All posts by heyharvs

Voltron Defender of the Universe

Remix of the Spaceman into one of my favorite childhood toys. This design was very tedious, but pretty easy because the shapes were pretty geometric and not as organic as the designs.

Draft print of the pieces. A few fails here

I got a bit lazy and didn’t make a few pieces combine into a single part. So when I tried printing it, the pieces broke as I was removing the support material. It’s ok, I need to physically handle it to get a feel for how to make changes.

Sectional analysis of the pieces together.

The head / torso / wings / neck / helmet were pretty crucial in getting to fit properly. A sectional analysis is amazing for getting an idea of how much tolerance you need to add to each piece in order for things to fit properly, or to know how thick/thin something might be in a specific spot.

Take a look at the helmet where it meets the top circumference of the head. The material is so thin there and initially it was poking through the helmet. Luckily the sectional showed me this and I added a few mm here and there to account for that.

Daft Punk

Remix of the Spaceman of the infamous DJ duo! The helmets were a bit tricky to make because they had somewhat organic shapes. It was a real learning curve to start to work with surfaces in Fusion360 in order to achieve the correct geometries that looked good.

A lot of surface and solid lofting to achieve the correct look

The helmets are a remix of what the real life ones should look on a round LEGO head.

This sketch was pretty fun to draw. A combination of solids and surface lofts.

Lofting is when you transition from one surface to another, or one curve to another to generate a new solid or surface. It’s like morphing 2 lines in 3D space. The most important part of that however is the guides or centerlines. That dictates how the surfaces blend together, otherwise you’re left with a pretty rigid transition.

Designing curves to tell Fusion how to transition from one profile to another is amazing!

Block Like Space Man

This is just an exercise to sharpen my skills in Fusion. The goal was to practice re-creating specific bodies and joints. Learned a lot from doing this. There were a lot of dimensions that I simply assumed were parallel, when in fact there were subtle things that were off.

The arms were the hardest part of this build. Most of the other pieces were pretty parametric. The arms were a little organic and finding the right angles and dimensions was tricky.


  • The outside thigh is not perpendicular to the foot/ground. In fact, there is a slight bow inwards, making the feet wider than the hips.
  • The face cutout for the helmet is not perpendicular so the shell of the helmet, which means you can not de-boss the cutout. In fact, you need to cut the opening directly from the left/right sides, making the edge of the cutout appear thicker than the actual thickness of the helmet.
  • The strap around neck (for the tanks on the back) are not a perfect U shape. In fact, the traps bow inwards towards the tank ever so slightly.
  • Given the properties of PLA, I designed the joints to take advantage of the slight flexibility of the plastic. The male part of the joints are segmented to provide some tolerance, and the female parts of the joints had filets to help guide the parts in to snap together. Once the piece is snapped in, chamfers on the male help to keep it gently in place and allow for some wiggle room.
Here is it printed just for testing purposes. Not for sale or distribution, relax.

I added tolerance in the designs of about 0.1mm to 0.2mm to the joints based on what I know about my 3D printer. However, I think those need to be removed because if I print a scaled version, the tolerance will scale with it, which doesn’t make sense because the accuracy of the printer doesn’t increase with the size.

Emergency SPAM

Guys. We’re in the middle of a global pandemic here (Covid19). There is a shortage on toilet paper, PPE and other things. Since I always like to be prepared, I made this emergency SPAM box.

Disclaimer: you can’t actually break the glass, it’s plexiglass.

Granite BBQ Table

I love my kamado! I’ve been wanting to design a custom bbq table for it because the old table didn’t have enough counter space for me.

Does my BBQ need LEDs? Of course.

The top us a custom granite piece with rounded nose on top, and custom cut out designed specifically for my bbq.

Weathered grey stained wood covered in polyeurathane.
Custom sewn cover

CNC Dust Shoe (80mm)

I’ve been building my own CNC machine this year, and slowly designing parts to go with it. I needed a dust shoe to collect all the wood and MDF shavings. Didn’t want to pay $150+ and it seemed like a fun project to design to get acquainted with airflow.

My first design, a big fail

The pink version was my first design. It was comprised of 2 parts (actually 3 but 2 were glued together for better printing orientation without supports).

The idea is to have 1 piece permanently attached to the spindle. The other piece snaps down vertically into the mount. In theory it seemed like it would work, but in practice, as the CNC cut deeper, the materials would push up against the brushes and make the piece pop off 🙁

Into the trash and onto V2. I still wanted the show to have multiple pieces so I could remove the parts and have room to work under the spindle.

Behold, the glorious v2!

The ring, after being squeezed into the flat plate under it, mounts onto the 80mm spindle. Then the front and back pieces slide on to the plate via a groove, then the front and back pieces are secured with binder clips!

Here are the pieces with the brushes attached

The brush strip can be found online, and is just cut to length. There is a groove inside that lets you jam the bristles and the part was designed to be nice and snug. It was printed in PETG for durability.

Universal Spool Holder

There are many spool holders out there. The problem is there are many spool sizes that makes it hard to build a universal one that works well. I decided to make a spool holder that mounts horizontally and uses the weight of the spool itself to keep the spool in place.

This is version 7 of my design, it’s still in progress and was a good motion study for the joints in CAD. How will it work in practice? We’ll soon find out.

Sponge Holder

This year my goal is to focus on designing more complex assemblies that rely on gears, joints, or parts that leverage the flexibility of the material itself to its advantage as in compliant mechanisms.

Fusion 2 piece build of the part

This part is very specific to my sink, although I could probably rebuild this so the ring clips utilize the flexibility of the material to expand or contract allowing more generic fits.

It’s ugly, I know, but functional. The main exercise here for me was to design pieces that snap together, with the correct tolerances for my machine.

Shower Hook + Suction Cup

I bought some cheap adhesive hooks for the shower but the were poorly designed, flexed, and did not hold up enough weight. Amazon sells a 20 pack of suction cups which I got for a variety of projects so I created these durable hooks to go with them.

Here is the file to download. All the parameters of the suction cups are variables, so if you buy different ones, just enter your specific dimensions.


Fusion 3D designed hook

The design allows for the larger round part of the suction cup to slide in, then slide up unto the smaller diameter area at the top. The bottom of the hook features a mini extension exactly the thickness of the suction cup to keep the hook perfectly horizontal and also get the most leverage from the suction cup as well.

The best orientation to print this is sideways for the best strength.