Week 9 - Challenge 2 - Switch Bezel Design

Given Class A Surface:

Tooling Axis:

A point is placed on the center of the bottom surface of the class A surface.

The Class A surface is intersected along the yz plane.

The two slant lines are bisected to get a new line along the point on the bottom surface.

The Class A surface is intersected again along the xz plane.

The slant line obtained from the intersect and a new line drawn at a 3 degree from the point on the bottom surface are bisected to get a new line.

The two previously obtained lines from bisecting is bisected with each other to obtain the tooling axis.

CLASS B SURFACE Creation:

BEZEL REST SURFACE:

The switch bezels hand rest part of the surface is extracted and untrimmed.

WALLS:

The wall surfaces are also extracted and untrimmed.

They are also extrapolated in order for them to intersect each other.

The wall surfaces are then trimmed with each other.

BASE:

The base surface of the switch bezel is extracted, untrimmed and extrapolated.

All the newly created surfaces are offseted by 3 mm to form the class B surface.

The offsetted surfaces are trimmed with each other to form the Class B surface.

Fillets are added to the Class B surface.

CLASS C SURFACE CREATION:

The borders of the class A surface is extracted using multiple extract. The extraction process is done half of the borders at a time.

The extracted curves are smoothened to produce smooth curves.

The curves are then swept with an outwards draft angle of 3 degrees.

The edges are extrapolated and trimmed to form the Class C surface.

Closed Surface:

Join Class A and Class C surfaces.

Trim the joined surfaces with the Class B surface.

Use closed surface command to create the part body using.

Draft Analysis is performed to see if the part can be drafted or not.

Isometric View:

Front View:

Side View:

Top View: