# Onshape Walkthrough — Override Game Elements (Print Version)

**Goal:** Build placeholder CAD of the Override game elements (cup, pin, goals, toggle) in Onshape for Hero Bot fitment testing and assembly visualization.

**Deliverables:** STEP files for each element, suitable for chassis-fitment work and design reviews. Not authoritative for stress analysis or competition-legal duplication.

**Estimated time:** ~50 minutes total — Cup 10 min, Pin 15 min, Goals 20 min for all 3, Toggle 5 min.

**Audience:** Spartan Design vets and league rookies with Onshape Part Studio basics (sketch, dimension, revolve, extrude, loft, export STEP).

**Companion site page:** [/onshape-game-elements](https://spartandesignrobotics.org/onshape-game-elements) — same content with interactive section navigation, inline 2D profile SVGs, and links to deep-dive guides.

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## Why This Walkthrough Builds Placeholders, Not Authoritative CAD

The Override v0.1 game manual (April 27, 2026) gives partial dimensions for each element in Appendix A. Some dimensions are missing. You'll estimate the rest. The result is good enough for "does my manipulator clear the cup at the top of the goal?" but not for stress analysis or competition-legal duplication.

**When VEX publishes official element CAD** on `vexrobotics.com/v5/competition/vrc-current-game` (typically 1–2 weeks after manual drop), import that and retire these placeholders. Your team will own the placeholder, but you should know its limits.

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## The Workflow (Same for Every Element)

Whether the element is a cup (revolve), a pin (stacked extrude), a goal (extrude with hole), or a toggle (extrude prism), the workflow is the same five-step pattern:

1. **Sketch the 2D profile on the right plane.** Front plane for revolves, Top plane for extrudes.
2. **Apply dimensions** until the sketch is fully defined (Onshape turns it black when fully defined).
3. **Run the operation** — revolve, extrude, or loft.
4. **Verify dimensions with the Measure tool** before export.
5. **Export STEP** in millimeters and document in the engineering notebook.

**Why 2D first?** The 2D sketch lets you sanity-check dimensions before committing to a 3D operation. Mistakes are cheaper to fix in a 2D sketch than in an extruded solid. The manual's Appendix A drawings ARE 2D profiles — reading them and reproducing them as Onshape sketches is the same skill.

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## Element 1 — Cup

**Manual reference:** Appendix A Figure A6 (page 102).

### Verified vs. Estimated Dimensions

| Dimension | Value | Source |
|---|---|---|
| Top opening diameter | 80.2 mm (Ø3.16″) | Manual Fig A6 |
| Waist diameter | 59.0 mm (Ø2.32″) | Manual Fig A6 |
| Total height | 164.5 mm (6.48″) | Manual Fig A6 |
| Waist Y-position | 55 mm above base | **Estimated** |
| Bottom diameter | 80 mm | **Estimated** |
| Wall thickness | 2.5 mm | **Estimated** |

### Onshape Steps (10 minutes)

1. **Create document.** New document → name it `Override_Cup_Placeholder_v1` → open Part Studio.
2. **Sketch on Front plane.** Click Front plane → Sketch (S key). Draw the right half of the cup outline with a vertical centerline along the Y-axis.
3. **Apply dimensions.**
   - Vertical axis line: 164.5 mm
   - Bottom horizontal: 40 mm
   - Top horizontal: 40.1 mm
   - Waist Y-position: 55 mm
   - Waist X-position: 29.5 mm
4. **Revolve 360°.** Exit sketch → Revolve → select sketch region as face, vertical axis line as axis, type Full.
5. **Shell to hollow.** Shell tool → select top circular face to remove → thickness 2.5 mm → direction inward.
6. **Verify with Measure.** Confirm top OD = 80.2 mm, waist OD = 59 mm, total height = 164.5 mm.
7. **Export STEP.** Right-click part → Export → STEP → Millimeter → `Override_Cup_Placeholder_v1.step`.

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## Element 2 — Pin

**Manual reference:** Appendix A Figure A5 (page 101).

### Verified vs. Estimated Dimensions

| Dimension | Value | Source |
|---|---|---|
| Top hex flat-to-flat | 80.3 mm (Ø3.16″) | Manual Fig A5 |
| Mid taper diameter | 59.6 mm (Ø2.35″) | Manual Fig A5 |
| Bottom hex flat-to-flat | 35.6 mm (Ø1.40″) | Manual Fig A5 |
| Total height | 165 mm (6.50″) | Manual Fig A5 |
| Taper section height | 74.5 mm (2.93″) | Manual Fig A5 |
| Bottom flange height | 16.2 mm (0.64″) | Manual Fig A5 |
| Top hex section height | 74.3 mm | Computed: 165 − 74.5 − 16.2 |

### Two Build Methods

Pins aren't radially symmetric (they're hex), so a simple revolve doesn't produce the right shape. Two practical approaches:

- **Method A (preferred):** stacked extrudes + loft. Three operations: extrude bottom flange, loft tapered middle, extrude top section. Result: accurate hex prism.
- **Method B (faster, less accurate):** revolve approximation. Sketch a cup-style half-profile and revolve. Result is a tapered cylinder, not a hex prism. Good for fitment, not for orientation-sensitive interactions.

### Onshape Steps (Method A, 15 minutes)

1. **Create document.** New document `Override_Pin_Placeholder_v1` → Part Studio.
2. **Sketch the bottom hex.** Sketch on Top plane → Polygon (regular) → 6 sides → flat-to-flat 35.6 mm.
3. **Extrude the bottom flange.** Exit sketch → Extrude → Blind, depth 16.2 mm → New solid.
4. **Sketch the lower loft profile.** On the top face of the flange → sketch hex flat-to-flat 80.3 mm.
5. **Sketch the upper loft profile.** Create a parallel plane offset 74.5 mm above → sketch hex flat-to-flat 80.3 mm. (For visible taper, offset the upper hex by ~5 mm and adjust.)
6. **Loft.** Loft tool → select lower hex as profile 1, upper hex as profile 2 → Add to existing solid.
7. **Extrude the top section.** Sketch on top face → hex flat-to-flat 80.3 mm → Extrude Blind 74.3 mm.
8. **Combine, verify, export STEP.** Boolean Union if needed → Measure → Export `Override_Pin_Placeholder_v1.step`.

**Note on bicolor pins:** real Override pins are bicolor (red/yellow, blue/yellow, yellow/yellow, red/blue per Manual SC2). The placeholder is single-color — fine for fitment work. Color-coding can be added in Onshape part appearance settings or saved for V2.

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## Element 3 — Goals (3 sizes)

**Manual reference:** Appendix A Figure A7 (page 103).

### Verified Dimensions

| Dimension | Value | Source |
|---|---|---|
| Base square side | 142.5 mm (5.61″) | Manual Fig A7 |
| Top square side | 88.8 mm (3.49″) | Manual Fig A7 |
| Corner radius | 81.9 mm (R3.22″) | Manual Fig A7 |
| Receptacle hole diameter | 60.1 mm (Ø2.37″) | Manual Fig A7 |
| Alliance goal height | 82.5 mm (3.25″) | Manual Fig A7 |
| Short neutral height | 146.5 mm (5.77″) | Manual Fig A7 |
| Tall center height | 222.7 mm (8.77″) | Manual Fig A7 |
| Top cap thickness | 37.8 mm (1.49″) | Manual Fig A7 |

### Field Quantities

The field has **9 goals total**: 4 alliance-colored (2 red, 2 blue), 4 short neutrals (one per quadrant), 1 tall center neutral. All 9 goals have AprilTags on their bases.

Build the alliance goal first, then duplicate for the other two heights.

### Onshape Steps (20 minutes for all 3)

1. **Create document and base sketch.** New document `Override_Goal_Alliance_v1` → Part Studio. Sketch on Top plane → 142.5 mm square centered on origin → Fillet R81.9 mm at each corner. (This radius is larger than the square's half-side, so corners blend into a near-circular shape — that's correct.)
2. **Extrude the base footprint.** Exit sketch → Extrude → Blind, depth 10 mm → New solid.
3. **Sketch the top profile.** Create a plane offset 72.5 mm above the Top plane (alliance: 82.5 − 10 mm base layer). Sketch a square 88.8 mm with R81.9 corners.
4. **Loft from base to top.** Loft between the bottom-face profile and the upper square sketch. This creates the trapezoidal frustum.
5. **Cut the receptacle hole.** Sketch on top face → circle Ø60.1 mm centered on origin → Extrude → Operation Remove → Through all (or 37.8 mm depth).
6. **Duplicate for short neutral and tall center.** Either duplicate the document and edit the offset plane to 136.5 mm or 212.7 mm, or use Onshape configurations to parameterize the height.

Export each as STEP: `Override_Goal_Alliance_v1.step`, `Override_Goal_ShortNeutral_v1.step`, `Override_Goal_TallCenter_v1.step`.

**Goal positioning matters for fitment.** When importing into your Hero Bot assembly, place the goals at expected match locations (use the field overview from Manual Figure A10 for spacing). The 18″ midfield height limit (SG12) only applies in the last 10 seconds — before that, your manipulator must reach all 3 goal heights including the 222.7 mm tall center. Verify clearance.

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## Element 4 — Toggle

**Manual reference:** Appendix A Figure A8 (page 104).

### Verified Dimensions

| Dimension | Value | Source |
|---|---|---|
| Triangle height | 51.6 mm (2.03″) | Manual Fig A8 |
| Triangle base width | 30.2 mm (1.19″) | Manual Fig A8 |
| Extrude length | 660.2 mm (25.99″) | Manual Fig A8 |
| Field count | 4 toggles per field | Manual SC5 |
| Mount | One per perimeter side | Manual Fig A8 |

### Onshape Steps (5 minutes)

1. **Create document and triangle sketch.** New document `Override_Toggle_Placeholder_v1` → Part Studio. Sketch on Front plane → isosceles triangle with base 30.2 mm wide along X-axis, apex 51.6 mm above the base midpoint.
2. **Extrude 660.2 mm.** Exit sketch → Extrude → Blind, depth 660.2 mm.
3. **Verify and consider rounded corners.** Use Measure to confirm dimensions. Real toggles have ~5 mm fillets on long edges; placeholder can be sharp.
4. **Export STEP** as `Override_Toggle_Placeholder_v1.step`.

**Why toggles matter strategically.** Each toggle controls yellow-pin scoring in its quadrant. With 39 yellow pins on the field (62% of all pins), toggle control is a major scoring lever. For CAD purposes: toggles are mostly relevant for drive-contact checks if your team plans to flip them mechanically. See the [override-toggle-strategy](https://spartandesignrobotics.org/override-toggle-strategy) page for the full scoring math.

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## Hero Bot Assembly

Your Hero Bot assembly is where the manipulator, drivetrain, and game elements come together. It answers questions you can't answer from individual part files:

- Does the manipulator clear the cup at the top of the tall center goal (222.7 mm + cup height)?
- Does the gripper open wide enough to capture an 80 mm cup OD?
- Is the chassis low enough to fit under the midfield boundary at ≤18″ (457 mm) for the endgame?
- Does the manipulator interfere with itself when it tries to flip cup orientation?

### Assembly Workflow

1. **Create the assembly.** In your team's Hero Bot Onshape document → Insert tab → New Assembly → name it `HeroBot_V1_Assembly`.
2. **Insert Hero Bot parts.** Insert drivetrain and manipulator parts. Mate them with Fastened mates.
3. **Insert game elements.** Insert the cup, pin, and at least one alliance goal from the STEP files. Position at expected match locations.
4. **Run the manipulator through its range of motion.** Use Mate values to drive the manipulator's revolute joints through full angle range. Watch for collisions.
5. **Check critical clearances.** For each goal size (alliance 82.5 mm, short neutral 146.5 mm, tall center 222.7 mm), confirm reach and 5–10 mm clearance at placement.

The 18″ midfield height limit only applies in the last 10 seconds (SG12). During the rest of the match, your robot can be tall — up to the 50″ vertical expansion limit. Don't over-constrain your manipulator height for normal scoring; just make sure it can collapse to ≤18″ at endgame.

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## Engineering Notebook Documentation

For each element you CAD, your notebook entry should include:

- **Why this CAD exists.** "Placeholder for chassis-fitment testing in HeroBot_V1_Assembly."
- **Verified vs. estimated dimensions table.** Reproduce the dim tables above with checkmarks for what your team measured and what you estimated.
- **The Onshape document URL.** Anyone on the team should be able to open and edit it.
- **Verification checks.** Bounding-box measurements you confirmed, with screenshots.
- **What you'd swap for.** "Replace with VEX official element CAD when published on vexrobotics.com."

This is orange-EDP (Build & Program) content. See [build-log-entry](https://spartandesignrobotics.org/build-log-entry) for the entry format.

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## When to Replace These Placeholders

Three triggers:

1. **VEX publishes official Override CAD** on `vexrobotics.com/v5/competition/vrc-current-game`. Authoritative. Replace immediately.
2. **Your team's actual measurements** show a placeholder is meaningfully wrong (e.g., the real cup waist is at 70 mm, not 55 mm).
3. **A new manual version** revises any verified dimensions. Manual v1.1 is expected August 13, 2026.

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## Related Site Pages

- [/spartan-hero-bot](https://spartandesignrobotics.org/spartan-hero-bot) — V1 Hero Bot spec these elements get assembled with
- [/mechanism-claw](https://spartandesignrobotics.org/mechanism-claw) — manipulator architecture decision matrix; references cup and pin geometry
- [/onshape-mechanism](https://spartandesignrobotics.org/onshape-mechanism) — general mechanism CAD workflow
- [/override-manual-summary](https://spartandesignrobotics.org/override-manual-summary) — full manual summary with field dimensions
- [/onshape-game-elements](https://spartandesignrobotics.org/onshape-game-elements) — interactive site version of this walkthrough

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**EN4 reminder:** RECF EN4 prohibits AI-generated content in engineering notebooks and programming code. If you used this walkthrough as reference, write your notebook entries in your own words, including the dimensions tables and Onshape step descriptions.