CAD Onboarding

Onboarding Process

  1. Learn Basics → Complete Fusion 360 Self-Paced Learning (Intro to Fusion + Get Started with Modeling). Upload tutorial files to the form.
  2. Assignments:
    • Sketch Concept: Draw casing for the sleep apnea system, submit photo.
    • Fusion Enclosure: Design a Nano 33 BLE Sense case with lid + USB cutout, submit STL/screenshots.
  3. Review → Officer checks your design for fit, manufacturability, and ergonomics.
  4. Discord Role Update → Once approved, officer grants the CAD Designer role.

Role Purpose

CAD Designers create professional, ergonomic enclosures for our prototypes. They make sure our medical devices are usable, manufacturable, and presentable for demos and competitions.

Why This Role Matters

CAD Designers ensure our hardware and firmware work is usable in the real world:

  • Demos look professional → better outreach, competitions, and sponsorships.
  • Enclosures keep electronics safe and reduce noise from movement.
  • Ergonomics = devices people actually want to use.

Downloading Fusion360

  1. Visit Fusion Online
  2. Sign up with purdue email
  3. Enter school address: 610 Purdue Mall West Lafayette, IN 47907
  4. Enter school website: https://www.purdue.edu/
  5. Ensure around 5 GB is free on your device
  6. Once account is complete revisit: Fusion Online
  7. Request or renew access
  8. Select Fusion
  9. Download Fusion and run installer

Skills to Learn

3D Modeling Basics

  • Fusion navigation and part creation.
  • Sketching, extruding, cutting, fillets, and assembly constraints.

Human Factors & Ergonomics

  • Designing for handheld devices, wearables, and comfort.
  • Clearances for buttons, screens, and ports.

Manufacturing Awareness

  • Design for 3D printing (layer orientation, tolerances).
  • Design for laser cutting (2D profiles, flat assemblies).
  • PCB mounting methods (standoffs, bosses, slots).

Integration

  • Fitting Arduino Nano 33 BLE Sense boards, sensors, and batteries.
  • Planning cable routing and ventilation when necessary.

Learning Materials

Setup Tools

  1. Download Fusion 360 (free student license)

Complete Basics

  • Visit the Fusion 360 Self-Paced Learning
  • Follow along and complete Introduction to Fusion module
    • Start at lesson: Introduction to Fusion
    • End after lesson: Use the Fusion Toolbox
  • Follow along and complete Get started with modeling module
  • Add the complete files into this form, after the next step you will submit this form

Learn Ergonomics

Integration Practice Learn how to import a part into designs in Fusion 360 for the assignment.

Assignment 1 - Needs To Be Done In Person

  • Sketch a quick paper concept of casing for the sleep apnea detection system
    • Sketch 1: the ideal placements of the parts on a human body model
      • Consider:
        • Where the sensor should be placed to get the most accurate data
        • Where would it be comfortable
        • If the sensor has wires to retrieve data, we can place the sensor far from the data input point, to somewhere more comfortable.
    • Sketch 2: Sketch the casings for each part individually
      • Consider:
        • The rules and practices from the wearable design articles that pertain to the casing.
        • The wire hole placements on each device, we want to leave a gap in the design for them to flow.
  • Look at the parts on GrabCad for an idea of the shape and then look at the datasheets for their dimensions.
  • Main Parts
    • Arduino Nano 33 BLE Sense Rev2
    • MAX30102 Pulse Oximeter
    • SparkFun Single Lead Heart Rate Monitor - AD8232
    • WWZMDiB MAX4466 Electret Microphone Sensor
  • Keep in mind:
    • The rules and practices from the wearable design articles that pertain to the casing.
    • The wire hole placements on each device, we want to leave a gap in the design for them to flow.
    • Take a picture and add the picture to the second file drop in the same form
    • Submit the form ***

Assignment 2

Create a Fusion 360 enclosure that fits the Arduino Nano 33 BLE Sense

Steps:

  1. Find arduino nano / arduino nano BLE sense on GrabCAD
  2. Build case around the nano (You don’t have to leave holes for wires just USB cable)
    • Make box with one open end
    • Make a simple lid
In the future, for real design you need to consider the inputs and outputs of the component you are encasing.

Requirements:

  1. Lid for container
  2. Cutout for USB port.
  3. Fits arduino with decent tolerance

Submission:

  • Upload screenshots and STL files into this google form