Course Outline:

Module 1: Introduction to Fusion 360 and the Design Workflow

• Overview of the Fusion 360 interface and workspace

• Cloud-based project setup and data management

• Overview of the product development process

• Navigation, sketching, and basic tools

Case Study: Design a phone holder stand from sketch to model

Module 2: 2D Sketching and Parametric Design

• Creating 2D sketches with constraints and dimensions

• Design intent and parametric control

• Construction geometry and sketch management

• Best practices in 2D sketching

Case Study: Sketch and model a parametric desk lamp bracket

Module 3: Solid Modeling and 3D Features

• Extrude, revolve, loft, and sweep features

• Fillets, chamfers, shells, and drafts

• Design history and timeline editing

• Working with multiple bodies

Case Study: Model a reusable water bottle with threaded cap

Module 4: Assemblies and Joints

• Top-down vs. bottom-up design

• Assembling components using joints and constraints

• Creating motion links and contact sets

• Exploded views and motion studies

Case Study: Assemble a robotic gripper mechanism

Module 5: Sculpting and Surface Modeling

• Introduction to the sculpt (T-spline) environment

• Creating organic shapes and ergonomic designs

• Edit forms, symmetry, and control point manipulation

• Converting surfaces to solids

Case Study: Design an ergonomic wireless mouse shell

Module 6: Rendering and Visualization

• Applying appearances and materials

• Setting up environments and lighting

• Creating realistic renderings for presentations

• Exploded views and animation creation

Case Study: Create a product showcase render of a kitchen appliance

Module 7: Simulation and Stress Analysis

• Static stress and safety factor analysis

• Setting up constraints, loads, and materials

• Meshing and interpreting results

• Basic thermal and modal simulations overview

Case Study: Analyze structural stress on a bike crank arm

Module 8: Preparing for 3D Printing and Additive Manufacturing

• Design rules for 3D printing (FDM, SLA)

• Checking and fixing geometry (manifold, watertight)

• Generating STL and slicing basics

• Integrating Fusion 360 with slicers

Case Study: Design and export a custom phone case for FDM printing

Module 9: CNC Toolpath Generation (CAM) and Manufacturing Setup

• Introduction to the Manufacture workspace

• Tool library, stock setup, and operation types (2D, 3D milling)

• Generating and simulating toolpaths

• Post-processing and exporting G-code

Case Study: Generate CAM paths for a wooden phone amplifier block

Module 10: Capstone Project and Design Presentation

• Capstone Project: Design, simulate, and prepare a product for manufacturing

• Peer reviews and team presentations

• Portfolio preparation tips

• Final Q&A, wrap-up, and certification

Capstone Case Study: Complete design and manufacturing plan for a portable Bluetooth speaker housing