BY CHRISTOPHER F.

SIKORA

Copyright 2013 Christopher Sikora

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Rhino 3D is a registered trademark of Robert McNeel & Associates.

Other brand or product names are trademarks or registered trademarks of their respective holders.

The information discussed in this document are subject to change without notice and should not be considered commitments by
Christopher F. Sikora.

The software discussed in this document is furnished under a license and may be used or copied only in accordance with the terms
of this license.

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CAD220 COURSE SYLLABUS
Rhino 3D

Course Description:
Industrial / Product Design (Rhino 3D) Basics
3 credit hours
Exploration of the theory and application of Industrial Design, conceptual hand
sketching and solid modeling techniques for industrial product design. Prerequisite:
Intro to Engineering Drawings 101 or consent of instructor.
(1 lecture hours, 2 lab hours)

Course Objectives:
Provide the student with the knowledge and practical experience in the areas of
Industrial / Product Design along with construction of 3D CAD modeling of parts,
assemblies, and the creation of prototypes.

General Course Outline

Date Week Topic

1. Introduction to the Interface Lecture (Exercise 1 - E1)

Modeling Theory - Sketching and Base Feature Geometry
Creation.

2. Hand Sketching - Industrial Design Enhancement Project #1 (P1 -

Due 9/23/10)

3. Introduction to Freeform Part Modeling (E2)

4. Intro to 3D Printing/Lab time to work on (P1)

5. Intro to surfacing and modeling an organic shape (E3)

6. Industrial Design Enhancement Project #2 (P2 - Due 10/30/10)

7. Creating Assemblies (E4). Review for Mid Term

8. Mid Term Exam

9. Curves and Sweeps (E5)

10. Lab time to work on (P2)

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11. Industrial Design Enhancement Project #3 (P3 - Due 11/23/10)

12. Introduction to Photo-Realistic Rendering

13. Industrial Design Enhancement Project #4 (P4 - Due 12/10/10)

14. Project (continued)

15. Lab time to complete exercises, Review for Final Exam

16. Final Exam

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 EXERCISE 1
Basic Solid Modeling (60 pts.)

This lesson is a basic introduction to the Rhino Solids capabilities..

Objective: Create a
flashlight derived
from hand sketches.

1. Go to file/new and select the Inch template. Save it as CE1.

2. Select the Polyline segment icon with the left mouse button.

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3. Zoom out on the Top view to allow at least 10, 1 grid blocks to fit in the
screen.

4. Draw the sketch below. Use the grid and snap option.

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5. When finished Right Mouse Button (RMB) click on the Solid icon. This
will bring up additional options to select from. Find the Extrude closed planar
curve icon. And LMB click on it.

6. Select the sketched profile and hit the Enter key. Drag it out on the Right
view approximately 1.5 with the BothSides option used.

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7. Using the Polyline icon again, draw a handle profile on the Top view.

8. Use the Solid extrude feature again. Extrude it only .5.

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9. RMB on the Boolean icon to locate the fillet tool. Use .5. Add them as seen
below.

10. Add .375 fillets as seen below.

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 11. Add .125 fillets to finish the handle.

Performing a Boolean Union

12. Select the Boolean Union icon and then select both the body and handle
sections.

13. Add .06 fillets to the intersecting edges between the body and the handle.

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 14. At any time you can reset your view orientation by RMB clicking on the Set
View icon, and choosing a view.

Adding Embossed Text

15. Select the Text icon. Type in your text and hit OK. Enter 1 for Height and
.06 for the thickness.

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16. Click to drop the text on the Top view.

17. Window around the letters to merge into a group. Select the Group icon.

18. Select the text and drag it (with snap on) to the Top surface of the Flashlight.

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Design Enhancement Project I

Objective: Redesign the stapler to enhance its appearance and try to include new ideas
to enhance the overall product.

Create a presentation and be prepared to sell your concept to the class.

You will be awarded points on the following:

Appearance 20pts.
Functionality 20 pts. (Supply sketches, CAD drawings, and or renderings)
Analysis (Mechanical and Marketing) 20 pts.
Presentation 40 pts.

Total Contract Award: 100 Points max.

Due: Wed. Sept. 23rd.
Samples:

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Harris Profile (Source: Wikipedia)
Method for assessing a design
A new product profile (or Harris profile) is a graphic representation of the strengths
and weaknesses of design concepts. Originally, a new product profile is applied as a
useful tool to evaluate and select development projects (ideas for new business
activities). But this method can also be used to evaluate and decide in later phases
of product development. Per design alternative a Harris profile is created. A number
of criteria are used to evaluate the design alternatives. A four-scale scoring is used
for all criteria. The decision maker should him/herself interpret the meaning of the
scale positions (i.e. -2 = bad, -1 = moderate, etc.). Because of its visual
representation, decision maker(s) can quickly view the overall score of each design
alternative on all the criteria, and compare these easily.

CONCEPT 3 -2 -1 1 2 CONCEPT 1 -2 -1 1 2
SAFE SAFE
FORM FORM
STABLE STABLE
STRONG STRONG
COMPACT COMPACT
COLOR COLOR
STYLE STYLE
FUNCTION FUNCTION
TEXTURE TEXTURE
WEIGHT WEIGHT

CONCEPT 2 -2 -1 1 2
SAFE
FORM
STABLE
STRONG
COMPACT
COLOR
STYLE
FUNCTION
TEXTURE
WEIGHT

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 EXERCISE 2
Introduction to Freeform Modeling

This lesson is a basic introduction to the Rhino Freeform capabilities.

Objective:
Create a
flashlight using
freeform tools.

1. Go to file/new and select the Small Object Inch template. Save it as CE2.

2. Select the Curve: interpolate points icon with the left mouse button.

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3. Zoom out on the Right view to allow at least 6, 1 grid blocks to fit in the
screen.

4. Draw the sketch below. Use the grid and snap option.

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5. On the Top view draw the sketch below. Use the 3- Point arc tool (RMB to
access option) with the grid and snap option.

6. Select the Mirror icon. Select the arc then hit enter, and then draw a vertical
center at the origin.

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7. Using the Polar Array icon to create a copy 270 rotated around the Front
view origin.

8. Use the Surface/Loft feature. Be sure to select all curves and the Closed
Loft option.

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9. Surface Patching: RMB on the Surface icon to locate the Patch tool.

10. Change dialog box values as seen below. Select the open back edge

11. Select the Join icon, and then select both surfaces. Hit enter.

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12. Capping a planar hole: RMB the Solids icon, and locate Cap. Select the
surface body.

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 EXERCISE 3
Modeling a Pumpkin

This lesson explores one way to make a pumpkin.

Objective:
Create a
pumpkin using
the freeform
tools inside
Rhino.

1. Go to file/new and select the Inch template. Save it as CE3.

2. Draw a circle on the top view. This is used for approximating pumpkin dia.
3. Select the Curve: interpolate points icon with the left mouse button.

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4. Draw the spline around the circle as shown. Delete the circle when done.

5. Use the Scale tool to make four smaller profiles centered. Select the profile.
Then click in the center of the profile for location.

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6. On the Top view select the sketch profile. Be sure to activate the copy with
typing in Copy in the command line.

7. Move the smaller pairs of profiles above the Top view and the larger
profiles below.

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8. Use the surface loft tool.

9. Select the five profiles in order.

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10. Draw two guide rail curves as shown on the front view. RMB on the
Surface icon to locate the Patch tool.

11. Use the Sweep with 2 Rails surface option. Select the two rails and inner
pumpkin profile.

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12. Apply lights, material and a base. Then render.

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Design Enhancement Project II (Cell Phone Project)

Objective: Redesign the cell phone to enhance its appearance and try to include new
ideas to enhance the overall product.

Create a presentation and be prepared to sell your concept to the class.

You will be awarded points on the following:

Appearance 20 pts.
Functionality 20 pts. (Supply sketches, CAD drawings, and or renderings)
Analysis (Mechanical and Marketing) 20 pts.
Presentation 40 pts.

Total Contract Award: 100 Points max.

Due: Wed. Oct. 30th.
Samples:

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 EXERCISE 4
Modeling a Bottle and Cap

This lesson explores one way to make a bottle assembly.

Objective:
Create a bottle
using the
freeform tools
inside Rhino.

1. Go to file/new and select the Inch template. Save it as CE4.

2. Draw a following profile on the front view. Join the curves when done.
3. Use the interpolate points tool for the neck and base transition. Use tangency.

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4. Use the Surface, Revolve tool to create the bottle.

5. Draw the cap profiles using two separate interpolated curves.

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 6. Use the Surface, Sweep with two rails. The two curves will be the rails and
the edge of the bottle will be the cross section curve.

7. The cap should be finished.

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7. Add model materials, lights and base then render.

EXERCISE 5

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 Modeling a Freeform Bottle

This lesson explores one way to make a bottle.

Objective:
Create a bottle
using the
freeform tools
inside Rhino.

1. Go to file/new and select the Inch template. Save it as E5.

2. Draw a following profile on the front view. Join the curves when done.
3. Use the interpolate points tool for the neck and base transition. Use start and
end tangency. Mirror.

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4. Activate the Analysis toolbar, Select the Geometric Continuity icon. Then
select the two curves close to the junction.
Continuity The smoothness at a junction between two curves or
surfaces.

Position - Position continuity (G0)

Position (G0) continuity means that the end points of a curve or the
edges of two curves or surfaces touch each other. End control points
are at the same location.

Tangent - Tangent continuity (G1)

Tangent (G1) continuity means that the tangent direction of the two
curves or surfaces is the same. Fillet arcs form this kind of
continuity with the lines or surfaces filleted. The two control points
of the arc and the adjacent curve line up.
Curves and surfaces with G1 continuity are also G0 continuous.

Curvature - Position, curvature, and tangency match (G2)

Curvature (G2) continuity means that the tangent direction and the
curvature of the two curves or surfaces is the same. Blend,
BlendSrf, Match, and MatchSrf form this kind of continuity. Three
control points of the blend and the adjacent curve line up (up to
degree 3 curves).
Curves and surfaces with G2 continuity are also G1 and therefore
G0 continuous.
Source: Rhino 3D Help

5. Draw the guide rails using two separate interpolated curves.

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 6. Use the Surface, Sweep with two rails. The two curves will be the rails and
the edge of the bottle will be the cross section curve.

7. The cap should be finished.

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7. Split and Delete the excess surfaces.

8. Sketch a concove spline between the opening at the bottom. Use the Sweep
with two guide rails.

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9. Sweep with two guide rails.

10. Patch the top and bottom openings. Cut handle hole. Add fillets and neck.

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Design Enhancement Project III (Wrist Watch)

Objective: Redesign the wrist watch to enhance its appearance and try to include new
ideas to enhance the overall product.

Create a presentation and be prepared to sell your concept to the class.

You will be awarded points on the following:

Appearance 20 pts.
Functionality 20 pts. (Supply sketches, CAD drawings, and or renderings)
Analysis (Mechanical and Marketing) 20 pts.
Presentation 40 pts.

Total Contract Award: 100 Points max.

Due: Wed. Nov 30th.
Samples:

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Design Enhancement Project IV (Microwavable Food Tray)
Use this project or come up with your own idea for Project IV!

Part design for Thermoforming

What is thermoforming?

Thermoforming is a manufacturing process for thermoplastic sheet or film. Specifically,

it is more of a converting process, where plastic sheet or film is converted into a formed,
finished part. The sheet or film is heated in an oven to its forming temperature, then
stretched into or onto a mold and cooled. Early generation thermoforming machines
usually incorporated cal-rod type heaters, similar to heating elements found in
conventional electric kitchen ovens. These are still used, but more modern equipment
frequently uses quartz heaters or radiant-panel heaters for more efficient sheet heating
and ease of zone control. Cast or machined aluminum is the most common mold
material, although epoxy, wood and structural foam are sometimes used for prototypes,
samples, and low volume production runs. Aluminum molds are normally water-cooled
by a cooling tower or chiller system for faster production capabilities. Thermoforming
differs from injection molding, blow molding, rotational molding, and other forms of
processing plastics, and is primarily used in the manufacture of disposable cups,
containers, lids, trays, blisters, clamshells, and other products. A thermoform machine
can utilize vacuum only, or vacuum combined with air pressure, in the forming process.
It can be as small and simple as a table-top sample former where small cut sheets of
material are placed into a clamp and heated and formed, or as large and complex as a
complete inline extrusion, thermoforming, trimming, granulating, and material handling
system for continuous high-speed production. Many thermoforming companies do not

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extrude their own plastic sheet, but rather purchase it in roll-wound form for running on
their forming equipment. Others purchase plastic resin in bulk pellet form and extrude
the sheet for use on roll-fed or inline forming machines. (source: Wikipedia)
STAGES IN PROCESS

1. Hand-sketch three concepts.

2. Choose the best concept for production
3. Scan in the sketch
4. Import the sketch into SolidWorks
5. Measure and Draw the profiles
6. 3D Model tray
7. Choose material (FDA approved?)
8. Create production drawing

Once complete turn in all materials

3 - Hand Sketches
Rhino, ProE or SolidWorks model
Rhino, ProE or SolidWorks drawing (print out copy)
Prepare brief summary of design and reasons for designing it the way you did.
You will be graded on the quality of your work and the level of detail used.

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