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How do I design a model like this?

Question asked by Mike Barsky on Mar 2, 2015
Latest reply on Mar 17, 2015 by Mike Barsky

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I recently learned how to make a model like the one attached (1.png, 2.png) with a similar network but with hexagons instead of circles. So the result would be a hexagonal mesh instead of a circular one.

My question is, what if I wanted to take this a step further and incorporate this mesh into something else. I would like to create a 270 degree cylinder with solid rings around it and in between the rings this hexagonal mesh would exist.

I tried to draw a picture of what I mean (3.png). The drawing on the left is the front of the cylinder and the drawing on the right is the cylinder rotated 90 degrees. In the drawing on the left, the crisscrosses are the hexagonal mesh. In the drawing on the right, I tried to show that it is only a 270 degree cylinder--I didn't draw the hexagonal mesh in the second picture.

I would like to 3D print this.

Thank you very much for your help!

Jamil Snead Mar 2, 2015 5:22 PM

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See if this method works for you. I made the cylinder a sheet metal part, then in the flat pattern I used a Fill Pattern to create the hex mesh in a single step. Then I filled in where the solid rings are and folded it again.

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3.JPG1.4 MB
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1.png32.0 KB

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Jamil Snead Mar 2, 2015 5:22 PM
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See if this method works for you. I made the cylinder a sheet metal part, then in the flat pattern I used a Fill Pattern to create the hex mesh in a single step. Then I filled in where the solid rings are and folded it again.
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- HexPattern JS.SLDPRT.zip1.6 MB
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- Mike Barsky @ Jamil Snead on Mar 2, 2015 5:31 PM
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  Thank you so much Jamil! Looks perfect! Will try this now.
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  - Mike Barsky @ Mike Barsky on Mar 3, 2015 2:18 PM
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    Hi Jamil,
    
    Did you make a a regular cylinder and then convert to sheet metal or did you do it the other way around?
    
    Thanks,
    Mike
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    - Jamil Snead @ Mike Barsky on Mar 3, 2015 3:07 PM
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      I sketched a 270 degree circle and then used the Base Flange/Tab feature to extrude it as a sheet metal part from the beginning. Then to add the unfold feature, since there are no flat sections on the part, you need to select one of the end edges.
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      - Mike Barsky @ Jamil Snead on Mar 3, 2015 3:24 PM
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        Hey Jamil,
        
        Got up to here. Can you please explain how to add the rings?
        
        Thanks again!
        Best,
        Mike
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        Jamil Snead @ Mike Barsky on Mar 3, 2015 3:38 PM
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        After the fill pattern, before the fold, I sketched rectangles where the solid strips should be. Then I just extruded them to the thickness of the part, and folded it again.
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        Mike Barsky @ Jamil Snead on Mar 4, 2015 4:38 PM
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        Thanks Jamil, worked great. What if I wanted a separate and different pattern on the rectangles? I tried applying a linear pattern to them separately but it wouldn't let me.
        
        Lastly, is there a way to make a random pattern? I'm attaching an example below.
        
        Thanks again Jamil, really appreciate it!
        
        Best,
        Mike
        
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        Jamil Snead @ Mike Barsky on Mar 4, 2015 5:00 PM
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        If you want a different pattern on the rectangles then you could make a new fill pattern on one rectangle (after it is made solid on the part) and use a sketch to define the boundary (to keep it only within the rectangle). Then you could linear pattern to copy it to the other rectangles. Or you could manually cut out one shape and use a linear pattern to propagate it throughout one rectangle, then another linear pattern to copy to the others. It's not clear from your screenshot what you are trying to do with that linear pattern.
        
        As far as a random pattern, I don't know of a way.
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        Mike Barsky @ Jamil Snead on Mar 11, 2015 12:13 PM
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        Hi Jamil,
        
        I am still having trouble with this one. The fill pattern is affecting the area with where the rectangles are (pic 1). Is there a way to tell it to not enter that area other than using the instances to skip option? I did the instances to skip option and i would have to remove a lot of the hexagons.
        
        I also cannot figure out how to apply a separate fill pattern in the rectangles (pic 2). I drew a sketch of a rectangle on top of the first rectangle after extruding it. I used this as a boundary and it still won't let me apply a fill pattern.I tried doing it by selecting a face or selecting a feature and neither works. Says "unable to generate fill pattern instances." What am I doing wrong?
        
        Thank you very much for your help.
        
        Best,
        Mike
        
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        Jamil Snead @ Mike Barsky on Mar 11, 2015 1:18 PM
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        I'm not entirely sure what you want the end result to look like. But for what I think you want when you extrude the rectangles to make solid sections you need to merge the result so it becomes one body.
        Then you can use the rectangle sketch as the boundary for a new fill pattern. You should use the option to create seed cut, and then enter the hole info you want.
        I used a sketch of all 4 rectangles for the boundary, but you might have more control if you do each rectangle separately. If I am misinterpreting what you want let me know.
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        Mike Barsky @ Jamil Snead on Mar 12, 2015 2:36 PM
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        Thank you very much Jamil!
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        Mike Barsky @ Jamil Snead on Mar 13, 2015 1:45 PM
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        Hey Jamil,
        
        Is there a way to impose a depth boundary on the linear pattern. I would like for the holes not to cut all the way through the 4 rectangles. I tried decreasing the thickness of the 4 rectangles themselves but that did not affect the depth of the holes. I also tried inserting a plane about 2 mm into the side of the whole model opposite of where the linear pattern begins but SolidWorks wouldn't let me select that new plane as a fill boundary.
        
        Thanks again,
        Mike
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        Jamil Snead @ Mike Barsky on Mar 13, 2015 2:34 PM
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        You have a couple options. One of them is to simply extrude the rectangles part way back up from the bottom to fill in the bottoms of the holes. The other option would be to create your own seed hole for the fill pattern rather than checking the box for "create seed cut". You would need to cut a single hole at your desired depth, then in the fill pattern choose the "selected features" option and pick that hole. The boundary would still be the rectangle sketch.
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        Mike Barsky @ Jamil Snead on Mar 16, 2015 5:31 PM
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        Hi Jamil,
        
        This worked as soon as I checked create seed cut. I would like to change one last thing and that is instead of three dimensional rectangles I would like to put three dimensional semicircles. I attached a picture of what I mean (pic 1). Essentially I want this with the hexagonal mesh between the rings. My thought was to draw a semicircle and extrude it out and repeat until I have the necessary rings and then fold back up. However, when I do the fold the one ring I tried this with disappears.
        
        Is there a better way of doing this?
        
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        Jamil Snead @ Mike Barsky on Mar 16, 2015 6:51 PM
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        Using sheet metal tools you can't bend non-flat features. So in this case I would add the hex pattern as before using sheet metal, then fold it so that it is curved. Then I would add the semicircles to the curved model using a revolve (or model one of them and linear pattern for the rest). You could revolve only the 270 degrees or whatever the bend is, or you could revolve 360 and then extrude cut the portion you don't want.
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        Mike Barsky @ Jamil Snead on Mar 17, 2015 3:38 PM
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        Thank you
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How do I design a model like this?

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