Hairbrush
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Transcript of Hairbrush
©GabiJack.com 2010
This is a small tutorial detailing step-by-step instructions to model a plastic hairbrush in SolidWorks. The
model was made in SolidWorks 2010, but, since there’s no new functionality involved in the process, the
instructions can still be useful even for those working with previous versions.
1. Open a new part document in SolidWorks and set the units to inches.
2. Open a sketch on the Front plane. Sketch an ellipse, centered at the origin. I used the following
measurements, which I obtained from one of my own hairbrushes. You can use the same
measurements, for convenience.
3. Extrude Sketch1 4.3 inches from the sketch plane, as seen in the image below.
©GabiJack.com 2010
4. On the Feature toolbar, look for Reference Geometry and select Plane to create a new reference
plane using the Front plane as reference. Set the new plane a distance of 4.8 inches from the
Front plane as shown in the image.
5. Open a new sketch on the Top plane and sketch a three point arc on one of the ends of the
elliptical extrusion we made earlier, just like you see in this image. Notice that end points of the
arc are coincident with the silhouette edges of the extrusion.
©GabiJack.com 2010
6. Use the sketch from step 5 to make a cut at the end of the extrusion, using Extruded Cut from
the features toolbar. Cut through all in both directions. Repeat the same procedure for the
other end of the extrusion.
7. On Plane 1, created on step 4, open a new sketch and draw a 0.9 in diameter circle centered at
the origin.
©GabiJack.com 2010
8. Create a loft between the circle sketch and the edge of the extrusion (Features, Loft). Just like in
the image below, under Start/End Constraints use Normal to Profile for the sketch (Start
Constraint in this case) and None for the edge (End Constraint). Use a tangent length of 1 for the
sketch’s Normal to Profile constraint.
9. Use the Shell feature with a thickness of 0.18 in and removing only the face shown in blue in the
image.
©GabiJack.com 2010
10. Open a new sketch on the Top plane and draw a zigzag line like the one shown in the following
image. Tip: draw half of the zigzag line first and mirror with respect to the vertical construction
line, then finish adding dimensions.
11. Using Offset Entities, create a slot out of the zigzag line from the previous step. Use the
parameters you see in the following image. Offset distance of 0.05 in, bi-directional, cap the
ends with arcs and make the base construction.
©GabiJack.com 2010
12. Use the sketch of the slot created in the previous step to extrude a cut through all in both
directions (use Extruded Cut from the Features toolbar).
13. After extruding the cut, and if you so wish, add a 0.04 in fillet to the 12 edges shown in the
image.
14. Add a 0.01 in fillet to the edge shown in the image. Use tangent propagation. Add another
similar fillet to the edge on the opposite side.
©GabiJack.com 2010
15. If it isn’t showing already, show the Sketch5, the sketch of the zigzag slot. To show the sketch,
right click on it in the Feature Manager and select Show from the fly out toolbar. You’ll need
that sketch for the following step.
16. On the Features toolbar, click on Linear Pattern. Under Direction 1, select the vertical
construction line in Sketch 5. Enter a distance of 0.43 in as the space between instances in the
pattern and 9 for the number of instances. Under features to pattern, select the cut extrude and
the fillets created in steps 12 through 14 (they are highlighted in blue in the fly out feature
manager. Check that the direction of the pattern is like that of the image and reverse it if
necessary.
17. Open a new sketch on the Top plane. Use Offset Entities (Sketch toolbar) to offset the
construction zigzag line in Sketch 5 a distance of 0.2 in, as you see in the image. Reverse the
direction if necessary.
©GabiJack.com 2010
18. Use Insert, Curve, Projected to project the sketch from the previous step on the surface of the
body, just below the slot, as you see in the image. For projection type select sketch on faces. The
sketch, of course is Sketch6 (shown in a blue) and the face is the face of the body, shown in pink.
The projection is shown in yellow.
©GabiJack.com 2010
19. Now that you have the curve projected on the face of the body, you are going to create a couple
of reference points on the zigzag line. Later, you’ll use these points as an aid to create reference
planes and, ultimately, extrude the holes for the bristles. Go to Reference Geometry, Point and
create reference points in the middle of the two segments, as shown in the following image. In
the image, Point 1 has already been created and we’re in the process of adding Point 2 the same
way Point 1 was added: hover with your mouse over the line segment until you see a point show
up in the middle and then click on it; that’s your first reference. Now click on the face of the
body for a second reference. This creates a point that is in the middle of the line segment, on
the face of the brush.
20. Now we’re going to create five different reference planes that will be used as an aid in extruding
holes for the bristles. Go to Reference Geometry, Plane and choose the point at the left end of
the projected zigzag line and the face of the brush as the first and second references to define
the plane, just as you see in the image. A plane will be created, tangent to the surface and
coincident with the point selected.
©GabiJack.com 2010
21. The next four reference planes are created in a similar way…
©GabiJack.com 2010
©GabiJack.com 2010
22. Select the first reference plane created in the previous step (Plane2) and open a new sketch on
it. Draw a 0.04 in diameter circle centered on the origin (the point at the end of the curve). It
may be necessary to add relations to make sure the circle is indeed centered at the end of the
curve.
©GabiJack.com 2010
23. Use Extruded Cut and the circle you just sketched to create a hole 0.09 in deep. Repeat steps 22
and 23 for each of the remaining reference planes. You should end up with five holes evenly
spaced along the left side of the projected zigzag line.
24. Use Mirror to create a copy of the first four holes. Mirror the four first extruded cut features
about the Right plane, as shown in the image.
25. Now create a linear pattern, just like you did before. Pattern the five extruded cuts plus the
Mirror feature from the previous step. Use the vertical construction line of Sketch5 again to
©GabiJack.com 2010
specify the direction of the pattern, a spacing distance of 0.43 in and a number of instances of
nine.
26. Now create a new linear pattern, but this time as features to pattern select only the four
extruded cut features that you see in the image. Use the vertical construction line in Sketch 5 to
specify the direction of the pattern again, but reverse the direction to pattern, as you see in the
image. Use a spacing distance of 0.41 in and a number of instances of two.
©GabiJack.com 2010
27. Use Mirror to create a copy of the pattern from the previous step. Mirror the linear pattern
feature about the Right plane. Check the option Geometry Pattern. I’m not exactly sure why, but
the Mirror feature will give you an error if you leave this option unchecked.
28. Go to Reference Geometry, Plane and create a new reference plane 0.6 inches from Plane 1, as
you see in the following image.
©GabiJack.com 2010
29. Open a new sketch on Plane 7, the plane you created in the previous step, and draw an ellipse
centered at the origin. Use the dimensions from the image.
©GabiJack.com 2010
30. Create a loft (Loft feature in the Features toolbar) between the sketch from the previous step
and the edge of the brush, just like you see in the image. Use Normal to Profile as a constraint
for the sketch (Start Constraint) with a tangent length of 0.57 in, and Curvature to Face as a
constraint for the Edge (End Constraint), with a length of 0.43. Actually, you can play with the
valued of the length for both, the sketch and the edge, until you are satisfied with the way it
looks. If the surface in the preview appears to ripple or buckle then it probably means you need
to use a smaller value.
31. Open a new sketch on Plane 7 and use Offset Entities to offset the edge of the brush a distance
of 0.03 in, as shown in the image. Use Extruded Boss to extrude this sketch a distance of 3.5
inches to create a handle for the brush.
©GabiJack.com 2010
32. Use Dome (Features toolbar) to create a nice little dome at the end of the handle. Use a
distance of 0.3 in and make sure to un-check the option continuous dome, to keep it from
turning out pointy.
©GabiJack.com 2010
33. Go to Reference Geometry, Plane and create a new plane 0.03 in from Plane 7. This is Plane 8.
34. Open a new sketch on Plane 8. Use Convert Entities (Sketch toolbar) and select the edge of the
handle and Sketch 14 (created on step 29) as entities to convert. The result is a couple of ellipses
that we’ll use to create a cut in the handle.
©GabiJack.com 2010
35. Use Extruded Cut and the sketch from step 34 to cut a distance of 0.06 in, as shown in the
image.
36. Create a new linear pattern. Use the same vertical construction line from Sketch 5 to specify
direction. Pattern the Extruded Cut feature from step 35. Use a spacing distance of 0.09 in and
30 instances.
©GabiJack.com 2010
37. On the Top plane, open a new sketch and draw a circle like the one in the image below. Use it to
extrude a cut through all in both directions.
38. Open a new sketch on the Top plane and use Convert Entities (Sketch toolbar), select the sketch
from step 37 as the entity to convert. Then use Offset Entities (Sketch toolbar) and offset the
circle you just created by converting the sketch a distance of 0.06 in. The result is a couple of
concentric circles separated by a distance of 0.06 in.
39. Create a boss extrude using the sketch from the previous step. Under Direction 1, select Offset
from Surface. The surface is the face of the handle that appears in pink in the image. The
distance to offset is 0.03 in. It may be necessary to check the option Reverse Offset and to
change the direction of the extrude. Do the same for Direction 2, until the preview looks like in
the image below.
©GabiJack.com 2010
40. On the Top plane, open a new sketch and draw a vertical line. Use this line to create a slot, using
Offset Entities, just like we did previously.
©GabiJack.com 2010
41. Create an Extruded Boss feature using the sketch from the previous step. Under Direction 1
select Offset from Surface and select the face shown in pink in the image as the face to offset
from. The distance is 0.04 in. It may be necessary to check Reverse Offset and change the
direction of the extrusion until it looks like the preview in the image.
42. The body of the hairbrush is now complete. If you followed the steps correctly, you will now
have something that looks a lot like this.
©GabiJack.com 2010
43. Save the part and then create a new assembly from the part (File, Create new assembly from
part). The bristle part is provided. I won’t go into detail on how to model the bristle because it’s
very easy to make by revolving a sketch. Insert the bristle part into the assembly; you’ll need 9
instances of it. Position each bristle inside the holes of the second row of holes in the brush
using a concentric mate between the cylindrical faces of the bristle and the hole and a
coincident mate between the bottom flat face of the bristle and the bottom flat face of the hole.
The result should look like the image.
©GabiJack.com 2010
44. On the Assembly toolbar, select Feature Driven Component Pattern. Under Components to
Pattern, select the bristles you inserted in the previous step. Under Driving Feature, select the
linear pattern LPattern2 from the features in the hairbrush part. Select it from the fly out
Feature Manager. The bristles now populate each of the holes in the linear pattern.
45. Repeat the procedure from the previous step to create a new feature driven component
pattern, but this time select only the seven bristles shown in the image as the components to
pattern and LPattern3 as the Driving Feature.
©GabiJack.com 2010
And that’s it! If you followed the instructions correctly, you should have something that looks just like
this brush here.