Watch a functional automotive part go from concept to finished 3D print in real time.
Connor demonstrates the complete workflow from 3D modeling in Fusion 360 to printing on the Bambu Lab X1E, creating a simple but effective cable tie bracket for wire routing. This webinar "365 | How To 3D Model & Print A Usable Part In Real Time" has been available to High Performance Academy (HPA) Gold members for months, members get early access to every lesson.
You'll see live Computer Aided Design (CAD) modeling techniques including sketch-based design, extrusion features, filleting for stress reduction, and the combine tool for multi-body operations. Connor explains design decisions for 3D printing optimization, including print orientation, support requirements, and material considerations.
The session covers Fusion 360's configuration tables feature for creating multiple part variations from a single design file – in this case adapting the bracket for different rivet sizes without duplicating work. This workflow efficiency technique saves time and reduces file management complexity.
Connor addresses design for manufacturing principles, explaining how 3D printed parts require different design approaches compared to Computer Numerical Control (CNC) machined components. The discussion includes material selection for engine bay applications, from basic Polylactic Acid (PLA) to high-temperature nylons and carbon fiber reinforced materials.
Live questions cover heat resistance requirements, chemical compatibility, vibration resistance, and when to choose Fused Deposition Modeling (FDM) over other manufacturing methods. Connor provides practical material recommendations ranging from accessible Acrylonitrile Styrene Acrylate (ASA) to professional-grade polyamides.
The demonstration includes real-time slicing in Bambu Studio, print settings explanation, and the actual printing process with live camera monitoring. You'll see support removal and the finished functional part installation with rivets and cable ties.
This practical approach shows how 3D printing enables rapid problem-solving for project cars, creating custom solutions that would be expensive or time-consuming through traditional manufacturing methods.
TIME STAMPS:
0:00 - Real Time 3D Modeling Introduction
0:18 - Functional Part Overview
0:52 - Cable Tie Bracket Applications
2:24 - SR86 Installation Examples
3:17 - Fusion 360 Modeling Start
3:46 - Boss Design for Rivet Hole
4:55 - Three Concentric Circles Setup
5:22 - Cable Tie Profile Creation
6:21 - Construction Lines and Constraints
7:11 - Profile Circle Creation
8:41 - Angle Dimension Setup
9:25 - Profile Completion
10:09 - Symmetric Extrude Feature
10:56 - Rivet Head Clearance Cut
11:43 - Combine Bodies Operation
11:59 - Fillet Features for Stress Relief
13:54 - Multiple Selection Sets
15:06 - Export to 3D Print
16:15 - Bambu Studio Slicing
17:18 - Print Orientation Optimization
18:17 - Infill and Support Settings
19:19 - Slice and Print Preparation
20:29 - Configuration Tables Introduction
22:16 - M4 and M5 Rivet Versions
23:09 - Parameter Selection Process
25:06 - Dimension Modifications
27:19 - Configuration Switching
28:35 - Live Print Monitoring
30:00 - Q&A: Design for Manufacturing
31:31 - ProtoLabs Design Rules
32:38 - Print Completion and Part Removal
33:29 - Q&A: Engine Bay Materials
35:24 - ASA and Nylon Recommendations
37:42 - CAD File Sharing Forum
38:35 - Rapid Prototyping Benefits
39:32 - BUILD.TUNE.DRIVE
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