toy_truck

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TOYTRUCKPrepared by: Harry Hawkins

The following project is of a small, wooden toy truck. This exercise will provide you with

the procedure for constructing the various parts of the design then assembling them into

the final unit. Directions for creating an album of this project are also included. You will

use a variety of Pro/D tools such as extrude, revolve and others. The orthographic

drawing for this project is shown in figure 1.

Figure 1. Orthographic projections of project.

Figure 2 shows the dimensions for the Truck Cab and figure 3 shows the dimensions for

the dump bed. Figure 4 shows the dimensions for the wheels, axel and undercarriage.

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Harry Hawkins 2005 Page 2

These drawings are also located at the end of this tutorial. You will need to refer to them

for accurate numerical information while you construct each part.

0.07300.5210

0.375

4.500

2.750

2.085

5.000

2.750

1.500 0.6250.750

R1.250

Truck Cab

1/2 Button

0.521

1.250

All notmarked

72

R0.375

0.750

2.500

0.125

0.1875

0.375

HeadlightDetail

0.125

Figure 2. Truck Cab dimensions.

Typical

R0.125

1.415

4.500

Dump Bed

1.50072

0.3750.2810.500

2.229

0.125

0.712

5.381

1.500

1.064141

2.391

1.165

0.500

R0.125

39

0.750

0.500

0.500

5.381

5.631

4.000

0.750

1.986

0.250

0.667

1.500

1.500

-

Figure 3. Dump bed dimensions.

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9.000

6.500

Base Center

R0.125

2.000 0.250

Wheel (6 Req'd)

0.500

4.500

4.630

Axel (Rear)

Axel (Front) 0.250

1.500

3.438

1.000

0.500

0.500

1.000

0.500

0.281

1.000

0.969 0.969

1.500

Figure 4. Wheels, Axels and Base Center or Undercarriage dimensions.

The procedures for executing the design of each part will be presented separately. Each

step is numbered and they should be done in the order presented. After all parts are

completed, you will proceed to the assembly. Each section is appropriately named and

furnishes appropriate places where breaks may be taken if so desired. The numbers will

continue throughout the tutorial rather than be separate for each part.

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AXELS

1. Open a new design and underTools, select Options and set the Units to inches.

Edit the Workplane notation from initial to FrontAxel. Your screen should look like

figure 5.

Figure 5. New design for Front Axel.

2. Draw a 0.25 (1/4) diameter circle at the centerof the drawing field such as

shown in figure 6. This will be the profile that will be extruded.

Figure 6. Axel profile.

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3. Rotate the field so that you can see it in 3D such as figure 7.

Figure 7. Field rotated for 3D viewing.

4. Select the ExtrudeProfile button. The extrude profile dialog box will appear.Edit it according to figure 8. You should see a trial version of the extrusion in yellow.

Press the OK button to execute the extrusion.

Figure 8. Extrude Profile dialog edited for extrusion.

5. Figure 9 is the completed axel. Save this design and name it FrontAxel.

Figure 9. Completed Front Axel.

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BASE (UNDERCARRIAGE)

7. The base unit or undercarriage contains a main strip that runs from the front to the

rear of the vehicle and on which the cab and dump bed are eventually placed. It also

contains the structures that will support the axels and wheels. First start by opening

a new design and editing the initial workplane to base center.

8. Draw a Profile as shown in figure 11. You will need to use the orthographic

drawings to obtain the exact dimensions. Be sure to delete all construction lines so

that the profile will fill with color to indicate a valid profile.

Figure 11. Base Profile ready for extrusion...

9. Rotate the view so you can see it in 3D then select the extrude profile button.

Edit the dialog box according to figure 12. Press the OK button to execute.

Figure 12. Extrude Profile dialog box and trial view.

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10. The extrusion should look like figure 13.

Figure 13. Extruded Base or Undercarriage Strip.

11. We will now extrude or add parts onto the front to extend the housing for the front

wheels. First use the face selection tool to select the top face as shown in figure 14.

The face will turn red.

Figure 14. Face selected for new sketch.

12. With the face selected, right click and select New Sketch. Name it Right Front

Hub. Check create workplane then click the OK button to create the sketch.

13. Click the orthographicview and zoom in on the right front of the object. Construct

the new profile for the hub by drawing over the existing center hub. You will be able

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to use the snap points of the center hub to place the lines. Be sure to delete any

unwanted lines. The profile should fill and be ready to extrude such as in figure 15.

Figure 15. Right front hub ready for extrusion.

14. Rotate the view so it will be in 3D then select the Extrude Profile button. Complete

the dialog box to extrude a distance of0.969. Press the OK button to execute the

extrusion. It should look like figure 16.

Figure 16. Right front hub extruded. Rotated for clear view.

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15. In a similar fashion we will extrude the left front hub. First rotate the object to see the

left face and select it with the select face tool. It will turn red as in figure 17.

Figure 17. Left face selected for left front hub sketch.

16. With the face selected, right click and select New Sketch. Name the sketch Left

Front Hub. Press the OK button to create the sketch plane.

17. Use the view orthographic button to view the sketch.

18. As you did with the right front hub, construct a profile for the left front hub. It

should look like figure 18.

Figure 18. Left front hub profile.

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19. Use Extrude Profile to extrude the part a distance of0.969. After rotating, it should

look like figure 19. Save this design as the Base Center.

Figure 19. Completed Base Center or Undercarriage.

20. We will now design the wheel. There will be 6 wheels on the finished vehicle, 2 on

the front and 4 on the rear (double on each side). The wheel is relatively easy to

create and will take little time.

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WHEEL

21. Open a new design and edit the Initial to wheel.

22. Draw a 2.0 diametercircle at the work center and then a 0.25 diameter circle at

the center of the 2 circle. This should result in a profile such as shown in figure 20.

Figure 20. Wheel profile.

23. Rotate the image so it will be in 3D then select the Extrude Profile button.

Configure the dialog box as shown in figure 21. After configuring, press the OK

button to extrude the profile. Notice the yellow trial visual of the extrusion.

Figure 21. Wheel profile ready to be extruded.

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24. Figure 22 shows the resulting extrusion. This view has been rotated to better

visualize the illustration.

Figure 22. Profile after extrusion.

25. Use edge selection to select the two outsideedges of the wheel. Use the

shift key to select more than one edge. The edges will turn red as in figure 23.

Figure 23. Edges of wheel selected for rounding.

26. With the edges selected, right click to see the drop down menu. Select Round

Edges and another dialog box will appear. Edit it according to figure 24 for rounds of

0.13. Notice that trial rounds will appear in yellow. The wheel is in transparent

mode for better visual effect. Press the OK button to have the rounds completed.

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Figure 24. Round Edges dialog box ready for execution.

27. Figure 25 is the wheel after the rounds have been completed. Save this file and

name it Wheel.

Figure 25. Finished Wheel.

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CAB

28. Open a new design and name it Cab. Edit initial to cab. Construct the profile shown

in figure 26. We will add the rounds later. Refer to the Truck Cab dimensions to

complete this profile.

Figure 26. Cab profile.

29. To construct the wheel well, delete the bottom5 cab line then draw a .75 line

from the right end of the nose to the left. Draw another line 2.75 from the left

towards the nose. At the gap between these two lines, construct 3 circles of

R1.25. Use the snaps to do this. Figure 27 shows the three circles drawn. The top

of the red circle will be the arc. Delete all circle elements except the top arc of the

red circle. The profile should fill with color.

Figure 27. Constructing the wheel well arc using circles.

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30. Rotate the image to see it in 3D then select the Extrude Profile button. Edit the

dialog box as shown in figure 28. You will note a yellow trial extrusion.

Figure 28. Cab Extrusion ready to be executed.

31. Press the OK button to execute the extrusion. The result should look like figure 29.

The image has been rotated for a better 3D look.

Figure 29. Completed Cab Profile Extrusion.

32. Use facesselection to select the front ornose of the cab where the

headlights will be placed. The face will turn red. With the face selected, right click

to show a drop down menu and select New Sketch. Edit the name to Headlight

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holes and click the OK box to create the sketch. Figure 30 shows the dialog box

with the selected face in the background.

Figure 30. New Sketch dialog box for the headlight face.

33. Select view orthographic to display the new sketch face. You may need to

rotate it for better vision.34. Use lines to locate and place circles of0.37 diameter at the locations where the

headlights will be located. Figure 31 shows this layout for the left headlight. Be sure

to delete any construction lines so you will have a filled profile.

Figure 31. Layout for left headlight hole.

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35. Once the profile of both headlight holes are filled, select the Extrude Profile. Edit

the dialog box as indicated in figure 32. Notice that you will be removing material

below the workplane a distance of0.13. Notice the trial visual of the extrusion in

figure 32. Press the OK button to execute.

Figure 32. Headlight holes ready to be extruded.

36. Figure 33 shows the completed headlight holes.

Figure 33. Headlight holes completed by removal extrusion.

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37. We will now make the edges of the cab round. All rounds will be 0.38. The bottom

edges will be left square. Use edgeselection to select the edges at the front of the

hood, at the lower end of the windshield and the top front and back of the cab.

Hold down the shift key to select more than one edge. With the edges selected,

right click to see a drop down menu. Select Round Edges. Figure 34 shows the

dialog box and the trial round above it in the background. Click OK to execute the

rounds.

Figure 34. Using the Round Edges feature.

38. In the same manner, select the edges on the left side of the cab as shown on figure

35. Press OK to execute.

Figure 35. Selected left edges for rounding.

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39. In a similar fashion select the edges on the right side of the cab and round them to

the same value as previous rounds. The completed cab should look like figure 36.

Save it and give it the name Cab if you have not already done so.

Figure 36. Completed Cab.

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HEAD LIGHT

40. The headlight is a simple wooden hole plug. The following procedure is used to

create it. Open a new design and edit initial to headlight.

41. Draw the profile shown in figure 37. This is a half profile. It may be easier to create

the 0.52 circle first then delete line segments to arrive at the arc rather than

drawing the arc from point to point. You can draw a straight line then use the Arc or

Fillet tool to create the arc.

Figure 37. Full profile before deleting line segments.

42. After deleting unwanted lines, the profile will fill with color as in figure 38.

Figure 38. Half Profile ready for revolution.

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43. Click on base in the browser window. The three workplanes will show as glass. The

one on which the profile is contained, in figure 39, has a red perimeter. The other

two will be seen as cross hairs. The one with the red perimeter is selected. This will

be the axis about which the profile will revolve. It must be on the sameworkplane

as the profile but in a different sketch. Right click and select New Sketch. Edit the

dialog box as in figure 39. Make sure Addto workplane (base) is selected. Press

the OK button to proceed.

Figure 39. New Sketch added to the base workplane.

44. Draw a line over the bottom horizontal line. This will be the axis.

45. Rotate the profile sketch for 3D viewing then select Revolve Profile . A dialog

box will appear. Edit it to the contents of figure 40. Note that Headlight is the profile

that should show in the box sketch to use as profile. If it is not, click on the arrowat the right of the box and select Headlight. Notice that you will see a yellow trial

view of the revolution. When you have the trial view, click the OK box to finish.

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Figure 40. Revolve Profile dialog box edited for revolving the headlight.

46. Figure 41 is a view of the completed headlight part. Name it Headlight and save it

with the other designs in this project.

Figure 41. Completed Headlight.

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DUMP BED

47. Start a new design profile. Edit the initial to Dump Bed in the browser. In the

drawing field, construct a profile such as in figure 42. This will be the bottom and

front of the bed. Make sure the profile is filled with color to indicate that it is valid.

Refer to the drawings at the end of the tutorial for accurate dimensions.

Figure 42. Profile for Dump bed.

48. Select Extrude Profile to extrude this profile. Edit the dialog box as in figure

43. You will be adding material a distance of4.5below the workplane. Notice you

will see a yellow trial view. Click the OK button to complete the extrusion.

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Figure 43. Extrude Profile dialog box with trial view in background.

49. Figure 44 shows the completed extrusion, rotated for a better view.

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Figure 44. Extrusion of bed and front of dump bed.

50. We will now extrude the two sides of the dump bed. First use faceselection to

select the inside face of the bed. It will turn red. Right click and create a New

Sketch. Name this sketch Bed Sides. Click OK to create the sketch then use the

View Ortho Workpane to view it. Construct two rectangle shapes as shown in

figure 45.

Figure 45. Two side boards profile outlined for extrusion viewing from above.

51. Rotate the view to see it in 3D then use Extrude Profile to extrude the sides 1.42

above the workplane as shown in figure 46. Click OK to finish.

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Figure 46. Side Boards ready to be extruded.

52. Figure 47 shows the completed bed with side boards. Save the design at this time.

Figure 47. Completed bed with side boards.

53. Rotate the bed to show the bottom. We will extrude the rear axel supports so that

they are part of the bed. With the bottom showing, use Facesselection to select the

bottom face. Right click and select New Sketch. Name the sketch Axel Support.

Draw the profiles for the supports according to figure 48. Figure 48 shows

dimensional constraints. Refer to the drawings at the end of the tutorial for accuracy.

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Figure 48. Layout for Axel Supports.

54. Use delete line segments to remove all construction lines leaving only the two

rectangular profiles of the supports as shown in figure 49. They should fill with color

to indicate they are valid.

Figure 49. Axel support profile ready for extrusion.

55. Use Extrude Profile to extrude these supports by adding material a distance of

1.5above the workplane. Figure 50 shows the results.

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Figure 50. Axel supports extruded.

56. Select the face of the top axel support as shown in red in figure 51. After it is red,

right click and select New Sketch. Edit the dialog box as in figure 51.

Figure 51. Axel hole and taper Sketch on new workplane.

57. View the new sketch in orthographic and construct the triangular and hole profiles

as shown in figure 52. Be sure to remove all construction lines so that you have a

filled, valid profile.

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Figure 52. Profile for axel support hole and taper.

58. Use Project Profile to see the dialog box. Edit the dialog box according to

figure 53. Be careful to Subtract material, Below the workplane and Thruentire

part. Press the OK button to execute.

Figure 53. Project Profile dialog box set up to remove material from axel supports.

59. Figure 54 shows the result. The material removed has left the supports with a hole

for the axel and a taper to the front and rear. Save this design and name it Dump

Bed.

Figure 54. Completed Dump Bed.

60. Select the rear 4 vertical edges of the side boards and right click. Select Round

Edges and use a radius of0.12. Press OK to execute. Select the front edges of

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the bed and round them to 0.12 also. Figure 55 shows the completed bed with

rounds applied.

Figure 55. Completed bed with rounds applied.

61. This completes the design of the parts for the toy truck. Be sure to save the final

design of the dump bed. Our next step will be to assemble the parts into an

assembly that will show all the parts mated together to create the toy truck.

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ASSEMBLY

62. Open a new design. Save it as Truck Assembly. Under the Assembly drop down

menu, select Add Component and navigate to select the Base Centerdesign.

Click OK to load it. It should appear in 3D on the work surface. Rotate and move it to

a position as shown in figure 56. With the part selected, right click and Fix

Components.

Figure 56. Base Center Component added to Assembly.

63. In a similar fashion, add the component Dump Bed design. The design may be

behind the base center. Use select part and then select the bed. When the

cursor turns into a move unchanged symbol , you can drag the part around.

Figure 57 shows where the dump bed is located after moving it.

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Figure 57. Axel located near front axel support.

64. Use edgeselection to select the outside circle edge of the axelhole in the

support and the outside circle of the axelhole through the base center. Use the

shift key to select more than one face. Figure 58 shows these faces selected with

arrows pointing to the selected edges. The transparent mode is on for easier viewing

and clarity.

Figure 58, Selected edges in red.

65. With the two edges selected, right click and select Center Axis. The two parts will

center to the selected holes. This is shown in figure 59.

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Figure 59. Axel holes centered in support and base center

.

66. Use faces selection to select one face on the rear axel support and one facing

face on the base center. Figure 60 shows these faces selected. Move the image

around for the best view when selecting faces or edges. Right click and select

Mate. The two faces should come together.

Figure 60. Axel support and base center faces selected..

67. At this point you should have the dump bed attached to the center base so that you

can move the bed to simulate dumping. Figure 61 shows what the image should

look like at this point.

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Figure 61. Dump bed attached correctly to undercarriage.

68. At this point you can orient the image and use parts selection to select the dump

bed. When the moving cursor appears, click and drag near the top front of the bed.

You will notice that the bed rotates so that it appears to dump. Figure 62 shows the

bed in the upright or dump position.

Figure 62. Dump bed rotated to show upright or dumping position.

69. Use Add Components to add the Rear Axel (it is slightly longer than the front axel)

(it will turn red). Orient it relative to the parts such as in figure 63

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Figure 63. Rear Axel added.

70. Zoom in on the intersection of the rear axel and its support housing. Use select

faces and select the outside surface of the axel and the inside hole surface in the

base center or undercarriage (use shift to select more than one item). With both

surfaces selected (red), right click and select Center Axis. The axel will now center

on the housing hole as shown in figure 64. Move the axel so that an equal amount of

axel is protruding on each side of the support.

Figure 64. Axel centered in housing hole.

71. Using the same procedure, add the front axel (it is slightly shorter than the rear

axel). Be sure to center it as closely as possible.

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72. From the Assembly menu, add the component Wheel. Use faces selection to

select the inside surface of the centerhole in the wheel and the front axel

outsidesurface. Figure 65 shows the selection.

Figure 65. Surfaces selected prior to Centering Axis.

73. Whilethe surfaces are selected, Right click and select Center Axis. The wheel will

center on the axel. Use surface selection to select the outside surface of the

wheel and the end surface of the axel as in figure 66. Right click and select Align.

Figure 66. Surfaces selected prior to aligning.

74. The wheel surface should align with the end of the axel as shown in figure 67.

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Figure 67. Wheel aligned with axel.

75. Using the procedure you have just completed, add another wheel to the other side of

the front axel. You should now have a design such as shown in figure 68. The

transparency mode is turned off and the assembly is viewed as a solid in this

illustration.

Figure 68. Front wheels installed.

76. The rear wheels are dual. To make the dual wheel, add components and add two

wheels. You may also install these wheels one at a time. To make a dual wheel,

select the inside surfaces of the holes through both wheels then right click and

select Center Axis. Figure 69 shows the surfaces selected prior to centering the

axis.

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Figure 69. Surfaces selected for centering axis.

77. Select the inside wheel surfaces that face each otheras in figure 70. Right click

and select Mate. The two wheels will come together to form a dual wheel.

Figure 70. Wheel surfaces selected prior to mating.

78. Use edge selection to select the hole edge of the outside dual wheel. Hold the

shift key down and select the outside circle edge of the rearaxel. Right click and

select Center Axis. The dual wheel will center on the axel as in figure 71.

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Figure 71. Left rear dual wheel aligned.

79. Use surfaceselection to select the outside surface of the dual wheel and the

outside surface of the end of the axel. Right click and select Align. The dual

wheel will align with the end of the axel as shown in figure 72.

Figure 72. Left Rear Dual Wheel Installed.

80. Using the same procedure used to create and install the left rear dual wheel, create

another dual wheel and attach it to the right end of the rear axel. When completed it


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Figure 73. All wheels Installed.

81. UnderAssembly, select Add Component and insert the Cab design. Orient the

design to show the cab similar to figure 74.

Figure 74. Cab before mating to the wheel unit.

82. Use edge selection to select the bottom front edge of the cab and the top front

edge of the Base Center. Right click and select Center Axis.

83. Use face selection to select the top face of the Base Centerand the bottom face

of the cab. Right click and select Mate. The view will need to be moved and rotated

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so that you can see the front view of the cab and base center. Select the cab (it will

turn red) and move it until it is in alignment with the outside of the wheels. Figure 75

shows what it should look like.

Figure 75. Cab installed on Base Center.

84. Use Add Component to add a headlight. Move the headlight until it is at a position

similar to figure 76.

Figure 76. Headlight ready to be installed.

85. Use edge selection to select the circularrear edge of the lamp and the front

edge of the left headlight hole. Right click and select Center Axis. This selection


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Figure 77. Edges selected to Center Axis.

86. Select the circular face of the rear end of the headlight and the rear circular face

of the hole into which it will be placed. With both faces selected, right click andselect Mate. The headlight should be installed and look like figure 78.

Figure 78. Right headlight installed.

87. In the same fashion, add another headlight and install it in the left front hole. The

completed unit should look like figure 79.

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Figure 79. Headlights installed.

88. All parts have now been added to the assembly. You can rotate it and turn on the 3D

view to see the solid. You can move the dump bed to simulate the dumping position.

It should look similar to figure 80 (top view) and figure 81 (bottom view). Save the

completed assembly design. Name it assembly if you have not yet done so.

Figure 80. Finished truck viewed from the top.

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Figure 81. Finished truck view from the bottom.

PHOTO ALBUM

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89. An album is a single illustration of a design that can be saved as a JPEG or other

graphic standard file. You can also vary the background and material in the image.

90. To create an album, select Photo Album under the File drop down menu. A new

album page will be shown. Under the Image drop down menu, select New Image. A

Choose Modeling View dialog box will be shown as in figure 82. This dialog box

will list all the design files you have open at the time. If you have no files open, you

will need to navigate to the Toy Truck file and load the Assembly drawing.

Figure 82. Files that are currently open.

91. Select and load the assembly drawing. It will appear in 3D on the screen. You can

use the zoom + and zoom feature as well as normal rotation using the mouse

wheel. Orient the image according to figure 83 (or the view you want).

Figure 83. Image rotated for desired view.

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92. Notice the stop light orupdate icon at the top of the screen . Any time you do

anything to the image such as changing material, color or move it around, this will

light green. This means that you must click on the icon to update the screen.

93. In the browser at the top left, there are a number of selections. Select Material. You

will note that there are a number of selections with a + in front of each. If you clickthe + an additional list of materials will show. Click the Metal category and notice the

long list of materials available. Notice the bag at the left of each material. If you click

on a bag and drag it the cursor will turn into a spilling paint bottle . When

you cursor over an element in the design, the element will highlight. While it is

highlighted, release the mouse button to pour the material into the part. Notice that

duplicate parts such as wheels need only have material poured into one wheel. All

the rest will assume the same material. Figure 84 is an illustration of a cab of

Polished Gold, the under carriage is Cast Aluminum, the wheels are Rubber, the

axels are Polished Brass and the dump bed is Stainless Steel.

Figure 84. Image rendered using different materials.

94. You can also use special materials such as checkerboard or polka dots with

foreground and background settings. Also the background can be of different styles.

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To experiment with changing color, simply double click on a part. The dialog box

will direct you to color selections.

95. To make changes on foreground and background of special materials such as

checkerboard and polka dot patterns, use the Image Properties under the Image

drop down menu. You can change the background or foreground as well as the

relative size of the pattern. You can change lighting settings as well as other aspects

of the image presentation. Figure 85 is a case where a number of materials were

used and a JPEG sunset background is shown to demonstrate some of the

capabilities for an album. Experiment and enjoy.

Figure 85. Rendering using Polka dots, checkerboard patterns and various colors with a sunset background.

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