Section 2: Creating a speaker housing
Creating a speaker shell around required components
Now that you have studied basic modelling on Fusion 360 you will use and develop these
skills to create a 3D model of a speaker. You will use your knowledge of multibody design
and assemblies to help create the model. You will use the rigid joint tool to assemble
components into the design and create a top-down model around these components.
The components below must be downloaded and uploaded to your data panel. They will be
used throughout the design.
CAD Skills Guide
Figure 3.2.1
95
Copyright © Ministry of Education – United Arab Emirates
Video tutorial: creating the speaker shell Video tutorial: assembling components
a) Create a new sketch on the top plane (to create a plan view as studied in chapter 2).
b) Sketch a 140 mm x 140 mm centre rectangle > set the rectangle as a construction
line type
CAD Skills Guide
Figure 3.2.2
96
Copyright © Ministry of Education – United Arab Emirates
c) Expand the data panel > locate the amplifier you have uploaded > right click and
select ‘insert to design
d) Move and position the amplifier using the triad.
e) Use the view cube to view the position of the amplifier from the top and side views.
Figure 3.2.3
f) Repeat with the battery pack and Arduino Leonardo board > position within the
rectangle as shown
CAD Skills Guide
Figure 3.2.4
97
Copyright © Ministry of Education – United Arab Emirates
g) Create a new sketch on the top plane > expand the sketch tab > select polygon >
inscribed polygon > sketch a 70 mm inscribed hexagon as shown
Figure 3.2.5
CAD Skills Guide
h) Select the extrude tool > select the hexagon sketch as profile > set the height to 80
mm (this should be above the highest component)
Figure 3.2.6
98
Copyright © Ministry of Education – United Arab Emirates
The shell feature
The shell tool is used to create a hollow cavity in parts. It removes material leaving a wall of
a specified thickness. Here we will use the shell tool to remove material from the top face
of the hexagon.
i) Expand the modify tab > select shell > select the top face > set inside thickness to 3
mm
Figure 3.2.7
j) Expand the assemble tab > select joint > select the centre point of the amplifier as
shown for component 1
CAD Skills Guide
Figure 3.2.8
99
Copyright © Ministry of Education – United Arab Emirates
k) Rotate the view to look inside the hexagon from the top > select the centre of the
front edge on the floor of the shell as component 2
Figure 3.2.9
CAD Skills Guide
l) Offset the amplifier 0.5 mm from the wall of the shell to create clearance > set joint
as rigid and complete joint
Figure 3.2.10
100
Copyright © Ministry of Education – United Arab Emirates
m) Open the data panel > right click and insert the speaker > use the triad to position
outside the design as shown
Figure 3.2.11
n) Expand assemble tab > select joint > select the centre of the speaker as component
1 > select the centre of the hexagon face as component 2
CAD Skills Guide
Figure 3.2.12
101
Copyright © Ministry of Education – United Arab Emirates
o) Use the arrow or dimension box to position the speaker level with the edge of the
hexagon as shown.
Figure 3.2.13
The mirror feature
Previously, you used the pattern and move/copy tools to duplicate bodies. The mirror tool
also allows you to duplicate faces, features, bodies or components. However, the mirror
tool is unique because it duplicates an exact mirrored copy an equal distance across a
selected face or plane.
Here we will use the mirror tool to create a second identical speaker in the same position
on the opposite side of the hexagon.
CAD Skills Guide
p) Expand the create tab > select mirror > set pattern type as ‘Components’ > select the
speaker as object > select the YZ plane as mirror plane
102
Figure 3.2.14
Copyright © Ministry of Education – United Arab Emirates
Mounting the speakers in the shell
Now that you have positioned the speakers
and amplifier in place, you must create
holes to mount them into the shell. There
are two main ways of creating a hole in
Fusion 360. As you have seen previously,
you can create an extruded cut which
removes the shape of a specified sketch
profile to a specified depth. We can use
the extrude cut feature to create holes by
simply sketching cylinders as the extrude
profiles.
Video tutorial: Creating speaker holes
However, there is also a second option when the shape to be cut is a circle the hole feature
creates cylindrical holes to specified standards.
The hole feature
The hole tool allows you to create a user-specified
hole on any face using edges or sketch points to
position. You can then select various hole types such
as simple, countersunk, counterbore, and tapped
(threaded) as shown in Figure 3.2.15 . The diameter
of the hole must be selected as well as the extent.
The extent can be set as a specified distance, up to a
surface or through all material.
Look at the shape of the speaker, you can see the
speaker is wider at the front than the piece that
goes through the shell. A counterbored hole will,
therefore, be suitable to mount the speaker.
Figure 3.2.15
CAD Skills Guide
Figure 3.2.16
103
Copyright © Ministry of Education – United Arab Emirates
a) Open the speaker file > select the measure tool > measure the diameters shown and
record the measurements
Figure 3.2.17
CAD Skills Guide
b) Expand create > select the hole tool > position the hole on the same centre as the
speaker > set the extent as ‘to’ > set the hole type as counterbore > create the head
0.5 mm greater than the diameter measured to create clearance > set the hole as 0.5
mm greater also > set the depth as 1.5 mm
Figure 3.2.18
104
Copyright © Ministry of Education – United Arab Emirates
c) Rotate the model and select the inside face as the extent to cut up to.
Figure 3.2.19
Creating the same speaker holes as extruded cuts
To create the holes using extruded cuts we must sketch a suitable circle profile. The sketch
project/include tool is very useful when creating the same profile of a different body or
component on the chosen sketch plane. In this case, we can simply project the speaker
profile and offset these sketches by 0.5 mm to create clearance. Another tool that will prove
useful when working with multiple bodies is “opacity control”. This is how transparent a
body appears.
We can set body 1 to be transparent to see the speaker profile more easily.
To make any body transparent, locate the body in browser > right click to get the short
menu > select opacity control > set the level of transparency required
CAD Skills Guide
Figure 3.2.20
105
Copyright © Ministry of Education – United Arab Emirates
a) Create a new sketch on the hexagon face > expand sketch tab > select project/include
> select project > select the required edges of the speaker as shown
Figure 3.2.21
CAD Skills Guide
b) Set the 2 circles as construction lines > offset the two construction circles by 0.5 mm
Figure 3.2.22
106
Copyright © Ministry of Education – United Arab Emirates
c) Select extrude > select the smaller circle as sketch profile > set operation to cut > set
extent to object > select the inside face as shown
Figure 3.2.23
d) Create an extrude > select the outer profile this time > set operation as cut > set
depth to 0.5 mm
CAD Skills Guide
Figure 3.2.24
107
Copyright © Ministry of Education – United Arab Emirates
The hole tool vs extruded cuts
In this case, both can provide the same result. However, using the hole feature is much
quicker and requires fewer steps. Also, let us take an example where the speaker size
changes, and we need to edit the model. Which will be easier to edit? Using the hole tool
means we only have one feature to edit. In this feature, we can adjust the size, the depth
and the style of hole.
Based on the ease of use and the ability to easily edit, it is best practice to use the hole
tool where possible to create cylindrical cuts.
Mirroring features
When you have created one hole you can mirror it to the other side just as you did with the
speaker. This time you will mirror the feature or features.
e) Expand the modify tab > select mirror > set
CAD Skills Guide
Figure 3.2.25
108
Copyright © Ministry of Education – United Arab Emirates
Creating mounting holes for the potentiometer and the audio jack
You must now create holes to mount the
potentiometer and audio jack in the audio
amplifier model. These components are
soldered to the PCB. When you design
your own unique speaker you will have the
choice to solder it to the board or connect
it with wires and place it anywhere in the
design. The process will be the same as
described below but you must place the
mount holes in the required position.
Video tutorial: Creating a potentiometer
and audio jack holes
Figure 3.2.26
a) Locate body 1 in the browser > right click to get the short menu > select opacity
control > set to 50%
b) Locate the joint between the housing and the audio amplifier PCB > right click and
select edit joint
CAD Skills Guide
Figure 3.2.27
109
Copyright © Ministry of Education – United Arab Emirates
c) Offset the joint by 2 mm along the z-axis using the arrow or the dimension box.
Figure 3.2.28
d) Select the measure tool > rotate the view to see the potentiometer shaft and audio
jack > select the audio jack profile to check diameter > record diameter
CAD Skills Guide
e) Repeat with the potentiometer shaft and record diameter
Figure 3.2.29
110
Copyright © Ministry of Education – United Arab Emirates
f) Create a new sketch on the front face of the hexagon body > sketch two centre
diameter circles approximately in the position shown > avoid having the centre
locking on to any relation > then select the concentric relation > select the circle and
the circle of the potentiometer to give them the same centre
g) Repeat with the second circle and the audio jack.
Figure 3.2.30
Cutting the holes
To cut the holes we have the choice of using the hole tool or an extruded cut. In this case,
the holes need to be 2 mm larger than measured to allow for plenty of clearance when
fitting. The two holes needed are different diameters so two separate holes would need
to be used. Another option is to dimension the circles 2 mm greater than measured and
create one extruded cut using both profiles. This only requires one feature; therefore, the
extruded cut is a good option here.
CAD Skills Guide
111
Copyright © Ministry of Education – United Arab Emirates
a) Dimension the circle profiles 2 mm greater than the measured diameters in Figure
3.2.31.
Figure 3.2.31
CAD Skills Guide
b) Select extrude > select the two circle profiles > set extent to object > select the inside
face > set operation as cut
Figure 3.2.32
112
Copyright © Ministry of Education – United Arab Emirates
Creating a top cover for the speaker
Video tutorial: Creating a top cover
You have now completed a speaker
housing to hold all the required electronic
components. You must now model a cover
to fit on the top of the speaker. You will use
your knowledge of multibody design to
create a separate body and ensure it is the
correct size to fit.
Figure 3.2.33
a) Create a new sketch on the top surface of the hexagon speaker body > select the
sketch project tool > set selection filter to body and select body 1
CAD Skills Guide
Figure 3.2.34
113
Copyright © Ministry of Education – United Arab Emirates
b) Expand sketch tab > select offset > select the inside hexagon > offset by 3 mm
Figure 3.2.35
CAD Skills Guide
c) Select extrude > select the complete hexagon to as the profile > set operation to new
body > set height as 30 mm
Figure 3.2.36
114
Copyright © Ministry of Education – United Arab Emirates
Adding Fillets/chamfers
Chamfers and fillets can be used to improve the appearance or function of a body.
Chamfer
The chamfer tool adds a bevel or angle to edges.
Fillet
The fillet tool adds a round or radius to edges.
Adding external chamfers or fillets removes material. This can reduce weight, improve the
aerodynamics of a project or can simply improve the aesthetics of a project. Adding an
internal fillet or chamfer adds material. This can improve strength and appearance
Figure 3.2.37
d) Expand the modify tab > select chamfer > select the front edge of hexagon top body
> set chamfer type to ‘two distances’ > use the arrows or dimension boxes to set the
distances.
CAD Skills Guide
Figure 3.2.38
115
Copyright © Ministry of Education – United Arab Emirates
e) Hide body 1 and all the electronic components in the browser for clarity
f) Ensure the offset sketch is shown in the browser
g) Select extrude > select the offset sketch profile > set distance to -5 mm > set
operation as join
Figure 3.2.39
CAD Skills Guide
h) Expand the modify tab > select shell > select the inside cade as shown > set the wall
thickness to inside and 3 mm
Figure 3.2.40
116
Copyright © Ministry of Education – United Arab Emirates
i) Expand modify > select chamfer >select the edge of the 3 mm extrude as shown >
apply a two-distance chamfer > set the distances to create a chamfer
Figure 3.2.41
j) Show all bodies again > expand the modify tab > select fillet > add fillets to the edges
shown to improve the model’s appearance
CAD Skills Guide
Figure 3.2.42
117
Copyright © Ministry of Education – United Arab Emirates
Inserting an LED matrix module
You have now used basic Fusion 360
modelling skills to create a speaker
housing and top cover. You must now build
on these skills to add an LED matrix. This
section will help you understand how to
insert and position an LED matrix in your
design.
Video tutorial: Inserting LED matrix
First, you must download the LED matrix
file and then upload it to your data panel.
Figure 3.2.43
a) Hide the main body and all other components.
CAD Skills Guide
b) Expand the data panel.
118
Figure 3.2.44
Copyright © Ministry of Education – United Arab Emirates
c) Right-click on the LED matrix > insert to current design
d) Rotate the LED matrix to face the correct direction > use the triad or dimension box
Figure 3.2.45
e) Expand the assemble tab > select joint
f) Select the centre of the underneath of the top cover as component 1 > select the
centre face of the LED matrix as component 2 > set the joint type to rigid
CAD Skills Guide
Figure 3.2.46
119
Copyright © Ministry of Education – United Arab Emirates
g) Right-click on the top cover body to expand the short menu > select opacity control
> set to 50%
Figure 3.2.47
h) Right-click the joint in the timeline and select edit joint.
CAD Skills Guide
i) Offset the Z axis -1.5mm to sink the LED matrix into the cover.
Figure 3.2.48
120
Copyright © Ministry of Education – United Arab Emirates
j) Ensure the capacitor (highest point on an LED matrix) is not past the edge of the top
cover.
Figure 3.2.49
Creating mounts for the LED matrix
a) Select create sketch > select the inside face of top cover as shown
CAD Skills Guide
Figure 3.2.50
121
Copyright © Ministry of Education – United Arab Emirates
b) Expand sketch tab > select circle > centre circle > draw two centre circles
approximately with centres in LED matrix mount holes as shown
c) Select the circle profile of the LED matrix hole > hold ctrl and select the circle you
sketched > select the concentric option from sketch palette
d) Repeat with the second circle.
Figure 3.2.51
CAD Skills Guide
e) Select sketch dimension (D) > dimension both circles as diameter 6mm
Figure 3.2.52
122
Copyright © Ministry of Education – United Arab Emirates
f) Select the extrude tool > Select the full circle profile. Use the left click and hold option
to display possible selections.
Figure 3.2.53
g) Rotate to look down on the LED matrix > set extent to object > select face of LED
matrix mount plate as shown > set operation as new body
CAD Skills Guide
Figure 3.2.54
123
Copyright © Ministry of Education – United Arab Emirates
h) Select create sketch > select the face of the newly extruded cylinder as shown
Figure 3.2.55
i) Expand sketch tab > select point > sketch two points inside the holes with no
relations
CAD Skills Guide
j) Select the circle > hold ctrl and select the point > select the coincident constraint
from the sketch palette > repeat with the second point
Figure 3.2.56
124
Copyright © Ministry of Education – United Arab Emirates
Note:
If the point has become defined, you can remove the relation and
then apply the concentric constraint.
Figure 3.2.57
k) Expand the create tab > select hole > select the two sketch points > set hole diameter
to 1.5mm as it will be a pilot hole for an M2.5mm screw
CAD Skills Guide
Figure 3.2.58
125
Copyright © Ministry of Education – United Arab Emirates
Cutting an opening for the LED matrix display
Now that you have created mounts to screw the LED matrix in place, you must create an
opening to allow the LED display to pass through the speaker’s top cover.
a) Rotate the view to look down on top of the cover.
b) Select create sketch > select the top surface
Figure 3.2.59
c) Expand the sketch tab > select rectangle > center rectangle > sketch a rectangle
larger than the LED matrix
CAD Skills Guide
d) Select the sketch dimension tool (D) > set the distance between the edge of the LED
matrix and the rectangle as 0.5mm
126
Figure 3.2.60
Copyright © Ministry of Education – United Arab Emirates
e) Repeat with each edge to fully define the rectangle
Figure 3.2.61
f) Select the extrude feature > select the rectangle sketch as profile > set operation as
cut > set extent to all
CAD Skills Guide
Figure 3.2.62
127
Copyright © Ministry of Education – United Arab Emirates
Combining bodies
Now you have completed the top cover with mounts and an opening for the LED matrix. You
must now combine the mounts and main body so they can be 3D printed as one. This will
apply to any parts that you design for your unique portable speaker that are to be 3D printed
as one part.
a) Expand the modify tab > select combine > select the main body as target body >
select the two mounts as tool bodies > set operation to join
Figure 3.2.63
CAD Skills Guide
You can use this method to add an LED matrix to any design.
128
Copyright © Ministry of Education – United Arab Emirates
Hybrid education in the Emirati school
Within the strategic dimension of the
development plans in the Ministry of Education,
and its endeavor to diversify education channels
and overcome all the challenges that may prevent
it, and to ensure continuity in all circumstances,
the Ministry has implemented a hybrid education
plan for all students at all levels of education.
Study Plan
School
learning
Direct
e-learning
Prekindergarten/
kindergarten
Cycle 1
-
-
Cycle 2
Cycle 3
Self
Channels for obtaining a textbook:
Electronic units
Doctorate Degree / Applied Sciences
)Years 3-5(
Master’s Degree / Applied Sciences
)Years 2(
Education System in the United
Arab Emirates
Postgraduate Diploma / Applied Sciences
(1-2 Years)
Bachelor’s Degree / Applied Sciences
)Years 3-4(
Diploma / Postgraduate Diploma
)Years 2-3(
Joining
Work
Bridging
Program
Vocational Qualification
Vocational Education and
Development Centre
Continuous Education
Home
General &
Schooling Academic Stream
Applied
Stream
Literacy
Technical & Vocational Streams
Specialised
Academies
Technical
General
Academic Streams
Technical
Advanced
General
Applied Technology
Secondary School Program
Advanced
Elite
Top 10 percent
of students in
national test scores
6
International
Classifications
Grades 1 - 4
)Ages 6-9 (4 Years
12
3
International
Classifications
Cycle 1
Basic Education
Cycle 2
)Elite Program (Grades 5-8
Top 10 percent of students in national test scores
)Ages 10-14 (4 years
Early Childhood
)Kindergarten Ages 4-6 (not compulsory
)Nursery/ Care Ages 0-4 (not compulsory
International
Classifications
12
Cycle 3 / Secondary Stage
)Grades 9-12 Ages 14-18 (4 years
Grades 5 - 8
)Ages 10-14 (4 Years
UAE National Qualifications
Framework Level 10
18
International
Classifications
The Ministry coordinates with national higher education institutions to admit students in various majors in line with the needs of the labour
market and future human development plans. Higher Education institutions also determine the number of students that can be admitted
according to their capabilities, mission and goals. They also set the conditions for students’ admission to various programmes according
to the stream they graduated from, the levels of their performance in the secondary stage, and their results from the Emirates Standard
Assessment Test.
Integration and coordination between General and Higher Education systems allow for the approval and calculation of school
study courses within university studies according to the school stream and university specialisation, which reduces the duration of
.university studies
International
Classifications
Advanced University
Enrollment
)Years 3(
)Years 3-4(
Applied
18
Level 7-8
Bachelor’s Degree
Level 5-6
)Years 4-5(
Bachelor’s Degree / Applied Sciences
Level 1-4
Postgraduate Diploma
(1 Year)
Theoretical
International
Classifications
Postgraduate Diploma
(1-2 Year)
International
Classifications
22
)Years 2(
UAE National Qualifications
Framework Level 9
)Years 2(
International
Classifications
Master’s Degree
UAE National Qualifications Framework
Dual Degree
Bachelor’s/Master’s
Master’s Degree
UAE National Qualifications Framework
24
)Years 3-5(
UAE National Qualifications Framework
Doctorate Degree
Starting Age