{"id":68,"date":"2026-08-08T11:30:29","date_gmt":"2026-08-08T06:00:29","guid":{"rendered":"https:\/\/kalyaniguraodesign.com\/?page_id=68"},"modified":"2026-08-10T08:27:44","modified_gmt":"2026-08-10T02:57:44","slug":"solidworks-projects","status":"publish","type":"page","link":"https:\/\/kalyaniguraodesign.com\/index.php\/solidworks-projects\/","title":{"rendered":"SolidWorks projects"},"content":{"rendered":"\n

1. Single-Cylinder Reciprocating Assembly<\/h3>\n\n\n\n
\"\"<\/figure>\n\n\n\n
\"\"<\/figure>\n\n\n
\n\t\n
\n\t\n\n

The Objective<\/h2>\n\n\n\n

To design, model, and assemble a functional single-cylinder reciprocating engine to demonstrate precise mechanical clearances and moving linkages.<\/p>\n\n\n\n

The Process<\/h2>\n\n\n\n

To create this assembly, I modelled several individual complex components from scratch, ensuring proper mates and tolerances for the final assembly. Key components and modelling techniques included:<\/p>\n\n\n\n

    \n
  • Cylinder Block & Crankcase End Cover:<\/strong> Utilized Boss-Extrude, Cut-Revolve, Circular Patterns, and Rib features to create the main housing and structural supports.<\/li>\n\n\n\n
  • Connecting Rod & Cap: <\/strong>Modelled the linkages using Boss-Extrude, Mirroring, and Chamfers for accurate mating.<\/li>\n\n\n\n
  • Piston & Crankshaft: <\/strong>Relied heavily on Revolve and Cut-Extrude features to generate the precise cylindrical geometry required for the reciprocating motion.<\/li>\n<\/ul>\n\n\n\n
    Parts<\/strong><\/summary>\n

    Cylinder Block
    <\/strong>Boss-Extrude
    Cut-Extrude
    Cut-Revolve
    Mirror
    Fillet<\/p>\n\n\n\n

    Crankshaft<\/strong>
    Boss-Extrude
    Mirror
    Cut-Extrude
    Chamfer<\/p>\n\n\n\n

    Connecting Rod<\/strong>
    Boss-Extrude
    Mirror
    Cut-Extrude
    CirPattern
    Fillet
    Chamfer<\/p>\n\n\n\n

    Connecting Rod Cap<\/strong>
    Boss-Extrude
    Cut-Extrud
    Chamfer<\/p>\n\n\n\n

    Piston<\/strong>
    Revolve
    Plane
    Cut-Extrude
    Boss-Extrude
    Mirror<\/p>\n\n\n\n

    Piston Pin
    <\/strong>Revolve<\/p>\n\n\n\n

    Crankcase End Cover<\/strong>
    Revolve
    Cut-Extrude
    CirPattern
    Rib<\/p>\n<\/details>\n\n<\/div>\n\n<\/div>\n\n\n\n

    2. Legoman Assembly<\/h3>\n\n\n\n
    \"\"<\/figure>\n\n\n
    \n\t\n\n

    The Objective<\/h2>\n\n\n\n

    To reverse-engineer and accurately model a fully articulated figure, demonstrating proficiency in multi-part assembly, spatial relationships, and precise dimensional tolerances.<\/p>\n\n\n\n

    The Process<\/h2>\n\n\n\n

    For this project, I modeled a 10-part assembly from the ground up to recreate a classic toy design. Key elements of the workflow included:<\/p>\n\n\n\n

      \n
    • Component Modelling: <\/strong>Designed individual, highly specific parts including the Upper body, Face, HAT, Arms (ARM, Arm_2), Hands (Hand, hand2), and lower body joints (Hip joint, LEG, LEG2).<\/li>\n\n\n\n
    • Assembly & Articulation:<\/strong> Mated the components to ensure the final assembly accurately represented the real-world physical constraints and moving joints of the character.<\/li>\n<\/ul>\n\n\n\n
      Parts<\/strong><\/summary>\n
        \n
      • LEG<\/li>\n\n\n\n
      • Arm_2<\/li>\n\n\n\n
      • ARM<\/li>\n\n\n\n
      • Face<\/li>\n\n\n\n
      • Hand<\/li>\n\n\n\n
      • hand2<\/li>\n\n\n\n
      • HAT<\/li>\n\n\n\n
      • Hipjoint<\/li>\n\n\n\n
      • LEG2<\/li>\n\n\n\n
      • Upper_body<\/li>\n<\/ul>\n<\/details>\n\n<\/div>\n\n\n\n

        3. Headphone Assembly<\/h3>\n\n\n\n
        \"\"<\/figure>\n\n\n
        \n\t\n\n

        The Objective<\/h2>\n\n\n\n

        To design an ergonomic, consumer-facing electronics product, balancing aesthetic surface modeling with internal mechanical component integration.<\/p>\n\n\n\n

        The Process<\/h2>\n\n\n\n

        This assembly required designing both structural and internal acoustic components, bringing together 9 distinct part types.<\/p>\n\n\n\n

          \n
        • Structural & Ergonomic Parts: Modeled the Headband, Frame, and Sliders to ensure adjustability and user comfort.<\/li>\n\n\n\n
        • Housing & Acoustic Elements: Designed the Casing, Cover, and Shell to house the audio components, integrating the Driver_assembly and soft-body Earpads.<\/li>\n\n\n\n
        • Hardware Integration: Incorporated adjustment Knobs to complete the mechanical stack-up.<\/li>\n<\/ul>\n\n\n\n
          Parts<\/strong><\/summary>\n
            \n
          • Casing<\/li>\n\n\n\n
          • Cover<\/li>\n\n\n\n
          • Driver_assembly<\/li>\n\n\n\n
          • Earpad<\/li>\n\n\n\n
          • Frame<\/li>\n\n\n\n
          • Headband<\/li>\n\n\n\n
          • Knob<\/li>\n\n\n\n
          • Shell<\/li>\n\n\n\n
          • Slider<\/li>\n<\/ul>\n<\/details>\n\n<\/div>\n\n\n\n

            <\/p>\n","protected":false},"excerpt":{"rendered":"

            1. Single-Cylinder Reciprocating Assembly 2. Legoman Assembly 3. Headphone Assembly<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"_zipai_imported":false,"footnotes":""},"class_list":["post-68","page","type-page","status-publish","hentry"],"spectra_blocks_featured_image_url":null,"spectra_blocks_author_info":{"display_name":"kalyani","avatar_url":"https:\/\/secure.gravatar.com\/avatar\/4bb428c07de0b9a54d5622fe1503c54665e9b283f1b6afcae060f5ca0d3a8808?s=96&d=mm&r=g","author_link":"https:\/\/kalyaniguraodesign.com\/index.php\/author\/kalyani\/","description":""},"_links":{"self":[{"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/pages\/68","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/comments?post=68"}],"version-history":[{"count":4,"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/pages\/68\/revisions"}],"predecessor-version":[{"id":162,"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/pages\/68\/revisions\/162"}],"wp:attachment":[{"href":"https:\/\/kalyaniguraodesign.com\/index.php\/wp-json\/wp\/v2\/media?parent=68"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}