# preface

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continuing the theme of locks/opening doors, i decided to make a 3d model/3d print of the key to my dorm room for this week's assignment.

i thought this would be a good candidate for this week's assignment because it contains three-dimensional inner grooves that are both intricate and that curve in on each other — making it difficult to reproduce by laser cutting or milling.

# creating the 3d model

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because of the importance of accurate measurements of the key's dimensions, i decided to upload an image of the key as a canvas on fusion 360, and then create my sketch based on that canvas.

i also took a picture of the key's side view to use as a perpendicular canvas.

using this lateral view, i first created a sketch of the side profile of the key

i then extruded this to form the shaft of the key

then, using the other canvas of the top view of the key, i created another sketch outlining the key's teeth.

then, using the "intersect" setting of the "extrude" function, i extruded this sketch to form a body that consisted of the intersection between these two sketches.

lastly, there were two additional notches on the other side of the key that weren't accounted for in this draft:

as such, i had to flip the model over, and create a sketch of the indentation. then, using the "cut" setting of the "extrude" function, i was able to remove these two notches from the model.

# printing the key

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having completed a preliminary model, i then exported it as a .stl file, prepared the 3d print in prusaslicer using the DRAFT settings, and printed.

unfortunately, this version was much thinner than my actual key. i'm not sure why this happened; i assume it was because i measured incorrectly or calibrated the canvas incorrectly. so, i re-measured the dimensions and did another, more accurate 3d model, which i then printed using black filament

here, you can see a comparison of the thicknesses of my first version (blue), my second version (black), and my actual key:

and here's a comparison of it and my original key

unfortunately, it did not successfuly unlock the door. i think this is a combination of the measurement inaccuracies in my original 3d model as well as the inexactness of the 3d printing. perhaps for a future iteration, i will refind the 3d model and print on a more detailed nozzle setting.

Here is my final .3mf file, and here is my final .gcode file.