1.

Create a New Component called Roller Pin

2. Use the Cylinder Primitive to create a 11.5mm diameter x 11.25 inch cylinder
3. Chamfer the ends with a 0.5mm equal distance chamfer
4. Position the Roller Pin in the middle of the End Caps and set the Motion Type to
Revolute

a.
5. Activate the Extension Arm Assy
6. Switch to the Sheet Metal Tab
7. Create a new Sheet Metal Component using Stainless Steel (mm) called Workpiece
Stop
a. Draw a 260mm x 50mm rectangle on the front plane
b. Use the profile to create a sheet metal flange
8. Select the top back edge and create a Full Edge flange
a. Height = 13mm
b. Angle = 90
c. Height Datum = Outer Faces
d. Bend Position = Adjacent

e.
9. Select the bottom front edge and create a Symmetric flange
a. Distance = 107mm
b. Height = 19mm
c. Height Datum = Outer Faces
d. Bend Position = Adjacent
e. Bend Relief Override = Tear

f.
10. Select the front left vertical edge of the sheet metal part and create a Two Offset
flange
a. Pick the bottom edge of the rectangular face as Reference 1
i. Offset = -5.5mm
b. Pick the corner that defines the top corner of the rectangular face as Reference
2
i. Offset = -22mm
c. Height = 40
d. Angle = 90
e. Height Datum = Outer Faces
f. Bend Position = Adjacent
g. Bend Relief Override = Tear

h.
11. Full Round Fillet doesn’t always work on Sheet Metal parts, so we will have to fillet the
arm the old way.
a. Select the top short edge of the arm and right-click and select Fillet
b. Next to the 1 Edge field, click the 3 dots and select Measure

c.
d. Select the vertical edge defining the “height” of the arm
e. The fillet will use that measurement (22.5mm). We want half of that, so type in /2
after the measurement
f. Select the bottom short edge to create the other fillet

g.
12. Use the Hole Command to create a 12mm Diameter hole in the arm centered around
the fillets

a.
13. Create a Midplane Construction Plane between the vertical faces of the sheet metal
part (the original rectangular flange faces)

a.
14. Mirror the Flange, Fillet, and Hole Features over to the other side using the midplane
construction plane
15. Fillet all the sharp edges (6) with a 5mm fillet

a.
16. Create a Revolute joint between the Workpiece Stop and the Roller Pin
a. Use Between 2 Faces for both to get the Workpiece Stop to be perfectly
centered
b. Set the Angle to -90

c.
17. Notice that the Workpiece Stop clashes with the roller.
a. Edit the last flange in the timeline (the one that makes the arm)
b. Change the Height from 40mm to 50mm

c.
18. Press OK and notice how the Workpiece Stop updates and is still in the correct location,
but no longer clashes with the roller
19. Activate the Extension Arm Assy
20. Use the Hole command to create a 9mm hole in the center of the vertical Extension
Arm tube

a.
21. Insert a McMaster-Carr M8 Steel Hex Nut (90592A022)
22. Use a Rigid Joint to position it over the hole you just created
23. In the Sheet Metal tab, click on Modify-->Sheet Metal Rules
24. Expand open the Library in the dialog that appears
a. Hover over the Stainless Steel (mm) and then click on the New Rule icon that
appears.

b.
25. In the New Rule dialog that appears, change the Thickness to 0.6mm

a.

26. Create a new Sheet Metal component called Stainless Steel Plate
a. Set the rule to the new Stainless Steel 0.6mm you created
b. Create a sketch on the side of the extension tube
c. Project the extension arm geometry onto the sketch
d. Create lines like in the image below.
e. Dimension the length of the “arms” to be 55mm
27. Use the Sheet Metal Flange command to create a sheet metal part -25mm in height
28. Create a Rigid Joint to position the sheet metal flange into the correct position
a. Select the middle snap point of the inside line (see image)

b.
c. Select the middle snap of the inside-top edge and the middle of the edge of
the support tube.

d.
29. Use the Hole command to create a 10.5mm hole on the front-angled face
a. Reference the side of the sheet metal part and enter 12.50mm for the distance
b. Reference the bottom of the sheet metal part and enter 24mm for the distance
c. Diameter = 10.5mm
d. Extents = To (select the inside face of the angled section)

e.
30. Fillet the bottom edges of the sheet metal part 6mm.
31. Use McMaster-Carr to insert in a Plastic Seven Arm Grip Knob (2907T27)
32. Position it with a Revolute Joint into the nut
33. Create a New Component under the Extension Arm Assy called Frame End Cap
34. Create a Box Primitive on the side plane, 30mm x 30mm x 3mm
35. Create a sketch on one of the large flat faces
a. Draw a Centered Rectangle, 28mm x 28mm
b. Extrude the profile 10mm

c.
36. Shell the part out 3.5mm
37. Fillet the 8 small edges 2mm

a.
38. Fillet the front face edges of the part 1.5mm
a. Click on the face to select all the edges at once

b.
39. Edit the original sketch and offset the rectangle profile inward 2mm
40. Select the profile between the large rectangle and the smaller rectangle and
Extrude/Cut 3mm into the part

a.
41. Create a Rectangular Pattern of the extrude feature
a. Distance Type = Extent
b. Quantity = 2
c. Distance = 5mm

d.
42. Edit the original sketch again
a. Draw a Centered Rectangle on the centerpoint of the inside edge, and snap it to
the outside rectangle
b. Set the height to be 8mm
c. Repeat the same on the other side

d.
43. Notice our profiles are not constrained. We should fix this.
a. Show the tip with Horizontal/Vertical constraint with the Shift Key
44. Extrude/Cut the outside rectangle profiles you just created To Object and select the
end face

a.
45. Change the appearance of the Frame End Cap to Black Plastic Texture Random
46. Use a Rigid Joint to position the Frame End Cap into the end of the Extension Arm

a.
47. Activate the Top Level Assembly
48. Right-Click on the Extension Arm Assembly and select Move/Copy
a. Make sure you check the Create Copy option first
b. Drag and rotate the Extension Arm Assy toward the other side
c. Press OK

d.
49. Create a Slider Joint using Between 2 Faces to position the copied Extension Arm
Assy into the correct location.

a.
50. Save!