Solidworks Lego Man Part 1, Parts

For our last project we have to reverse engineer a plastic Lego man, we had to use our Solidworks experience to make all the parts from scratch even getting our own measurements using calipers. the only part that had instructions was the arm but that was a really tricky part and I would have been lost making that without the instructions.

The head was the easiest part by far, a simple revolve and add some fillets gave us the Lego head.

The chest for the most part was simple until it came to adding the curvy features that old in the waist. I used the sketch picture tool trace the feature once and the mirrored it to get an accurate end result.

The arm, even with instructions was tricky, it involved creating a template sketch that we used to create multiple planes that we would later use to sketch on and then use the loft tool to connect them all. after that a simple cut extrude gave us the opening for the hand and adding the ball joint was just a simple revolve. Adding a variable fillet to give it a nice finish and we had our arm.

The first part of the had was easy just a extrude, cut and then fillet. adding the angled extended part was tricky but I added a plane to sketch on and that made it easier, after getting the right angle I used a revolve to give me the part.

The waist looked like a very intimidating part when we started this project but there was nothing tricky about it. Most of it was just sketching s simple shape and extruding it to the desired length, the only thing that was a bit challenging was adding the bumps on the parts that go into the legs.

The leg was again pretty straight forward, started with  sketch and just cut bits off according to the measurements I had taken from my Lego man. The hardest part for it was the little cut at the top of the back of the leg.

So far it has been a really interesting and fun project to put to use all that we have been learning, there is definitely so much more to learn and one of the things I have noticed is that I tend to forget to define some of my construction lines, this leaves me with an undefined sketch even though the main body of the part is all defined I forgot to add a simple relation or dimension for a construction line.