Cutter-Base Part

An inside-corner between the right face cheek and side-boss features (illustration 1.0.7 lower right) make a single-model of the joystick handle problematic to shell.  The current solution is to divide the model along this corner in two parts, shell each separately, and then join them.  That is why there are two cutter-parts (items 8 and 9) one for the head and one for side boss features.

Both cutters are made from copies of a cutter-base part, item 7, in illustration 1.0.7.  This saves time, because only the base part needs to be edited for identical changes to features in both cutter parts.

The cutter-base part is a surface model created with a single loft operation.  To speed the design process, each cross-section used by the loft has the same number of curve segments and corresponding curve types.  I copy a master sketch of the desired cross section shape and paste them onto other planes, then re-constrain and dimension as needed.  Each set of sketch curves are, in-turn, converted to reference curves and selected for section curves to create the lofted model.  Finally, I edit dimensions of curves in sketch planes to desired shape of the loft.  Part is ready for assembly in illustrations 7.1.0. and 7.1.1.

Illustration 7.1.2 shows history tree first-node minor-operations and the cutter-base CS structure on the bench.  In this part, CS4 is the lone child of CS3.  The rest of the coordinate systems are children of CS4 and are translated along the Z-axis.  CS15 is extra hidden under CS4.

Another close up of CS network with layout-handle part also on the bench.  Origin of the cutter-base CS4 is located at the vertex of layout-handle parabola with X-Y plane coincident to the top button boss plane.  The rest of the CS are translated up or down from CS4 along the Z-axis.

First sketch in illustration 7.2.0 on X-Y plane of CS14.  Note function of dimensions to shape the face features.

Illustrations 7.2.2 and 7.2.3 show how the layout-face part (item 10) is used to initially size joystick face features.  I adjusted the dimensions after initial settings to cut a more desired shape.

Second sketch shape same as the first with slightly different dimension values.  There are 10 more sketch steps, scroll down to animate the process.

Final set of cutter-base sketch curves in illustrations 7.12.0 to 7.12.3.

Illustration 7.13.0 shows sections chosen for the cutter base part loft Boolean operation.  Solid cutter-base part is ready in illustration 7.13.1 with extra reference curves for head and side boss cutters.

Illustration 7.14.0 shows difference section curves used to make the cutter-head and cutter-side  boss parts.