Modeling the Universal Joint in Blender

Introduction

In this tutorial, we'll be modeling a universal joint, also known as a U-joint, using Blender. This component is crucial in mechanical designs and can be applied in various fields, including robotics and industrial design. By following these steps, you'll gain hands-on experience in 3D modeling within Blender.

Step 1: Set Up Your Blender Environment

• Download and install Blender from blender.org.
• Open Blender and create a new project.
• Optionally, download the project file from this link for reference.

Step 2: Create the Base Cylinder

• Add a cylinder with 64 vertices by pressing Shift + A and selecting Mesh > Cylinder.
• Set the cap to "Nothing" and rotate the cylinder 90 degrees on the X-axis.
• Scale the cylinder up along the Y-axis and apply the scale (Ctrl + A).

Step 3: Create the Inner Cylinder

• Add another cylinder with 32 vertices and scale it down slightly.
• Scale this cylinder up along the Z-axis and position it inside the first cylinder.
• Apply the scale and use the Boolean modifier:
  • Select the base cylinder.
  • Go to Modifiers > Add Modifier > Boolean.
  • Set the operation to "Difference" and apply the modifier.
• Hide the inner cylinder.

Step 4: Modify the Base Cylinder

• Enter Edit Mode (Tab) and switch to Wireframe view (Z).
• Select and delete unnecessary faces and vertices as needed.
• Use X to dissolve vertices where necessary.
• Return to Object Mode and apply all transformations (Ctrl + A).

Step 5: Symmetrize the Model

• Select all (A) and go to Mesh > Symmetrize.
• Set the direction to copy from the positive Z-axis to the negative Z-axis.

Step 6: Add Subdivision Surface Modifier

• Add a Subdivision Surface modifier with 3 levels.
• Select the edges you want to extrude and press E to extrude them.

Step 7: Create Additional Components

• Add another cylinder with 16 vertices; rotate it 90 degrees on the Y-axis.
• Scale it down and position it as needed.
• Enter Edit Mode and delete the right half of the cylinder.
• Select all and use Alt + E to extrude faces along normals.

Step 8: Finalize the Shape

• Use the Boolean modifier again to subtract shapes as necessary and apply changes.
• Continue to adjust and symmetrize your model to ensure symmetry.

Step 9: Add Thickness

• Add a Solidify modifier to give the model thickness.
• Adjust the thickness to your preference.
• Check for overlapping vertices and merge them if necessary.

Step 10: Add Details and Finishing Touches

• Create screws and additional features as desired.
• Use the Bevel tool (Ctrl + B) to soften edges.
• Ensure all elements are well-joined and tidy.

Conclusion

Congratulations! You've modeled a universal joint in Blender. This process has covered the essential steps from creating the basic shapes to adding details. You can now apply these skills to other mechanical designs. Feel free to share your final renders with the community and keep honing your 3D modeling skills!