How do I create clearance for an existing part I'm creating a holder/mount for? Boolean offset fail

jesse_starr

Project link: https://cad.onshape.com/documents/fe462946f50b092572ea427d/w/382d1aca84774d38a80121f3/e/41a00b9e3538520c261e610a?renderMode=0&uiState=637c20a768307e0562e40c45

I'm trying to learn how to make parts that can go around an imported/existing part by modeling an AirTag holder.  I can not seem to figure out what phrase to search anywhere for that results in a tutorial or advice on modeling around existing objects...

I have imported a good model of an AirTag and trying to use the Boolean tool to subtract it from my extrusion.  I can do the subtract operation but if I try to use the Offset option, I can't get it to solve...

Is there a different tool/method I should be using to do this? Any other tips on creating "pockets"/holders for an existing part?

MichaelPascoe

Hi @jesse_starr, there are several different ways to do this. In this case, since the boolean is failing, you could try something like this:

• Split the AirTag
• Offset the face of the split section
• Move boundary of the surface 1mm
• Revolve remove the offset face
• Boolean join the AirTag back together

You could also do this with sketches, but it is not as robust. Also, in your original model you had 1mm as the boolean offset. It will depend on the material you are using and your end goal, but this seems a little large. For a snug fit on a semi flexible object, I've found around 0.127mm to be a nice number.

https://cad.onshape.com/documents/c719276c682e45252f3cfe5d/w/6427f5d3553f415982dcef3c/e/c0993634552c60527a8e2005?renderMode=0&uiState=637cc4047490d301bca5c2b5

glen_dewsbury

Just another way. Picked up something new to me from Michael's sample.
Import is surfaces only. That's why your Boolean is failing.
Splitting  the surface will allow trace for a new revolve. Offset surface and thicken remove into the revolve for the apple logo.
https://cad.onshape.com/documents/cc4403f81b731594e868e5a0/w/aede04c7d40c9d4a7a59b7e5/e/b856b4db06c145d9c3a818f4