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Mechanical Design
Personal Engineering Project

Engine Cylinder Cover — Cast Part Study

An engine cylinder cover modelled the way a foundry would want it — drafted walls, generous radii, bolt flanges and a ported housing, built from a clean, readable feature tree.

Type
Personal practice project
Location
Kampala, Uganda
Year
2026
Turnaround
7 days
Before / After

From rough idea to production-ready

Before — initial concept sketch for Engine Cylinder Cover — Cast Part Study, Mechanical Design project by DesignForge UgandaBefore
Isometric pencil sketch of the cover with ports and mounting flanges.
After — finished CAD design of Engine Cylinder Cover — Cast Part Study, Mechanical Design project by DesignForge UgandaAfter
The finished SolidWorks part — layered boss-extrudes, revolves, fillets and linear patterns in a fully editable feature tree.
The Challenge

What needed to be designed

Cast parts fail on the details: no draft, sharp internal corners, or walls that would never fill. Every face had to stay pull-able from one parting direction while the model kept a feature tree someone else could actually edit.

The Approach

How DesignForge approached it

  1. 1

    Set the parting direction first, then built the main body with draft applied from the very first boss-extrude.

  2. 2

    Layered revolved bosses for the ports and cylindrical housings, keeping wall thickness consistent throughout.

  3. 3

    Added bolt flanges and pads with linear patterns so hole pitch stays parametric.

  4. 4

    Checked the result with section views and a draft analysis before finishing the model.

The Deliverable

What was produced

The finished SolidWorks part — layered boss-extrudes, revolves, fillets and linear patterns in a fully editable feature tree.

Tools

Software and capabilities used

  • Cast Part Design
  • Draft & Fillets
  • Boss-Extrude / Revolve Features
  • Section Views
Skills Demonstrated

What this project put into practice

Design for casting

Skill practised

Single parting direction

Draft

Fully editable

Feature tree

Draft + section analysis

Validation

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