Millie Mini AI Bot - FreeCAD Part 2 - Fillets & Chamfers

Millie Mini AI Bot – Designing in FreeCAD - Part 2: Fillets & Chamfers

Dream Cloud Millennial Tech | Robotics Course

In this lesson, we take the next hands-on step in designing real robot parts by using FreeCAD to create parametric geometry directly from drawings and existing components.

This video builds on the previous FreeCAD lessons and moves students from simple sketching into designing parts that must fit and align with other robot components.

🧠 Lesson Focus: Referencing Geometry and Building Real Parts

This lesson shows how engineers design parts in context, using existing geometry to ensure new components fit correctly and remain editable as designs evolve.

What We Do in This Video

In this lesson, we:

Set up new sketches in FreeCAD

Work from provided drawings and dimensions

Use Create External Geometry to reference existing edges and features

Apply construction guidelines for alignment

Create pads (extrusions) and pockets (cuts)

Add chamfers and fillets to refine geometry

Students learn how professional CAD workflows avoid redrawing geometry and instead reference existing parts to maintain consistency and accuracy.

🤖 Applying This to the Millie Mini AI Bot

All CAD work in this lesson directly supports the physical design of the Millie Mini AI Bot.

How this fits into the robot build:

Parts designed here become real 3D-printable components

Geometry is designed to align with existing structures

Hole placement and dimensions are intentional and reusable

Each body is created with future assembly in mind

This reinforces that CAD is not abstract — it directly translates into real hardware.

🛠 FreeCAD Concepts Introduced

This lesson introduces and reinforces:

Create External Geometry

Sketch guidelines and construction geometry

Pads and pockets

Chamfers and fillets

Dimensional constraints

Parametric design intent

These concepts are foundational and will be reused throughout the course.

🎓 Learning Objectives

By the end of this lesson, students will:

Understand how to reference existing geometry in sketches

Build parts that remain aligned when designs change

Translate drawings into parametric CAD models

Gain confidence designing parts that must physically fit together

Practice workflows used in real engineering and robotics projects

🧩 Who This Lesson Is For

Students new to CAD and robotics

Schools teaching engineering fundamentals

Makers learning 3D-printable design

Robotics clubs and STEM programs

Educators building hands-on coursework

No prior CAD experience is required — this lesson is designed to be approachable while teaching industry-relevant skills.

📚 Part of the Dream Cloud Millennial Tech Course

This video is part of Dream Cloud Millennial Tech, an open-source AI and robotics education platform focused on real projects, real tools, and real skills.

🔗 Learn More & Join the Community

For course access, files, and ongoing development:

👉 www.DreamCloudClub.org