Efficiency & Aerodynamic Designing 101 – Designing Faster Shapes With Fusion 360

First of all, allow me to redefine what "speed" means, usually it is the rate of which an object covers distance over time. But in the sense of engineering, speed can also refer to efficiency. (How smoothly an object can move through air or water without being slowed down by any resisting forces.)

In this Instructable, I am aiming to redesign a simplistic object by utilizing Autodesk Fusion 360 to make it more aerodynamic. By modeling the object after analyzing airflows I can optimize the shape in order to reduce drag, thus improving the overall performance. The entirety of the approach uses an engineering process similar to what professional designers & engineers utilize during the development of high-performance vehicles, drones, and sports equipment.

Rather than constructing something fast, my goal is to explore how both design and simulation can potentially improve the speed of any concept product prior to manufacturing tangible iterations. The results should be both smarter and efficient compared to other designs; therefore I am demonstrating how digital tools/resources can push performance further.

As the goal is to only show the impact of digital resources/tools on improving efficiency.

Software

1. Autodesk Fusion 360 (Free Student Version)
2. Device Capable of Running Autodesk Fusion 360

Design / Simulation

1. Fusion 360 Simulation or CFD tools
2. Stable Internet Connection

Documentation

1. Screenshot tool for capturing simulations. (E.g. QuickTime Player)

In order to begin this Instructable you need to grab your device and install Autodesk Fusion 360. Follow the instruction on this webpage: Link Once installed, open the application and login. Then ensure you see a workspace with a grid where you can create designs.

At this point of time we can start creating a new design in Fusion 360.

1. Click File → New Design. (Choose Parts Design)
2. Click Save and give your project a name like IShowEfficiency.

TIP: Save Earlier in order to prevent any potential loss of effort.

We need a starting object before optimizing it.

1. Click Create Sketch.
2. Click the top plane (the flat grid).
3. Select the Circle Tool.
4. Click the center of the grid and draw a circle.

Now turn it into a 3D object:

1. Click Finish Sketch.
2. Click Extrude.
3. Pull the circle upward to create a cylinder.
4. Click OK.

You now have a basic object that moves through air.

Now we make the shape smoother.

1. Click Modify → Fillet.
2. Click the sharp edges of the cylinder.
3. Increase the fillet size until the edges become rounded.
4. Click OK.

Rounded edges help air move around the object more smoothly.

Now test how air flows around your design.

1. Switch the workspace to Simulation.
2. Choose Shape Optimization.
3. Choose Preserved Areas – Click the parts of the object that must stay solid (these will not be removed).
4. Add a Force – Click Loads and add a simple force pushing on the object.
5. Fix One Side – Click Constraints and select a face to hold the object in place.
6. Set the Goal – Choose Minimize Mass so the software tries to make the object lighter.
7. Run the Study – Click Solve to start the simulation.

Look at the simulation results. (Areas with high pressure or turbulence cause drag.) If you wish to make a new iteration here are some modifications you can make to improve the design to reduce drag:

1. Round edges more
2. Make the front smoother
3. Reduce unnecessary mass

After editing, run the simulation again.

To Document Results:

1. Take screenshots of your CAD model
2. Show simulation results

Congratulations on learning how to transform simple 3-dimensional objects into aerodynamic & efficient complex objects in Autodesk Fusion 360. Now utilizing this newly obtained knowledge, make an attempt at applying the knowledge to something practical such as 3D Modeled Vehicles or Throwing Toys (Darts & Axes).