Fusion 360 Honeycomb pattern

As seen on (reddit)[https://www.reddit.com/r/Fusion360/comments/lbh243/a_short_workflow_on_how_to_create_a_hexagon/] / (YouTube)[https://www.youtube.com/watch?v=AFZVNVvmXJ4].

Parameters

Solid > Modify > "Change Parameters" Create the following parameters:

• Name | Unit | Expression
• AR | mm | 250mm // Area that will receive the pattern
• Hexagon | mm | 4mm // Hex size
• Walls | mm | 1mm // Hex wall tickness

Sketch

1. Create a sketch on plan XY

2. Create a rectangle with "Center rectangle" feature set and use ("AR" - "Walls" * 2) parameters as its dimensions

3. Create a circumscribed Polygon with "Hexagon" parameter as dimension and 6 edges Make sure to point the Polygon center point to the - X and - Y intersection (the dotted line between the left lower inside the square)

4. Create a Vertical constraint at the Left polygon edge ( the one above the fx 4.00 constraint line or -X and +Y)

5. Remove the fx 4.00 constraint.

6. Create two vertical lines between the vertical lines of the polygon: Create > Sketch Dimension select both vertical lines

• Set "Hexagon" feature as dimension

7. Create a second polygon close to the 1st one.

8. Create two Coincident Constraints between the two polygon corners.

• Click at the second polygon dot between two lines and do the same at the 1st polygon.
• Repeat this for one more edge.

9. Create two sketch lines at the first polygon:

• "Sketch palette" > Options > Line type: "Construction lines"
• Create > Line: then click at the first polygon center point and set the end at the edge between the two polygon's middle vertical lines ( 0.0 deg and 2.000 mm)
• Create > Line: 1st point at the 1st polygon center point and the 2nd at the middle of the diagonal +X +Y line of the first polygon (60 deg and 2.000mm)
• Those lines will be used to distribute the pattern

10. Finish the sketch

11. Extrude the 2nd polygon:

• Type: "Thin extrude"
• Start: "Profile plane" // default
• Direction: "One side' // default
• Extend type: "Distance" // default
• Distance: "4.00mm" // How tall you want it to be
• Wall tickness: "Walls / 2"
• Wall location: "Side 1" // default
• Operation: "New body" // default

12. Extrude the 1st polygon:

• Type: "Thin extrude"
• Start: "Profile plane" // default
• Direction: "One side' // default
• Extend type: "To object"
• Object: "select the 2nd polygon extrusion"
• Distance: "(To)" // default
• Extend: "To selected face" //default
• Offset: "0.00mm" // default
• Taper angle: "0.0 deg" // default
• Wall tickness: "Walls / 2"
• Wall location: "Side 1" // default
• Operation: "Join" // default

13. Create the pattern:

• Solid > Create > Pattern > Rectangular pattern
• Type: "Rectangular pattern" // default
• Object Type: "Features"
• Objects: Select the 1st polygon (2nd extrusion at the timeline) // as we used the JOIN on extrusion we don't need to combine into a solid body.
• Axes: select that 2 construction lines we created at the 1st polygon sketch.
• Distribution: "Spacing"
• Surpress: true

Axis 1:

• Quantity: how many it is necessary to fill it. (30 for the 14mm)
• Distance: "Hexagon" feature
• Direction: "Symmetric"

Axis 2:

• Quantity: how many it is necessary to fill it. (30)
• Distance: "Hexagon" feature
• Direction: "Symmetric"

This way only worked for less than 30x30 hexagon count. Feature is resource wasteful.

13.1 Workaround

If it is too much for your machine to handle:

Keep in mind that if you need to change anything in the Hexagon, you should redo it prior to this step, as the FEATURE will not be reflected from step 13 on. Do the same as above until step no 12.

13.2: Re-doing the base area:

13.2 Create the pattern:

• Solid > Create > Pattern > Rectangular pattern
• Type: "Rectangular pattern" // default
• Object Type: "Features"
• Objects: Select the 1st polygon (2nd extrusion at the timeline) // as we used the JOIN on extrusion we don't need to combine into a solid body.
• Axes: select that 2 construction lines we created at the 1st polygon sketch.
• Distribution: "Spacing"
• Surpress: true

Axis 1:

• Quantity: 2
• Distance: "Hexagon" feature
• Direction: "Symmetric"

Axis 2:

• Quantity: 63
• Distance: "Hexagon" feature
• Direction: "Symmetric"

Note: Of course that you could change the rectangle to grow to +X +Y and then start the pattern from square X=0 Y=0 and grow 1 up and 61 to only one side. But I didn't wanted to redo the whole tutorial.

13.3 Component feature:

• Select the honeycomb pattern Body
• Right click then > "Create component from bodies"

14. Cutting the form

• Move the camera under the plane
• Create > Extrude: select the area (the plane sketch in this case) and both hexagons sketches as well.

Lightweight solution:

If it is too much for your machine to handle:

Keep in mind that if you need to change anything in the Hexagon, you should redo it prior to this step, as the FEATURE will not be reflected from step 13 on. Do the same as above until step no 12.

1. Create a sketch on plan XY

2. Create a rectangle on X=0 Y=0 with "2-Point rectangle" feature set and use (AR - Walls * 2) parameters as its dimensions

3. Create a circumscribed Polygon with "Hexagon" parameter as dimension and 6 edges Make sure to put the Polygon center at X=0 and Y=0

4. Remove the fx 4.00 constraint.

5. Create two vertical lines between the vertical lines of the polygon: Create > Sketch Dimension select both vertical lines

• Set "Hexagon" feature as dimension

6. Create a second polygon close to the 1st one.

7. Create two "Coincident Constraints" between the two polygon corners.

• 1st: Click at the 1st Polygon intersection point (line limit) on Y axis and then click on a point on the 2nd polygon
• 2nd: Click at the 1st Polygon intersection point (line limit) on X and Y axis and then click on a point on the 2nd polygon Now you should have one polygon on top of the other.

8. Finish the sketch

9. Extrude the 2nd polygon:

• Type: "Thin extrude"
• Start: "Profile plane" // default
• Direction: "One side" // default
• Extend type: "Distance" // default
• Distance: "4.00mm" // How tall you want it to be
• Wall tickness: "Walls / 2"
• Wall location: "Side 1" // default
• Operation: "New body" // default

10. Extrude the 1st polygon:

• Type: "Thin extrude"
• Start: "Profile plane" // default
• Direction: "One side' // default
• Extend type: "To object"
• Object: "select the 2nd polygon extrusion"
• Distance: "(To)" // default
• Extend: "To selected face" //default
• Offset: "0.00mm" // default
• Taper angle: "0.0 deg" // default
• Wall tickness: "Walls / 2"
• Wall location: "Side 1" // default
• Operation: "Join" // default

11. Component feature:

• Select the honeycomb pattern Body
• Right click then > "Create component from bodies"

12. Create the pattern:

• Solid > Create > Pattern > Rectangular pattern
• Type: "Rectangular pattern" // default
• Object Type: "Components"
• Objects: Select the body component from step 11.
• Axes: select the X and Y axis
• Distribution: "Spacing"
• Surpression: true

Axis 1:

• Quantity: how many it is necessary to fill it. (62 for the 14mm)
• Distance: "Hexagon" feature
• Direction: "Symmetric"

Axis 2:

• Quantity: how many it is necessary to fill it. (30)
• Distance: "Hexagon" feature
• Direction: "Symmetric"