Repairing Various Things Around the House Using Fusion 360 and 3D-printing

Hello, I'm Johannes and I am a 14-Year-old student at Bischöfliches Gymnasium Graz in Austria.

In this Instructable I will guide you through the process of how I repaired a door latch with a simple shape I designed using Fusion 360 and then 3D printed it.

With the advancements in technology, it has become easier than ever to create and repair items right from the comfort of our own homes. In this tutorial, we will be focusing on how to use Fusion 360 to design objects, and how to use 3D printing to bring these designs to life. Whether you are a beginner or an experienced maker, this guide will provide you with the knowledge and tools necessary to create and repair objects in your home.

I'm going to give you some different examples as inspiration below.

So, let's get started!

Supplies

Here is a list of supplies you will need to complete this instructable:

1. A computer/laptop with an internet connection

2. Fusion 360 software (free for students)

3. Access to a 3D printer (either your own or access to one at a local maker space)

4. Filament for your 3D printer (covered in Step 5)

5. Digital calipers (for accurate measurements) alternatively you could use a normal ruler

6. Sandpaper and an exacto knife (for clearing tolerances)

8. Optional: If you have a 3D-Scanner you could use it instead of modeling the part yourself but I personally prefer just doing it from scratch.

Make sure to have these supplies on hand before starting the project so you can complete the steps smoothly.

Step 1: Identifying the Problem and Choosing a Method

There are a few different methods you can choose from depending on your problem:

1. If you have a broken Part that you want to replace you would need to reconstruct it which can be a bit challenging if too much is broken.
2. If you have another identical part you can recreate that one which is probably the easiest to do.
3. If you have nothing of the original Part or there was never a part with that specific purpose you would need to find your own solution which, depending on your situation, can be pretty complex but most of the time isn't too complicated.

Step 2: Taking the Required Dimensions and Sketching the Piece

1. Take clear photos of the broken part: Use a camera or your smartphone to take multiple pictures of the broken part from different angles. Try to capture the entire part in each photo and make sure the images are clear and in focus.
2. Use a ruler or caliper: Measure the broken part using a ruler or caliper. Measure the length, width, height, and any other dimensions that are necessary to create an accurate 3D model. Take note of the units of measurement (e.g. millimeters or inches).
3. Sketch the broken part: Use a pen and paper to sketch the broken part, including all the measurements you just took. This will help you visualize the part and ensure you have captured all the necessary details.

Step 3: Enter User Parameters

I'd highly recommend that you use User Parameters in your design because of:

1. Design Flexibility: User parameters provide you with the ability to make design changes quickly and easily. By defining parameters for key dimensions, features, or design aspects, you can modify them later without manually editing each instance. This flexibility allows you to experiment with different design iterations and adapt your model to specific requirements or constraints.
2. Parametric Modeling: User parameters enable parametric modeling, where changes to one parameter automatically update all associated dimensions and features in the model. This parametric approach allows for efficient design exploration and modification. By adjusting a single parameter, you can see the immediate impact on the entire model, reducing design time and effort.

Step 4: Create the 3D-Model

Next, open Fusion 360 and create a new design. Click the "Create Sketch" button and draw the broken part using the user parameters you defined earlier. Use the various tools in the software to make the part look as close as possible to the original piece. Save the design.

If you find yourself overwhelmed by the extensive toolset offered by Fusion 360, an alternative option is to use a simpler software like TinkerCAD for your design. However, I would like to emphasize that investing time in learning Fusion 360 can be highly beneficial as its learning curve is quite manageable. With some dedicated practice, you can quickly become proficient in this program.

Step 5: Choosing a Sufficent Material

When choosing the right filament for 3D printed repairs, it is essential to consider the performance of different materials outdoors in the sun or under high stress conditions. Here's a guide to help you make an informed decision:

1. PLA (Polylactic Acid):

  - Performance: PLA is a commonly used filament known for its ease of use and biodegradability. However, it is not suitable for outdoor applications or high-stress situations as it can degrade when exposed to sunlight or excessive force.

  - Recommendation: PLA is best suited for indoor use or applications that don't involve prolonged exposure to sunlight or heavy loads.

2. ABS (Acrylonitrile Butadiene Styrene):

  - Performance: ABS is more durable and impact-resistant than PLA. It can withstand moderate stress and is less prone to degradation in sunlight. However, it may still exhibit some yellowing over time.

  - Recommendation: ABS is a suitable choice for outdoor applications where moderate strength and resistance to sunlight are required. Keep in mind that it requires a heated print bed to minimize warping.

3. PETG (Polyethylene Terephthalate Glycol):

  - Performance: PETG is a popular filament with good durability, impact resistance, and resistance to UV degradation. It retains its mechanical properties even under outdoor conditions.

  - Recommendation: PETG is a versatile filament suitable for outdoor applications that require durability, weather resistance, and moderate strength.

4. Nylon:

  - Performance: Nylon filaments offer excellent strength, durability, and impact resistance. They are known for their toughness and ability to withstand high-stress conditions.

  - Recommendation: Nylon is a great choice for applications that require high strength and durability, especially under stressful conditions. It is also more resistant to UV degradation compared to PLA or ABS.

5. Polycarbonate (PC):

  - Performance: Polycarbonate is a robust and heat-resistant filament with excellent mechanical properties. It provides high impact resistance and can withstand prolonged exposure to sunlight without significant degradation.

  - Recommendation: Polycarbonate is ideal for applications that require exceptional strength, durability, and resistance to high temperatures and outdoor elements.

Remember, the specific performance of a filament can vary depending on the brand and formulation. It's always a good practice to refer to the manufacturer's specifications and conduct test prints or gather user experiences for the desired material and specific use case.

Step 6: Print It.

There are several ways to get your desired part:

1. Owning your own 3D printer:

  - Purchase a suitable 3D printer.

  - Slice the model and print it using your 3D printer.

  - Perform post-processing as needed.

2. Utilizing a 3D print service:

  - Choose a reputable 3D print service provider.

  - Prepare and upload your 3D model.

  - Receive the 3D-printed object and perform post-processing, if necessary.

Step 7: Summary

I hope you found this Instructable helpful, because i think it is very important to repair things around your home using 3D-Printing.

Here are a few reasons:

1. Cost-Effectiveness: Repairing broken parts saves money compared to purchasing new replacements. By fixing and reusing items, you reduce the need for constant buying, which can be costly in the long run.

2. Environmental Sustainability: Repairing broken parts aligns with sustainable practices by minimizing waste and reducing the demand for new resources. It promotes the circular economy, where items are kept in use for as long as possible, reducing the strain on natural resources and lowering carbon emissions associated with manufacturing new products.

3. Personal Empowerment: Repairing broken parts empowers individuals to take control of their possessions. Instead of discarding and replacing items, repairing allows you to extend the lifespan of your belongings, fostering a sense of ownership, self-sufficiency, and resourcefulness.

4. Customization and Adaptation: 3D printing offers the advantage of customization. When repairing with 3D printing, you have the opportunity to tailor the replacement part to your specific needs. You can modify the design, improve functionality, or even add personalized touches, enhancing the overall usability and satisfaction of the repaired item.

By embracing repair and utilizing 3D printing technology, you contribute to a more sustainable and resource-conscious lifestyle, while also enjoying the economic benefits and personal satisfaction of breathing new life into your broken items.

PS: I apologize for any writing and grammar mistakes as this is not my primary language.