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Don Bosco Technical Institute  |  IDEA-113 IDEA-BLADE Battle-Tops Design and Manufacturing Project
03Assignment
CAD Design Package
Collaboration
* Individual grades. Designs compete independently regardless of collaboration.
Before Opening SolidWorks
Review your Assignment 02 stackup and manufacturing sequence before modeling anything. Your build plan is your contract.
Have your physical materials in hand before designing fits. Do not guess at stock dimensions.
Enable dual dimensions in SolidWorks (Tools → Document Properties → Units). Use inches as primary, millimeters as secondary throughout.
Download 3D model files for all hardware (McMaster-Carr, Grainger, manufacturer sites) before modeling. Insert actual hardware models into your SolidWorks assembly — do not approximate geometry.
Model components in your stated sequence order from Assignment 02. The first part sets the reference geometry for everything else.
Design to target dimensions, not stock dimensions. Tolerancing is applied at the feature level, not by changing the nominal design.
Submission Instructions
01
Complete all 5 modules and obtain instructor approval
02
In SolidWorks: File → Pack and Go, zip all files
03
Upload zip file to Google Classroom
04
Click Export HTML in the toolbar above
05
Upload the .html file to Google Classroom
Required Reading - IDEA-Blade Rulebook
Open Rulebook
All design constraints, blade contact rules, scoring criteria, and competition
format are defined in the rulebook.
Assignment Weight80 PointsComplete all 5 modules & obtain instructor approval  |  Click [ Rubric ] for grading criteria
01Design Continuity5 pts ▾
Grading CriteriaPoints
Plan Unchanged: Radio confirmed unchanged and statement complete.
5 pts
Plan Deviations: All changes documented with original plan, final decision, and justification. Deviations earn full credit if honestly and completely documented.
5 pts
No response or incomplete: Radio not selected, or deviations present but not documented.
0 pts

Your Assignment 02 build plan was a commitment. Before modeling, confirm whether your design followed that plan or evolved during the CAD phase. Both outcomes earn full credit — honesty is what counts.

02Component CAD Documentation30 pts ▾
Grading CriteriaPoints
Component Documentation: All components named with final modeled dimensions and SolidWorks mass values entered.
12 pts
Competition Compliance: Total assembly mass ≤907g, 3+ distinct processes, 3+ fasteners confirmed.
6 pts
Hardware Documentation: All COTS hardware has supplier link and 3D model download confirmed.
6 pts
Bolt Clearance Documentation: All bolted joints documented in clearance table with treatment specified.
6 pts

Document every component in your SolidWorks assembly. Pull all dimensions and mass values directly from SolidWorks — do not estimate. OD is the diameter of the circle the component traces when spinning: measure between the two furthest points in any direction, even for non-circular geometry.

▶ Watch: SolidWorks Measurement Tool
How to Override Mass Properties — click to expand ▶
Context
  • You have physically weighed a completed or prototype part using a scale — this is the most accurate value.
  • You have sliced a 3D printed part in Bambu Studio which shows the actual filament mass including infill, walls, and supports — more accurate than SolidWorks geometry mass for printed parts.
Steps — Official SolidWorks Procedure
  1. 01Open your part file in SolidWorks.
  2. 02Go to Tools → Evaluate → Mass Properties.
  3. 03In the Mass Properties dialog, click Override Mass Properties.
  4. 04Check the Override mass checkbox.
  5. 05Enter your measured or sliced mass value. SolidWorks accepts grams internally — convert if needed:
1 lb = 453.6 g   |   1 oz = 28.35 g
  1. 06Click OK then Close. The overridden value will show in the Mass Properties dialog with an asterisk.
  2. 07Enter this value in the mass column of the component table.
Note: Override applies per configuration. If you have multiple configurations, select All Configurations unless you have a reason to override only the active one.
Ctrl Qty Component Material Process
Thickness
in / mm
Spin OD
in / mm
Mass
 Supplier / HW Interface Screenshot
Total Assembly Mass
0 g
0.000 lbs  |  Limit: 907g / 2.000 lbs
Distinct Processes
0
Min required: 3
Mechanical Fasteners
0
Min required: 3
Fastener count is calculated automatically from your component list. Only bolts and screws are counted, not nuts or washers.
Bolted Joint Clearance Log

Document every bolted joint in your assembly. Clearance holes in 3D printed parts must be nominal + 0.016" (0.4mm). Clearance holes in laser cut metal are nominal (kerf compensated in MetalFab software). Socket head screws should be counterbored into printed parts so the head sits flush or below surface.

Joint DescriptionName the two parts being bolted together Bolt Sizee.g. M4, 8-32 Clr Hole — Printedin — bolt nom + 0.016" Clr Hole — Metalin — nominal (no add) Head TreatmentHow the bolt head sits Counterbore øin — head diam + 0.020" Counterbore Depthin — head ht + 0.010" Nut TreatmentHow the nut is retained
All dimensions in inches. Common bolt sizes for reference: M3=0.118", M4=0.157", M5=0.197", M6=0.236" — add 0.016" to each for clearance in printed parts.
03Tolerance & Fit Verification20 pts ▾
Grading CriteriaPoints
Hex Bore Check: Bore diameter entered and within acceptable clearance range.
4 pts
Wall Thickness & Feature Size: Minimum wall and minimum feature confirmed or N/A (combined card).
4 pts
Metal Wall Thickness: Minimum metal wall confirmed or N/A.
3 pts
Shaft Engagement Confirmation: Modeled engagement matches Assignment 02 plan or deviation documented.
3 pts
Hex Extension Height: Modeled hex extension within 0.45"—0.55" rule.
3 pts

Work through each check while your SolidWorks model is open. Enter what your model actually shows — not what you intended. If a check does not apply to your design, mark it N/A. Out-of-spec values earn no credit but can still be corrected before submission.

Zone A — Fit Calculator
Joint Fit Calculator

Select your joint type and enter the nominal dimension. The calculator will output the recommended bore or offset dimension to model in SolidWorks.

These are starting values based on Bambu enclosed-chamber behavior. A test print is recommended for critical fits.
Zone B — Printed and Metal Design Limits
3D Printed Parts
Structural wall minimum: 2.0 mm / 0.079 in. Absolute floor: 1.2 mm / 0.047 in (2 perimeters at 0.6 mm nozzle). Minimum printable feature: 1.2 mm / 0.047 in.
Awaiting input
Awaiting input
Laser Cut Metal
Steel minimum: 0.031 in / 0.8 mm. Aluminum minimum: 0.039 in / 1.0 mm.
Awaiting input
Zone C — Assembly Geometry
C2 — Hex Shaft Engagement Confirmation
Your Assignment 02 build plan specified a hex shaft engagement depth. Confirm your SolidWorks model reflects that planned depth. If it changed, document the deviation and reason.
Enter both values to compare
C3 — Hex Extension Height
The hex shaft must extend above the full body height by 0.50 in ± 0.05 in (12.70 mm ± 1.27 mm). Acceptable range: 0.45–0.55 in / 11.43–13.97 mm. This extension mates with the standard launcher. Too short and the launcher won't grip. Too long and launch will be inconsistent.
Target: 0.500" / 12.70mm  |  Range: 0.45"–0.55" / 11.43–13.97mm
Awaiting input
04Assembly Validation20 pts ▾
Grading CriteriaPoints
Assembly Dimensions: Mass, height, OD, and hex extension all entered and within competition limits.
8 pts
Center of Mass: CoM offset from spin axis entered. Within target earns full credit; above target with explanation earns partial.
4 pts
Interference Check: SolidWorks interference detection run and result documented.
4 pts
Required Screenshots: All 4 screenshots uploaded (mass properties, isometric, top, cross-section).
4 pts

Pull all values directly from your SolidWorks assembly. Mass properties: Evaluate → Mass Properties with all components visible and correct materials assigned. Run Evaluate → Interference Detection before submitting.

Total Assembly Mass
Limit: 907g / 2.000 lbs  |  Weighed fight-ready including hex shaft
g lbs
Awaiting input
Full Body Height
Target: 3.00" ±0.1"  |  Range: 2.90"–3.10" / 73.66–78.74mm  |  Base tip to top of body, below hex extension
in mm
Awaiting input
Maximum Spinning OD
Max: 5.000" / 127.0mm  |  Furthest two points in any direction, all components assembled
in mm
Awaiting input
Hex Extension Above Body
Target: 0.50" ±0.05" / 12.70mm ±1.27mm  |  Range: 0.45"–0.55"
in mm
Awaiting input
How to Find Center of Mass in SolidWorks
Evaluate menu → Mass Properties → check "Show center of mass on screen". Read the X and Y coordinates from the origin. The offset is the straight-line distance: √(X² + Y²).
Center of Mass Offset from Spin Axis
Target: ≤1.0mm / ≤0.039" offset  |  From SolidWorks mass properties, X and Y distance from origin on spin axis
mm in
Awaiting input
SolidWorks Interference Detection
Evaluate → Interference Detection → Calculate  |  All conflicts must be resolved before submission
Not selected
Required Assembly Screenshots

All four screenshots are required. Take them with your full assembly visible, correct materials assigned, and no suppressed features.

How to screenshot on Windows
WIN+SHIFT+S
⬤ CAPTURED
Tip — after Win+Shift+S, press Ctrl+V here to paste directly from clipboard.
Click to upload mass properties screenshot
0 images (required)
How to screenshot on Windows
WIN+SHIFT+S
⬤ CAPTURED
Tip — after Win+Shift+S, press Ctrl+V here to paste directly from clipboard.
Click to upload isometric screenshot
0 images (required)
How to screenshot on Windows
WIN+SHIFT+S
⬤ CAPTURED
Tip — after Win+Shift+S, press Ctrl+V here to paste directly from clipboard.
Click to upload top view screenshot
0 images (required)
How to screenshot on Windows
WIN+SHIFT+S
⬤ CAPTURED
Tip — after Win+Shift+S, press Ctrl+V here to paste directly from clipboard.
Click to upload cross-section screenshot
0 images (required)
Instructor Design Approval
Your design must be reviewed and approved by Mr. Pina before you can submit. When your design is ready, bring this document up during class for review. Mr. Pina will enter the approval code to unlock Module 05 and your submission.

Do not submit without approval. Unapproved designs will not be accepted.
Incorrect code. See Mr. Pina.
✓ DESIGN APPROVED
🔒
Instructor Approval Required
to Unlock This Module
05Deviation Log5 pts ▾
Grading CriteriaPoints
Full Credit: Radio selected. If deviations occurred, each one is honestly and specifically documented. Deviations earn full credit when documented.
5 pts
No Credit: Radio not selected, or deviations clearly present but not documented.
0 pts

After instructor approval, document any final deviations between your approved design and your actual submission. This is your last chance to flag changes made between approval and submission. Full credit for honest documentation — zero credit for leaving this blank when deviations exist.

Final Submission — Pack and Go
Before submitting, you must export your SolidWorks assembly using Pack and Go so all referenced files are included. Without this step, your assembly will open with missing parts on any other computer.
Step 1 — In SolidWorks, go to File → Pack and Go.
Step 2 — Check Include all referenced components and Save to Zip file.
Step 3 — Name the file with your name and upload the zip to Google Classroom.
Step 4 — Click [ Export HTML ] in the toolbar above and upload the HTML file to Google Classroom.
Both files are required for a complete submission.
▶ Watch Tutorial
Academic Integrity Declaration
I confirm that the SolidWorks assembly and documentation submitted here represent my own design work. All screenshots are from my own model. I understand that using AI tools, reference designs, online calculators, manufacturer resources, and any other available resource is permitted and expected — the design decisions are mine. I understand that submitting without instructor approval or submitting someone else's model constitutes academic dishonesty.
ModuleDescriptionPts PossiblePts EarnedNotes
01Design Continuity5  
02Component CAD Documentation30  
03Tolerance & Fit Verification20  
04Assembly Validation20  
05Deviation Log5  
Total80  
IDEA-BLADE  |  Assignment 03  |  Don Bosco Technical Institute  |  IDEA-113 80 Points Total