Start the Mouthpiece

We started this project by mocking up the PVC pipe purchased at the local hardware store. We are now ready to begin creating our penny whistle mouthpiece and we can use the pipe we just built as a guide for the next steps.

We need to build the body of the mouthpiece that will fit around the pipe.

Let's jump in!

Instructions

1. Let's start by drawing on the top of the pipe.
2. Select Circle from the Sketch menu.
3. Again you will see the origin planes appear, but this time make sure to select the top surface of the pipe.
4. Start the circle in the center of the pipe at the origin.
5. Create a circle 21.75mm in diameter.
6. Repeat the previous step and create a circle 24.75mm in diameter.
7. Click Stop Sketch on the right end of the toolbar.
8. Continue to the next step.

Now we can extend the mouthpiece down around the PVC pipe.

Instructions

1. Select Extrude from the Create menu or press E on the keyboard.
2. Select the outer profile of the sketch from the previous step.
3. Drag the blue arrow on the top of the shape down to extrude the profile around the pipe.
   Note: Because the shapes do not touch (or intersect) a new body (shape) will be created rather than joining the original shape.
4. Click OK to complete the Extrude.
5. Continue to the next step.

To prevent the two bodies (shapes) from joining together in future steps we will need to lift it above the pipe just a bit.

Instructions

1. Select the Move command from the Modify menu.
2. Select the mouthpiece body and drag it up 1mm.
3. Continue to the next step.

The next shape we will be creating will serve two purposes. It will be used to create the blade in the mouthpiece and it will act as a stop to prevent the PVC pipe from being inserted too deep in the mouthpiece. If the pipe were pressed to deep into the mouthpiece it would block airflow.

Instructions

1. Start by selecting Circle from the Sketch menu.
2. Start the circle in on the top face of the mouthpiece. (NOT the top of the pipe)
3. Create a circle 18.5mm in diameter. Because this circle overlaps the pipe it will act as a stopper to prevent the pipe from extending too far into the mouthpiece.
4. Create a second circle that extends to the outer edge of the mouthpiece and dimension it to be 25mm in diameter.
5. Continue to the next step.

Before we add the next extrude and create the pipe stop, we need to add a small flat we can turn into the blade of the mouthpiece.

Instructions

1. Select Line from the sketch toolbar.
2. Draw a line vertically on the left side of the sketch connected to the circle at 2 points.
3. Next draw a line from the mid-point of the vertical line to the center of the circle. This will center the line on the circle.
4. Select Dimension from the toolbar and select the vertical line. Set the dimension to 8mm. This flat will become the bottom of the mouthpiece blade.
5. Note: You can optionally set the horizontal centering line to construction. This will visually change the line to dashed and tell Fusion to ignore it when evaluating profiles in the extrude command. This is not required, but can help understand geometry in the sketch if you return to it later.
6. Click the Finish Sketch button on the right end of the toolbar to complete the sketch.
7. Continue to the next step.

With the body of the mouthpiece complete, we can create the pipe stop with an extrude feature.

Let's create that now.

Instructions

1. Select Extrude from the Create menu or press E on the keyboard.
2. Select the outer profiles and the flat.
3. Drag the blue arrow up and set the distance to 13mm.
4. Click Ok in the extrude dialog to complete the extrusion.
5. Continue to the next step.

The next steps is to cap everything off so we can start building the air channel.

Instructions

1. Select Circle from the Sketch menu or press C on the keyboard.
2. Draw a circle on the top of the mouthpiece starting at the center of the mouthpiece.
3. Set the circle to be 25mm in diameter.
4. Click Finish Sketch to complete the sketch.
5. Continue to the next step.

Now you can extrude the previous sketch to cap off the mouth piece.

Instructions

1. Select Extrude from the Create menu.
2. Select all the profiles on the top of the mouthpiece.
3. Drag the blue arrow up 1mm.
4. Click OK to complete the extrude.
5. Continue to the next step.

You now have the main body of the mouthpiece complete. Next you need to create the blade and the air channel to complete the mouthpiece.

To do this we will start sketching our blade shape on an origin plane in the center of the mouthpiece.

Instructions

1. Start by selecting the Projection command from the sketch menu.
2. This time select the XY Origin plane (remember you can select the plane in the browser by expanding the Origin folder)
3. Project the Y-Axis into the sketch
4. Project the Top of the mouthpiece into the sketch.
5. Using the line tool to create the triangle seen in the image.
6. Select the dimension command from the Sketch toolbar and add required dimensions.
7. Click the Finish Sketch button to complete the sketch.
8. Continue to the next step.

To complete the blade opening we use the sketch from the previous step to cut the blade opening.

Instructions

1. Select Extrude from the Create menu or press E on the keyboard.
2. Select all triangle profile from the previous step.
3. Drag the blue arrow 4mm.
4. In the Extrude dialog, set the Direction drop down to Symmetric.
5. Click OK to complete the extrude.
6. Continue to the next step.

Congratulations! You have your blade finished!

Next is the air channel. This is a critical step in the construction process because we need to ensure proper positioning of the air channel hole. Remember the air opening need to be positioned so air coming in is sent both under and over the blade.

Instructions

1. Select Projection from the Sketch menu and select the top of the mouthpiece.
2. Project the edge of the blade into the sketch. (you may need to rotate your view to see the blade edge)
3. Continue to the next step.

You can now use the Blade edge to control exactly where the air channel opening will be. The air channel will be offset slightly below the blade edge causing some air to flow out of the blade opening and some to travel under the blade.

We can create this with a couple rectangles.

Let's add those now.

Instructions

1. Select Rectangle from the Sketch menu or press R on the keyboard.
2. Start the rectangle on one end of the projected blade edge.
3. Drag one rectangle the one side of the edge.
4. Repeat that process to create a second rectangle on the opposite side.
5. Select the Dimension command or press D on the keyboard.
6. Dimension the rectangles to be 8mm wide (the width of the blade opening)
7. Make the rectangle under the blade 0.2mm tall. (the side closer to the center is under the blade)
8. Next Dimension from the edge of the 0.2mm rectangle to the opposite side of the other rectangle (the overall distance of the opening).
9. See the image for detailed dimensions.
10. Click Finish Sketch after adding the dimensions to complete the sketch.
11. Continue to the next step.

Now we need to cut the air channel through to the top of the mouthpiece.

Instructions

1. Select Extrude from the Create menu or press E on the keyboard.
2. Select both rectangle profiles from the previous step.
3. Drag the blue arrow down 1mm.
4. In the Extrude dialog, set the Direction drop down to Symmetric.
5. Click OK to complete the extrude.
6. Continue to the next step.

Great work! The air channel is now ready and positioned properly.

Let's extend the mouthpiece so it can be played.

Instructions

1. Select Circle from the Sketch menu or press C on the keyboard.
2. Hover the cursor over the center of the mouthpiece, this will "activate" the center point as a guide. Move the cursor to the left and start the circle.
3. Drag the circle to make it tangent to the outer edge of the mouthpiece on the left.
4. Select Dimension from the Sketch toolbar or press D on the keyboard.
5. Dimension the distance between the center of the mouthpiece and the center of the circle and set it to 4.5mm.
6. Draw a line vertically through the center of the circle. we will only use the half with the air channel opening for the mouthpiece extension.
7. Click Finish Sketch to complete the sketch.
8. Continue to the next step.

Let's Add the extension to the mouthpiece now.

Instructions

1. Select Extrude from the Create menu or press E on the keyboard.
2. Select the half of the circle profile that contains the air channel opening.
3. Drag the blue arrow up 20mm.
4. Click OK to complete the extrude.
5. Continue to the next step.

The last couple steps are quick and will help smooth the mouthpiece extension.

Instructions

1. Select Fillet from the Modify menu or press F on the keyboard.
2. Select the vertical edges of the mouthpiece extension and set the fillet distance to 2mm.
3. Click OK in the Fillet dialog to compete the fillet.
4. Continue to the next step.

Let's finish up by smoothing the connection where the extension connects to the body and the top of the mouthpiece.

Instructions

1. Select Fillet from the Modify menu or press F on the keyboard.
2. Select the edges at the top and bottom of the extension.
3. Set the fillet distance to 1.5mm.
4. Click OK in the Fillet dialog to compete the fillet.
5. Continue to the next step.

Congratulation! You did it!

Try some of the ideas below to practice your new skills!

Instructions

1. Can you add your initials?
2. Can you add your school/company logo?
3. How would you customize your Fipple mouthpiece?