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Clamp-on headphone hook

“Make a headphone hanger that clamps onto the edge of a desk. The desk is 25mm thick.”

2 parts
Raspberry Pi 5 case with vented lid

“Raspberry Pi 5 case with side vents, 4 standoffs”

Soap dish with drain slots

“Soap dish 110 x 80 mm with drainage slots and raised ribs.”

Straight bevel gear with flange

“Bevel gear with straight teeth. Pitch cone angle 45 degrees, 20 teeth, module 3mm. Face width 20mm. Shaft bore 15mm with set screw. Hub diameter 30mm, length 25mm. Mounting flange with 4 M4 holes on 40mm PCD.”

M16 castle nut with threads

“Design a castle nut (DIN 935). M16 thread, height 18mm, width across flats 24mm. 6 castellated crown slots for cotter pin retention. Slot depth 6mm, width 4mm. Hex body with through bore.”

6 parts
Lever ball valve, 30° open

“Make a lever-operated ball valve in the 30° open position as 6 separate solids (body, ball, 2 seat rings, stem, handle). Coordinate system: flow axis = X axis, ball center = origin, stem axis = Z axis. Direction d = (cos30°, sin30°, 0) = (0.86603, 0.5, 0) is the direction of the ball bore and the handle, and e = (-0.5, 0.86603, 0) is the horizontal direction perpendicular to it. (1) Body (one solid): block X=-40~40, Y=-30~30, Z=-30~30. A Ø20 flow hole runs through the full length in the X direction, with Ø26 pipe counterbores at both ends (X=30~40, X=-40~-30). Internal cavity: Ø48 cylinder on the X axis, X=-22~22 (enclosed space). A Ø12 stem hole on the Z axis runs from the cavity to the top face Z=30. (2) Ball: Ø40 sphere (centered at the origin). A Ø20 ball bore runs through along an axis in direction d. Stem tang slot on the top: long in direction d, width 6 (±3) in direction e, from Z=15 to the sphere surface (through the full length in direction d). (3) 2 seat rings: each an annular cylinder on the X axis, outer diameter Ø48, inner diameter Ø20, one at X=15~22 and the other at X=-22~-15. The side facing the ball is cut to the ball's spherical surface (Ø40) so that it seats against the ball. (4) Stem (one solid): tang = cuboid with length 16 (±8) in direction d, thickness 6 (±3) in direction e, Z=15~21 (inside the ball's slot). Ø12 shaft at Z=21~45. Top-end 10×10 square (sides parallel to directions d and e) at Z=45~55. (5) Handle (one solid): plate at Z=46~52. Measured from the stem axis, it runs from -20 to +100 in direction d, width 20 (±10) in direction e, with a 10×10 square hole that the stem square fits into (sides parallel to d and e). That is, the handle points in the same 30° direction as the ball bore.”

7 parts
Swivel caster, 7 parts

“Model a swivel caster as seven separate solids: top plate, thrust washer, kingpin bolt, nut, fork, wheel, axle. Frame: the kingpin (swivel) axis is the Z axis; the floor is Z=0 and the wheel touches it. Top plate: X=-40..40, Y=-40..40, Z=100..105 (edges parallel to X and Y), Ø12 hole on the Z axis and four Ø9 holes at (±30, ±30), all through along Z. Thrust washer: Ø40, bore Ø12, Z=92..100, on the Z axis. Kingpin bolt: shank Ø12 from Z=78 to Z=105 on the Z axis, head Ø20 from Z=105 to Z=110. Nut: Ø20 cylinder, bore Ø12, Z=78..84. Fork, one solid, described in a fork frame whose origin is on the Z axis: its x axis is the horizontal direction (cos35°, sin35°, 0), its y axis is (-sin35°, cos35°, 0), z = world Z. Crown plate: x=-42..15, y=-23..23, Z=84..92, with a Ø12 hole on the Z axis. Two legs, 5 thick, at y=18..23 and y=-23..-18; each leg (in the x-Z plane) is the rectangle x=-42..-18, Z=37.5..84 united with a disc R12 centred on the axle point (x=-30, Z=37.5), and has a Ø10 axle hole there. So the axle sits 30 behind the kingpin toward the 215° direction, at world (X, Y) = (-24.575, -17.207), Z=37.5. Wheel: axis along the fork y axis through the axle point. Tyre Ø75 over y=-15..15, hub Ø30 over y=-18..18 (the hub faces touch the legs), bore Ø10. Axle: Ø10 along the fork y axis from y=-26 to y=26 through the legs and wheel, with Ø16 heads over y=23..26 and y=-26..-23 bearing on the outer faces of the legs.”

2 parts
Meshing spur gear pair

“Model a meshing spur gear pair as two separate solids. Frame: both gear axes are parallel to the X axis. The pinion axis passes through Y=20, Z=-10; the wheel axis passes through Y=99.674, Z=36, so the line of centres runs 30° from +Y toward +Z (centre distance 92). Angular positions about each axis are measured in the YZ plane from +Y toward +Z. Tooth form for both: involute, module 4, pressure angle 20°, no profile shift, addendum 1.0m, root diameter = pitch diameter - 2.5m, root fillets free. Backlash: circular tooth thickness on the pitch circle = pi*m/2 - 0.15 = 6.133, symmetric about the tooth centre line. Both toothed widths span X=0..30. Pinion (a gear shaft, one solid): 17 teeth, pitch Ø68, outside Ø76, root Ø58. Shaft Ø30 from X=-50 to X=0 and from X=30 to X=75. The X=30..75 end has a square-ended keyway 8 wide from X=48 to X=75 on the 90° side (+Z side of the shaft), floor 11 from the pinion axis. Phase: the pinion has a tooth SPACE centred on the 30° direction (toward the wheel). Wheel: 29 teeth, pitch Ø116, outside Ø124, root Ø106. Both side faces are recessed: an annular pocket from Ø56 out to Ø88, 9 deep, is cut into the X=0 face (X=0..9) and into the X=30 face (X=21..30), leaving a web X=9..21. Hub Ø56 from X=-10 to X=30 (it sticks out 10 on the -X side). Ø32 bore through X=-10..30 with a 10 wide keyway on the 90° side over the full length, keyway floor 20.3 from the wheel axis. A radial Ø6.8 set-screw hole at X=-5 runs from the hub surface into the bore on the 0° side (+Y side). Phase: the wheel has a TOOTH centred on the 210° direction from its own axis (toward the pinion), which sits in the pinion's tooth space.”

6 parts
Bench vise, 6 parts

“Make a bench vise in the assembled state as 6 separate solids (body, movable jaw, fixed jaw plate, movable jaw plate, screw, handle). Coordinate system: the jaw moves in the X direction, and the screw axis is the line (Y=0, Z=45) parallel to the X axis. Bottom face Z=0. (1) Body (one solid): base plate X=-60~100, Y=-40~40, Z=0~12. Fixed jaw block X=-60~-40, Y=-40~40, Z=12~60. Guide bar X=-40~90, Y=-15~15, Z=12~30. End plate X=90~100, Y=-25~25, Z=12~60, with a Ø14 hole through in the X direction on the screw axis. (2) Fixed jaw plate: X=-40~-36, Y=-38~38, Z=40~60 (attached to the +X face of the fixed jaw block). (3) Movable jaw (one solid): block X=5.5~35.5, Y=-40~40, Z=12~60 with a channel Y=-15~15, Z=12~30 that wraps around the guide removed over the full length in X (the channel top face contacts the guide top face Z=30, and its side faces contact the guide side faces). A Ø14 blind hole on the screw axis from the +X face (X=35.5), depth 12 (X=23.5~35.5, flat bottom). (4) Movable jaw plate: X=1.5~5.5, Y=-38~38, Z=40~60 (attached to the -X face of the movable jaw). Therefore the opening between the two jaw plates (X=-36~1.5) is 37.5. (5) Screw (one solid, a cylinder with the thread omitted): Ø14 at X=23.5~110 (its end touches the bottom of the movable jaw's blind hole and it passes through the end plate hole), head Ø24 at X=110~122. A Ø8 hole through the head in the Z direction at X=116. (6) Handle (one solid): Ø8 rod passing through the head hole in the Z direction, axis (X=116, Y=0), Z=0~90. Ø14 knobs at both ends: Z=-6~0 and Z=90~96.”

Turbine disc with fir-tree slots

“Turbine rotor disc. Outer diameter 250mm, bore 80mm, thickness 35mm. 24 fir-tree blade attachment slots around rim, 15mm deep with 3-step profile. 6 assembly bolt holes (M8) on 100mm bolt circle. 12 lightening holes (10mm) on 180mm circle.”

Compressor blisk, 24 blades

“Design a gas turbine compressor blisk (bladed integrated disk). OD 300mm, bore 80mm. Hub 140mm diameter, 50mm thick. 24 integral blades 40mm height, 30mm chord, 35° stagger. 3 labyrinth seal teeth in bore. 8 bolt holes M8 on 110mm PCD. 8 lightening holes.”

NACA airfoil blade

“Make a twisted blade lofted through 3 NACA symmetric airfoil sections, together with a root block, as a single solid. Coordinate system: blade span direction = +Z, twist axis = Z axis (the 1/4-chord point of each section lies on the Z axis). Section definition (local coordinates x, y within the section plane Z=z): the chord line lies on the local x axis, leading edge (LE) at x = -c/4, trailing edge (TE) at x = 3c/4. The thickness distribution follows the NACA 4-digit symmetric formula y = ±5·t·c·(0.2969·√ξ - 0.1260·ξ - 0.3516·ξ² + 0.2843·ξ³ - 0.1036·ξ⁴), ξ = (x + c/4)/c (0~1), and the trailing edge closes to a sharp point. The local coordinates are rotated counterclockwise by the twist angle, as seen looking down from +Z, and then placed in the world (local x axis = (cosθ, sinθ, 0)). - Section 1: Z=0, chord c=60, thickness ratio t=0.15 (NACA 0015), twist θ=0°. - Section 2: Z=60, c=48, t=0.12 (NACA 0012), θ=15°. - Section 3: Z=120, c=36, t=0.10 (NACA 0010), θ=30°. Blade = smooth loft passing through the three sections in order (Z=0~120, flat ends). Root block: cuboid X=-20~50, Y=-14~14, Z=-20~0 (the blade root face attaches to its top face), with a Ø10 hole through in the Y direction, axis at (X=15, Z=-10).”

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