How to Design a Spur Gear in Fusion 360 – Step-by-Step Tutorial Introduction

Welcome to Exercise 6 of our Fusion 360 Beginner Tutorial Series! In this guide, we’ll create a 3D model using essential tools like Extrude, Rectangular Pattern, Rib, Mirror, Chamfer, Fillet, and Section Analysis.
This tutorial is perfect for beginners who want to:
✔ Improve sketching and parametric modeling skills
✔ Learn efficient pattern duplication with Rectangular Pattern
✔ Use the Rib tool for structural reinforcement
✔ Apply Mirror for symmetrical designs
✔ Enhance models with Chamfers & Fillets
✔ Generate realistic renders and section views for technical analysis
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We’ll start by creating a 2D sketch defining our model's core shape.
Line, Rectangle, Circle (for base geometry)
Constraints (to maintain design intent)
Dimensions (for precise control)
Pro Tip: Use fully constrained sketches to avoid errors during extrusion.
Select the Extrude tool.
Choose the sketch profile.
Define the distance (e.g., 10mm).
Use "New Body" if creating a separate component.
Instead of manually duplicating features, we’ll use Rectangular Pattern:
Select the feature (e.g., a hole or protrusion).
Set the direction (X/Y axis).
Define quantity and spacing.
Why? Saves time and ensures consistency.
The Rib tool adds structural support between walls.
Sketch a line where reinforcement is needed.
Use the Rib command.
Adjust thickness and direction.
Select the feature(s) to duplicate.
Choose a mirror plane (midplane or custom plane).
Apply Mirror to create identical geometry.
Chamfer: Bevels sharp edges (e.g., 45° angle).
Fillet: Rounds edges for a polished look.
Design Tip: Use Fillets last to avoid modeling errors.
Switch to the Render Workspace.
Apply materials (metal, plastic, etc.).
Adjust lighting & environment.
Export high-quality images.
Use the Section Analysis tool.
Cut the model along a plane (X/Y/Z).
Inspect internal features for design validation.
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