual mesh sketch sections and making the perpendicular lines is the only part of your tutorial I did not follow. But I suspect the issue is my part being much more curvy (A scan of hand molded to plasticine).

[@LearnEverythingAboutDesign]

You can certainly position them manually wherever you need to. Just remember that the auto curves generated from mesh section sketches are not great in terms of being smooth. Honestly probably the best workflow for you if you have a hand scan would be to convert your scan to a quad mesh in another program and use the Convert option in the freeform tools. If its not a mechanical part, the mesh section sketches are probably going to be a bit too much work. I think the 2nd video in this series shows how to manually make a form fit a scan which might help, but again a quad mesh conversion will probably be best. i think there is a free quad remesher, you can often do it in blender. and you can do it in Fusion if you have the Design Extension. Then on the Convert Mesh tool there is an organic option that will do the quad remesh and tspline conversion.

[@hillfortherstudios2757]

You saved me hours! You got a Patreon?

[@LearnEverythingAboutDesign]

Awesome. I don't, but I am working on www.learneverythingaboutdesign.com to sell courses for Fusion 360. I am not a huge fan of the donation sites, but if you are looking to support the channel you can buy a course(if you like). Thank you!

[@rifalse]

how to alignment stl?

[@LearnEverythingAboutDesign]

There isn't a great way to do this in Fusion. You can make planes based on selections on the mesh when in direct edit more of the mesh but there is not really a true alignment. This is something I have asked both creality and revopoint to add to their software... maybe we will see it soon.

[@jakeMTSU]

meshing with mesh does not look fun ... I have already design from a fresh start so this has never come up... but I got a new scanner and not sure its worth the trouble to turn into a file type i can use...lol

[@LearnEverythingAboutDesign]

Yeah. Doing freeform modeling and snapping to a mesh is a great option. But reverse engineering parts from scan data takes a lot of time. It is a bit easier with dedicated tools (expensive) and the seat time to learn them. It can be done in Fusion, but its really not the intention of the tool.

[@GeryS.]

You always say prismatic, don't you mean parametric?

[@LearnEverythingAboutDesign]

Not sure where you mean. Its possible I made a mistake in there but in general: Prismatic - Mesh/scan files are made up of triangles and while not a true prism the general definition usually means something like the same cross section/shape on both ends. When i talk about a mesh file generally i say prismatic meaning the elements are the same shape. Parametric - Generally means the design is controlled by parameters. Definitions/constraints with a history involved. Its possible i said one when i meant another as my videos aren't scripted, i just speak while doing them. If i did sorry for any confusion.

[@GeryS.]

@@LearnEverythingAboutDesign Ah i see, i thought you MEAN acutally parametric. ✌ BTW... love your vids! Thanks for the great training lessons!

[@LearnEverythingAboutDesign]

@@GeryS. no problem! thanks for watching!

[@RICHCREWSPLASHSET]

this is so dumb you should be able to use a touch screen trace with a pen the extrude

[@LearnEverythingAboutDesign]

Even if you did that you still have the issue of tolerance to a mesh. If the functionality to trace on a touch screen was there we would have to still find away to get a good spline off potentially noisy scan data.