How to Make an Aeroshell

General Notes

  • Never directly use one of the reference sketches, always make a new sketch and convert entities

    • using a reference sketch takes it away from the folder, so making a new sketch each time keeps the Internal References folder as always having all the sketches you will need

  • NAME ALL OF YOUR FEATURES

    • You and anyone else should be able to guess what the feature does just from the name

 

References

External References

  1. Import Frame Reference Sketch

Create Reference Planes

  1. Make planes where the frame begins and ends

  2. Make planes where the shell begins and ends

  3. Make a plane at the bottom of the shell

Create Internal References

  1. Create side view sketch of the middle and bottom shell

  2. Create a top view profile for the middle shell

  3. Convert entities the middle shell profile into a new sketch

  4. In a new sketch, Convert Entities the middle shell profile and then linear sketch pattern it downwards (2 inches), this creates the upper fillet reference

  5. Add 2 points into the same sketch, where the upper fillet intersect with the bottom shell profile

  6. Make a new sketch, and draw an airfoil between the 2 points from the step above.

  7. Make a new sketch, offset the airfoil (2 inches) and cut off the end of the airfoil, using arcs in the nose and lines in the tail to connect the ends to the front of shell and back of shell planes, this is the upper fillet top profile

  8. Make another sketch and offset the bottom shell airfoil inward

Bottom Half of Shell

Middle Shell

  1. Extrude surface with the middle shell side profile

  2. Trim surface with the middle shell top profile

Upper Fillet

  1. Make 2 new sketches, one containing the middle shell profile that had been extruded downward, and one with the one with the bottom shell airfoil

  2. Project curve the bottom shell airfoil onto the offset middle shell profile

  3. Project curve the upper fillet top profile onto the middle shell

  4. Make a set of reference planes in line with the front plane

  5. On each of these planes, make a sketch that has 2 guide curves, with each curve being a spline with one control vertex, with that control vertex being horizontal and vertical to the endpoints

  6. Make a 3D sketch using convert and split entities to make guide curves out of the part of the side profile that is between the 2 curves.

  7. Do a boundary surface between the 2 curves, and using all the guide curves that you made

Bottom Shell

  1. In a 3D sketch, convert entities on the lower edge of the upper fillet

  2. Boundary surface from the 3D sketch to the inward airfoil offset, with the inward airfoil offset on the plane that defines the bottom of the shell

  3. Surface trim the boundary extrude with the front of frame sketch and with the back of frame sketch

  4. Extrude the bottom flat line of the bottom shell side profile

  5. Trim the flat bottom extrude with the remaining part of the bottom shell boundary surface

  6. Knit the flat bottom extrude to the 2 sides of the bottom shell boundary surface

  7. Fillet the edges where the flat bottom extrude and bottom shell boundary meet

Nose/Tail

  1. Make a sketch on the Front of Frame plane and convert entities the edge of the bottom shell

  2. Make a 3D sketch and convert entities the edge of the upper fillet, up until it intersects with the bottom shell

  3. on the right plane convert entities the side profile and use trim entities to cut it down to the part that is between the 2 curves that you converted entities for in 17-18

  4. Add any other guide curves that you need in order to get the profile you want

  5. Boundary surface from the bottom shell to the upper fillet, using the guide curve of the side profile + anything else you made

  6. All the previous steps apply for the tail as well, except you use the the Back of Frame plane and you convert entities the back edge of the upper fillet

Middle Shell Lip

  1. In a sketch on the top plane, convert entities the middle shell top profile

  2. extrude the sketch upward, far past the middle shell

  3. trim surface using the flat part of the middle shell to get rid of the bottom part of the new extrusion

  4. Make a new sketch, convert entities the middle shell lip and linear sketch pattern it upward

  5. Trim the middle shell lip with that sketch

Top Half of Shell

Top Shell Lip

  1. Offset Surface the middle shell lip

  2. Convert Entities on the top edge of the top shell lip

  3. Extrude that sketch out past the top shell lip

  4. Do a surface trim with mutual surfaces of the surface offset and the surface extrude, removing the parts of the extrude that go out past the lip, and removing the part of the surface offset in the tail that goes up past the rest

  5. Do a surface extend, taking the bottom edge of the surface offset near the tail end to match to the rest

Canopy

  1. Draw the right half of the side profile for the canopy in a sketch on the right plane

  2. Draw the right half of the top profile for the canopy in a sketch on the top plane, making sure the ends of the top profile match with the side profile

  3. Project curve the top profile onto the top shell

  4. Make a set of reference planes in line with the front plane along the path of the canopy curve

  5. Draw guide curves on the planes, going from the side to the projected top profile and making sure to avoid the roll cage

  6. Boundary surface from the side profile to the projected top profile, and using all of the guide curves.