CAD Level 2 - Part Design & Assembly

Learning Objective

Create complex 3D parts using advanced modeling features (revolve, sweep, loft, patterns), build multi-part assemblies with proper mate constraints and interference checking, apply design for manufacturing principles including tolerances and standard fasteners, and generate technical drawings with dimensions and annotations.

Prerequisites

• CAD Level 1

Primary Resources

• OnShape "Assemblies" and "Drawings" learning paths
• FRCDesign.org "Assembly Design" and "Drivetrain Design" courses
• OnShape "Advanced Part Modeling" modules

Tasks

1. Advanced Part Features

• Complete OnShape "Advanced Part Modeling" learning path
• Follow FRCDesign.org "Advanced Part Design" tutorials
• Master revolve, sweep, and loft operations
• Create complex patterns (feature-driven, table-driven)
• Use multi-body part design techniques
• Apply configurations for part families
• Project Series: Complete FRCDesign.org "Wheel Design Challenge"
  • Design custom omni wheel with multiple configurations
  • Use advanced features: revolve, circular patterns, configurations
• Assessment: Design a custom FRC bumper bracket with 3 size configurations

2. Assembly Creation & Management

• Complete OnShape "Assemblies" learning path (all modules)
• Follow FRCDesign.org "FRC Assembly Best Practices" course
• Insert parts and sub-assemblies into main assembly
• Apply mate constraints (fastened, revolute, cylindrical, planar, ball)
• Create assembly configurations for different robot states
• Check for interferences using OnShape collision detection
• Major Project: Build complete FRC drivetrain assembly following FRCDesign.org tutorial
  • Include: chassis, wheels, motors, gearboxes, chain/belt drives
  • Demonstrate proper mate relationships and configurations
• Assessment: Assembly functions properly with no interferences, all DOF controlled

3. Design for Manufacturing (DFM)

• Complete FRCDesign.org "Manufacturing Considerations" course
• Study OnShape "Sheet Metal" and "Weldments" features for FRC applications
• Apply appropriate tolerances using OnShape's tolerance analysis tools
• Design parts considering FRC manufacturing constraints (waterjet, 3D printing, machining)
• Integrate standard FRC fasteners from OnShape Parts Library
• Use FRCDesign.org material selection guidelines
• Integration Project: Redesign Level 1 roller for actual manufacturing
  • Include: proper tolerances, fastener selection, material specifications
  • Consider waterjet cutting and 3D printed components
• Assessment: Manufacturing review with mentor/machinist approval

4. Technical Documentation

• Complete OnShape "Drawings" learning path
• Follow FRCDesign.org "Technical Drawing Standards" tutorial
• Create dimensioned drawings with proper GD&T
• Add section views, detail views, and exploded views
• Generate automated Bill of Materials (BOM) from assembly
• Include material specifications and finish callouts
• Create assembly instructions using OnShape's drawing tools
• Documentation Project: Complete drawing package for drivetrain assembly
  • Assembly drawing, individual part drawings, BOM, assembly instructions
• Assessment: Drawing package review for completeness and clarity

Level 2 Completion Requirements

• Complete all OnShape Learning Center assembly and drawing assessments
• Finish FRCDesign.org "Assembly Design" course with certificate
• Submit complete drivetrain assembly with documentation package
• Mentor approval of DFM principles application
• Peer teaching demonstration to Level 1 student

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