Learn some A'maze'ing Tips in Fusion

I recently worked on a maze project at my local creator space to get certified on a CNC machine. During that process, I learned some useful tricks to simplify the design process. These tips will help you create complex shapes with fewer headaches and better results.

Utilizing Sketch Shortcuts for Efficiency

Fusion has handy shortcuts, like the S key. Instead of clicking through menus, just press S in your viewport. A small search window appears, letting you type commands like "center rectangle." You can also add these commands to the toolbar for even faster access. Customizing shortcuts streamlines your workflow, especially when repeating tasks.

Designing the Basic Maze Structure

Creating the Overall Shape

Use the center rectangle command for the main shape. Simply type "CEN" after pressing S, then click for the rectangle. Specify dimensions—say, 9 inches wide and 6.5 inches tall. This quick start sets the base for your maze. Next, add a shelf for the Plexiglass by offsetting a sketch inward by 0.625". Extrude both profiles with a negative value like -0.75 inches to form the main block.

Material and Appearance Settings

Apply a wood look to your maze by selecting a maple material preset. Use the appearance shortcut (A key) to quickly change the visual style. This helps visualize how the final piece will look and can make adjustments easier.

Developing the Maze Path Using Surfacing Techniques

Creating Path Profiles with Sketches

Design the maze path with simple straight lines. Instead of modeling each channel in width, draw the overall route that the ball could follow. This keeps your design fast and flexible. Think of it as sketching the trails on a map rather than carving every road.

Building Maze Channels with Surfacing Commands

Extruding Edges Using Surface Tools

Turn off solid bodies before surfacing. Then, go to the Surface tab and select "Extrude." Click on the maze lines—these are your profiles—and drag to create thin walls by extruding inward. For example, an extrusion of -0.375 inches forms the walls' height.

Thicken Command for Wall Thickness

Use the "Thicken" command to give width to the extruded surface lines. Select the outline, then choose symmetric to have equal wall thickness on both sides. Set the thickness to about 0.15 inches, so the wall totals 0.3 inches. This method keeps your design flexible—adjust the sketch, and the maze updates automatically.

Other Methods?

You could also use the Thin Extrude option in the Extrude command. This method accomplishes the same ideas as the surfacing/thicken method, but with fewer steps.

Cutting the Maze Channels from the Wooden Block

Using Boolean Operations for Material Removal

With the maze walls created as separate bodies, subtract them from the main wooden block using the "Cut" operation. Select the maze channel bodies as tools, and perform subtraction to hollow out the maze.

Refining the Maze Geometry for Accuracy

Adjust the sketch routes to perfect your maze by dragging the lines in the sketch. Because the maze is linked to the surface extrusions, any change updates your model immediately. This live feedback lets you see what the maze will look like without having to jump into and out of the sketch each time.

Rounding Edges for Safety and Aesthetic Appeal

Limitations of Rule Fillet for Complex Edges

While the rule fillet command is handy, it doesn’t always work well on complex shapes or internal edges. For example, if you try to fillet all vertical edges with a small radius, some edges may not round properly, leaving sharp corners or missed spots.

Advanced Edge Rounding with Selection Techniques

Using Selection Filters for Efficient Edge Selection

To speed things up, use the "Selection Filters." Set it to "Body Edges" only. This prevents accidental selections of faces or entire bodies, saving time. You can find this in the "Select" menu.

Cross-Box Selection Method

Next, draw a crossing window from right to left over your vertical edges. This selects all the edges crossing within the box at once. You can then apply a uniform fillet radius—say 0.125 inches—to all selected edges in one go.

After applying the fillet, reset your selection filter to include all elements. This ensures you don’t accidentally limit your future selections.

Final Touches: Enhancing the Design for CNC Machining

Adding Chamfers or Fillet Details

Sometimes, adding chamfers or larger radius fillets on the maze edges can help with tool entry or reduce sharp corners that might cause chip-out. Decide based on your CNC tool capabilities and safety needs.