How to Design a Pen Holder for 3D Printing in Autodesk Fusion

Autodesk Fusion (formerly known as Fusion 360) is a powerful tool for designing and prototyping 3D models. In this tutorial, we’ll walk through creating a unique pen holder using surface and solid modeling techniques. Follow along with the step-by-step guide below, and don’t forget to check out the full video at the bottom of this post for a complete walkthrough.

Step 1: Create a Reference Line

Start by sketching a straight line on the original construction plane. This line will serve as the foundation for the curved pattern. The exact length isn’t crucial, but for this example, we’ll set it to 60 mm.

Step 2: Set Up Offset Planes

We need to create two offset planes. These will act as the foundation for the curved pattern and provide flexibility for future design changes. Reference the top offset plane to the bottom offset plane so modifications will automatically adjust the design.

Step 3: Sketch Lines on Offset Planes

Sketch a line on the middle offset plane with a slight angle. This angle will influence the curvature of the final design. Then, repeat the process for the final offset plane, ensuring it is symmetrical but in the opposite direction.

Step 4: Create a Lofted Surface

Select the Loft tool in the Surface modeling environment. Lofting each line separately results in hard angles, but lofting them together creates a smooth, continuous curve. This method ensures a fluid shape for the pen holder.

Step 5: Add Thickness to the Surface

Use the Thicken tool to add material to the lofted surface. A symmetric thickness of 2 mm works well, but you can adjust this value to match your design preference.

Step 6: Create the Pen Holder’s Base

Sketch a center diameter circle on the original construction plane. The height of this extruded body should match the top offset plane, ensuring consistency in future modifications.

Step 7: Project a Linked Sketch

Use the Project command to capture the outer dimension of the cylinder. This creates linked geometry that adapts to any future design changes.

Step 8: Use Revolve Intersect

With the projected geometry, use the Revolve tool in the Solid modeling environment. Change the operation type to ‘Intersect’ to trim unnecessary areas and keep only the desired shape.

Step 9: Make the Body Hollow

Apply the Shell command to hollow out the pen holder. This ensures the design is functional while maintaining structural integrity.

Step 10: Use a Circular Pattern

To create a repeating pattern, use the Circular Pattern tool. Set the object type to ‘Bodies’ before selecting the pen holder body. A count of 36 instances gives a well-balanced design.

Step 11: Create and Edit a Fit Point Spline

Sketch a Fit Point Spline at the center plane, shaping it to control the curvature of the top design. Adjust the green handle bars to fine-tune the curvature.

Step 12: Extrude the Spline and Thicken the Surface

Use the Surface Extrude command and extend the spline symmetrically past the pen holder. Then, thicken the surface to create a cutting tool for the next step.

Step 13: Combine and Split Bodies

First, hide the thickened spline and combine all bodies into one using the Combine command. Then, turn the thickened spline back on and use the Split Body tool to cut the pen holder, finalizing the unique top shape.

Step 14: Apply a Glossy Appearance

Turn off the layout grid for better visualization. Apply a glossy material to enhance the look of the design. Different manufacturing methods, such as 3D printing and injection molding, offer a wide range of color options.

Step 15: Make Design Adjustments in the Timeline

Not satisfied with the final shape? Edit the feature through the timeline. Try symmetrical changes or freeform adjustments to achieve the desired look.

Final Thoughts

This tutorial covered essential tools in Autodesk Fusion, including Loft, Revolve, Shell, and Circular Pattern. By mastering these techniques, you can create complex 3D designs while maintaining flexibility for future modifications.

For more Fusion tutorials, subscribe to The Maker Letters on YouTube and check out additional workflows to enhance your 3D modeling skills!