I’ve got a 3D model I’d like to “engrave” into some aluminum to use as a heatsink. It’s a PCB that I have some thermal pads for, and I’d like to essentially make a clam-shell case for it, and then mill fins into the aluminum and maybe add a fan to keep the PCB cool.
I found that the manufacturer of the PCB has exported it as a step file (found here )
I imported that into fusion, deleted a couple RF cans that they removed (assuming FCC didn’t require them) and ended up with a combined model that looks like this:
So far so good. I saved that, and then created a new design, extruded an Aluminum billet, imported the combined model, lined up the origins, and then combined using the “cut” option which should “emboss” my model into the Aluminum, making a mold of my part (that I can line with the heatsinking and electrically isolating thermal pad).
Now I’d love to start worrying about toolpaths etc, but the issue is this (model hidden):
Notice the connectors, it looks like my model has some internal voids, and those, of course, aren’t being subtracted from the mold. Also, look for the large box that you see in the first photo, it exists, it’s just underneath the void which is now Aluminum in mold.
Any idea on how to tell fusion that I’d like my model to be my model but without any overhangs or internal voids? Or tell the cut command that I’d like an emboss instead of a subtraction? If I have to, I can remodel this manually instead of using the Altium export, but it won’t be nearly as accurate as the PCB model, and will be quite tedious getting the tiny components into the right locations.
I’ve tried Boundary Fill, and it doesn’t appear to be doing what I want. Same with liquid fill.
@nicksilva Feel free to laugh, I realize I’m in the weeds of 3D engraving/mold making, but eh, if you don’t start off on a hard project you’ll never learn.
If you want to help me with it in person, I’ll be up at DMS Saturday the 31st (August 2019) around noon messing with it, and if time permits, maybe cutting air on the HAAS.