In this tutorial I will show you how to create the Eureka Effect, the futuristic engineer wrench from Team Fortress 2. This wrench took me about two weeks to model, and not all of the pieces printed perfectly, but overall it came out pretty well. This is an image from the SolidWorks Photoview 360 add-in, for realistic rendering. It printed in green plastic. It is overall about 3.5 inches long, and is partially functional. I will show you the parts that it took to create this, and the final assembly of all of them.
Step 1: The Head
First you must create the head of the wrench. To do this you must first create a sketch of the round bit. then you must extrude that and then extrude another piece off of the bottom for the slider.
Step 2: The Handle
Next you must sketch out an outline of the handle, and extrude it. Use the extruded cut tool to add more detail to it. Add two holes at the top for the rack bit. Make sure that you make a good finger grip area.
Step 3: The Rack
Next sketch out the rack. To do this just draw it on the front or right plane. Then, cut out the middle, along with a couple of holes and a large circle. The smaller ones will be for screws and the larger one will be for the tesla coil thing.
Step 4: The Wheel
This part is for the wheel to raise the head up and down. This is the part that is not fully functional. I did not know how to create a thread along the inside of it, so that is the only problem. Anyway, create a circle that is a little bit bigger than how wide the long part of the head is. Then add another cut on the outside for grip and pattern it all the way around.
Step 5: The Tesla Coil
This is the final piece of the assembly. This is the piece on the back that looks like a tesla coil. All you have to do is create several extrusions, one large then one small all the way up six times. Then create a small sphere on the top, and print out your pieces. I could not get my 3D printer to work, so I was unable to print the pieces. You can use the realistically rendered model to reference your assembly.