How to Prototype a Propeller in Fusion: Step-by-Step Guide

You’ll find the full video tutorial below the text

In this tutorial, we'll walk through the entire process of designing a small propeller for a toy boat using Fusion (formerly known as Fusion 360). From sketching the cylinder to creating the final rendering, you'll learn essential tips and workflows to take your design to the next level.

Step 1: Sketch the Cylinder

Start by sketching the center diameter circle on the vertical construction plane facing the direction where the propeller will sit. This setup ensures your design is centered and aligned, setting a strong foundation for the rest of the project.

Step 2: Extrude the Cylinder

Once you have the circle, extrude the profile to form the solid cylinder. Adjust the extrusion direction and set the distance to 50mm. Ensure the new body operation is selected to keep the cylinder separate from other components in the model.

Step 3: Sketch the Propeller Blade

Now, create a new sketch for the propeller blade on a vertical plane behind the cylinder. Use lines, dimensions, and splines to shape the leading and trailing edges of the blade, focusing on smooth, flowing curves. Remember, this initial sketch doesn’t need to be perfect—we’ll refine it later.

Step 4: Loft the Propeller Blade

Using the surface modeling tools, loft the blade shape by connecting two lines that will define the propeller's geometry. While the lofted surface might appear small at first, we’ll adjust it to fit the overall design.

Step 5: Extrude the Propeller Blade Profile

To give the propeller blade shape and volume, use the extrude tool on the profile you just created. Set the extrusion to match the length of the cylinder so the blade fits onto the cylinder's end.

Step 6: Extend and Trim the Lofted Surface

If the lofted surface isn’t large enough, use the extend command to make it bigger. Once the surface is extended, use the trim tool to remove excess material, ensuring the blade is the right size and shape.

Step 7: Split the Propeller Surface

To clean up the geometry, use the Split Face tool. This will allow you to remove any excess surface material inside the cylinder, giving you a cleaner, more defined propeller blade.

Step 8: Fillet the Top of the Cylinder

Add a smooth fillet to the top of the cylinder with a 5mm radius. This creates a cleaner, more polished look and ensures a smooth transition between the propeller and the cylinder.

Step 9: Add Thread Detail

For a more realistic touch, create a visual thread inside the cylinder. This is optional—if you're 3D printing, make sure to check the "Modeled" option in the thread settings. Visual threads are more efficient for small models.

Step 10: Thicken the Propeller Blade

Thicken the propeller blade to 2mm using a new body operation. This gives the blade some real thickness while keeping it separate from the cylinder for easier adjustments.

Step 11: Apply Appearances

To save time, apply appearances to just one propeller blade. You can easily copy the appearance settings to the other blades later. Use keywords like “glossy” when searching for appearances to streamline the process.

Step 12: Create the Circular Pattern

Once the first propeller blade is ready, use the circular pattern tool to duplicate it around the cylinder. This ensures perfect symmetry and saves you time.

Step 13: Set Up the Rendering

Now, let's make the project look polished. Right-click the canvas, go to Scene Settings, and change the background from Solid Color to Environment. Drag and drop the Photo Booth setting onto the scene, then adjust the camera angle using the ViewCube and pan options to get the best shot.

Step 14: Start Cloud Rendering

Once you're happy with the settings, open Render Settings, adjust the width and height if needed, and start your Cloud Rendering. Your rendered image will appear in the Rendering Gallery, and Fusion will give you an estimated time for completion.

00:16 Sketching the Cylinder
00:48 Extruding the Cylinder
01:05 Sketching the Propeller Blade
02:45 Creating Loft Line 1 for Surface Modeling
03:18 Creating Loft Line 2 for Surface Modeling
04:00 Lofting the Two Lines
04:28 Extruding the Propeller from Lofted Surfaces
04:48 Extending the Surface from Lofted Lines
05:10 Trimming to Shape the Propeller
05:40 Using Split Face to Clean Up Surfaces
06:20 Applying a Fillet to the Cylinder Top
06:38 Creating an Internal Thread in the Cylinder
06:58 Thickening the Propeller Blade Surface
07:19 Tips for Searching and Applying Appearances
07:52 Creating the Circular Pattern for Propeller Blades
08:25 Rendering the Final Project
09:30 Wrap Up and Subscribe to The Maker Letters