Optical-alignment gimbal
A small mechanism with a complete assembly story: adjustable axes, printable parts, and checks that survive reopening the model.
Make adjustment simple.
Make assembly inspectable.
This project explores a two-axis fixture for positioning an optical module. The assembly uses a printed base, yaw stage, pitch frame, and split clamp, with separate hardware and documented stops.
The design intent is PETG FDM manufacture with accessible fasteners and configurable yaw and pitch positions. Native CAD generation used the SOLIDWORKS API, with separate verification of the saved assembly.
23 native parts
Editable SLDPRT files and 37 resolved component instances.
5 configurations
Neutral and endpoint poses saved in the native assembly.
8 printable meshes
Separate STL designs with recorded geometry-integrity checks.
Design beyond the assembled view.
The split clamp, separated frame members, bushings, and adjustment hardware make the build sequence visible. An exploded configuration and basic assembly drawing support that sequence, while print and assumption records document the design inputs for the next iteration.
The documented nominal motion range is yaw −90° to +90° and pitch −20° to +45°. Stops and hardware are represented geometrically, providing a clear basis for checks of retention, contact loads, and tolerance behavior.
Check the file that will be used.
The final assembly was saved, fully closed, reopened, and rebuilt. All 37 component paths resolved, and all 23 part files contained one solid body. The 108 mates returned zero error codes and no warnings across all five configurations.
Sampled yaw/pitch combinations
Native interference checks returned zero overlaps at the recorded positions. The sampled positions provide a repeatable baseline for the next motion study.
All eight STL meshes passed the recorded closed-edge, nonmanifold-edge, degenerate-triangle, and positive-volume checks. These checks document mesh integrity for fabrication preparation.
Next iteration
The next iteration moves from CAD into fabrication. The fabrication study focuses on fit, stiffness, creep, strength, payload capacity, angular repeatability, and print performance. The PDF captures the assembly definition and supports that build sequence.
The build sequence starts with a test print of the fits and moving interfaces, followed by assembly and repeatability measurements.