laser cut bicycle bottle cage

by:Petolar     2020-11-01
This guide shows how to quickly design customizable bottle cages for bicycles using Fusion Jingdong\'s new sheet metal tool.
The purpose is to laser these cages from 1.
2mm stainless steel, then bend them in place with a broken sheet of metal;
4 pieces can be connected with stainless steel rivets;
The assembly can then be connected by Bolt to a standard bike frame with low
M5 bolts.
This Fusion 360 file can be reused multiple times with various modes.
The process is as follows: 1)
Create a simulated water bottle
Create one side of the sheet metal cage around the bottle, movable sketch point with shape control 3)
Mirror cage create second side4)
Create two join tags, rivet them to the flange and attach the bolts to the bike frame 5)
Handle any simple silhouette images captured from Google Images6
Import the image and cut it to the side of the cage7)
Export the plane pattern to prepare for the laser cutting software: Autodesk Fusion 360 Inkscape (
A free Illustrator Clone)
Silhouette image of your favorite animation tool: Sheet metal (
It\'s better to have something like 1.
5mm stainless steel)Rivets (
Same material as sheet metal)
Low-M5 Bolt
Google search shows me that a standard bottle cage is used to install a cylinder with a diameter of 73mm and a height of 120mm.
But if we want to quickly make a dynamic cage that can be used for other bottle sizes, we should design an intelligent way: using user parameters!
We will add parameters for bottle mouth diameter, bottle mouth height, rivet diameter, Bolt size for bolt connection to bike frame and arch8 to be used later.
Then, create a new component called \"Bottle.
We will make a simple cylinder on the base plane, the diameter is equal to the diameter of the bottle mouth, and the height is equal to the height of the bottle mouth.
This should be enough to inform our design, but if you have a water bottle that you like, model it!
We will use an artistic technique to make the overall shape of the bracket.
The idea is to link the shape to a sketch without complete constraints
You can grab the handles, drag them, and change the overall aesthetic of the design.
Make a new part called \"main flange \".
\"Start the sketch on the base plane and the sketch should be aligned with the bottom of the water bottle.
The diameter of the water bottle is then projected onto the sketch and made into a construction line.
There are only three lines in the outline of the flange: one line will be connected to the other using a laser
Cut the label, two bends in place, fix the bottle in place.
All three lines should have tangent constraints crossed with the projected water bottlesection.
Only the minimum line at the bottom should be fully constrained with the set length, horizontal and tangent constraints.
Check if two unconstrained points can be moved to change the shape of the three pointsline segment.
In Fusion 360, flange tools in sheet metal work areas can make several different types of flanges.
We do two now.
First, tell Fusion which metal you will cut and bend.
Enter the sheet metal work area and then go to modify \"-
> Sheet metal rules.
As far as I\'m concerned, I\'m right.
Click on stainless steel to change the thickness to 1.
2mm because this is the metal I use most. Then I right-
Click on it and set it to default.
Create the main cage wall by selecting Create-
> Flange and click 3-
The segment sketch created in the last step.
The height of the flange is provided according to your user parameter bottlehigh.
Then, make sure that it creates the flange outside the bottle by selecting the thickness of \"Side 1.
Create the flange by OK.
Now, use the flange tool again, this time by selecting it and clicking on the two inner edges at the bottom of the original flange.
This will tell Fusion that you want to bend the two flanges into the part and it will even increase the relief cut (miters)
Make sure your parts are bent properly!
I did these flanges 10mm but it would be better to set them to user parameters.
I then added fillets to their edges, each with a value of 5mm.
FYou will want to do more at the back of the design process, but now is a good time to try and define a sketch of the main flange.
Open the sketch so you can see its endpoints and make sure you can drag them.
It may be necessary to correct-
Click on the bottle and select the ground.
Then do the same with the main flange.
Make sure the main flange is activated.
Open the origin of it, select the construct-> Offset plane.
Offset a plane of about 50mm from the axis in the design (
If you follow my design exactly, YZ aircraft).
Start the sketch on this plane and project the top edge and right edge of the main flange.
Use sketch-> 3-
Point the arc tool to make an arc from the top left corner of the flange down to the right edge.
Add tangent constraints on the right edge.
Mark the arc using the user parameter arcHeight you prepared earlier, and arcHeight is set to equal 75% of the height of the water bottle.
Stop the sketch and create-> Extrude.
Pull the extrusion into the flange to cut it into an arc.
Expand the object to be cut and cancel
Select the bottle so that only the flange is cut.
Now is a good time to create a flat pattern for this sheet metal part to make sure there is no problem. Go to Modify -
> Create a flat pattern and select the middle pane of the main flange as a fixed face.
In the process, you will most likely make a different mirror flange later, but now, create a mirror for the main flange, so when you create labels that hold the flanges together and hold the components on the bike, you have some work to do.
Exit the flat pattern, go to the top of the design, and then go back to the model workspace.
Make the Origin visible and use Create-
> Mirror to mirror the main flange parts around the central plane of the water bottle.
Activate the main flange, enter the sheet metal work area and place two mounting holes by drawing a sketch in the 10mm flange section.
In the sketch, make a center line along the flange and make it a construction line.
Then put two points on it and do two. 5in apart (63. 5mm).
I will leave their position without restriction so that you can move them easily in the future.
Stop the sketch and use Create-
> Add holes in the rivet holes.
Fusion should automatically pick up the position of the midpoint of the sketch and punch holes at each point.
Select all for depth, but remember to turn on the object to be cut and turn off the water bottle assembly.
Set the hole diameter to the user parameter rivet hole.
When I did this, the holes on my original main flange were not filled on my mirror flange.
So I removed the mirror flange and added a new one.
Create a new component called Tab.
Sketch with mounting holes on the surface and create a center line between the main flange and the two mounting holes on its mirror. Use Sketch -> Slot -
> Center point slot, select the center of the line and select one of the center points of the hole.
Give the label some thickness and add a center circle to the bolt hole.
With some trimming and sashimi you will end up with a good oneshaped tab.
The dimensions given with the user parameter boltSize add a hole at the center of the label.
Stop the sketch and make sure you are in the sheet metal work area and use the flange in another way: just like using the extrusion tool.
This will create a center hole of 5mm (
BoltSize user parameters)
And two external holes with diameter as rivet holes.
Enter the model workspace, activate the top of the design tree and use Create-> Pattery -
> The rectangular pattern where the second label is placed.
Jump on google pictures and find a cool-
A relatively simple outline to look at: favorite animals, cool plants, are relatively easy for any laser cutting.
If possible, you want to look for an image that is completely black outline --
We will extract the profile using Inkscape.
A good way to do this is to add \"silhouette\" to your search\"
For example, \"King Fisher silhouette\" or \"Darth Vader silhouette \".
In this example I entered \"Star Wars silhouette\" and grabbed an x-
Assuming there will be no copyright issues in the future, please leave Pinterest (yikes).
I just copy and paste into Inkscape.
Select the image and go to the path-> Trace Bitmap. . .
And use edge detection to set the edge of the captured image.
Press OK to delete the original image.
Depending on the level of complexity of the image, you may need to have some struggle with the settings to fix this.
In the lower left corner of Inkscape
Hand corner, right-click \"stroke\" and select \"black \". Then right-
Click fill and select remove fill \".
\"You may have two outlines, but you can always handle the issue inside Fusion.
Save the file. dxf.
Note: You may need to rotate in Inkscape and prepare the file further before porting the file to Fusion.
Activate the main flange to make sure you are in the sheet metal work area.
Add an offset plane from the main origin and place the plane outside the part.
Alternatively, you can use the same plane already used to cut the arc into that assembly. Insert the .
The dxf file can be obtained by selecting Insert-> Insert .
And specify the work plane just created.
This brings.
As a new sketch. Press OK.
Now you can edit the sketch by right-clicking the sketch and selecting edit.
Typically, it is useful to select the entire profile and use the sketch-
> Zoom tools and modifications-
> Move the tool to put it in place.
In my case, I\'m really trying to install the profile on the existing flange, but I can\'t reach the size I want. What to do. . . . . . ?
We will make the flange larger to contain x-wing.
Let\'s take x-first-
The wing passes through both sides of the flange. Select Create -
> Squeeze out and cut all the parts and uncheck the bottle parts so that the bottle is not cut.
It looks like an x.
Wing, but we can do better: Make sure to use the original sketch to make the shape of the main flange visible and drag the point down a bit.
By adjusting the size and shape of the flange, we can get more x-wing.
To be clear, this outline is really not the best shape for something like this --
But by adjusting the bottlehigh user parameters, you can get something that looks really good and still keep most of the water bottles.
That\'s what I did. I made a few renders.
To make sure you like the aesthetics of this part, use the madness of Fusion Jingdong-
Simple rendering tool to get some rest and rotation
A table view of the design.
Once you\'re happy, send it to the laser cutter, bend it in place, pin the label to both flanges and you can go!
I haven\'t had a chance to actually cut and assemble one of them yet, but I will be sure to post the photos once I have them.
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