FreeCAD – Part 1: Pads & Pockets

In this lesson, we start from a completely empty FreeCAD project and begin building the first physical components of the Milly Mini AI robot.

This is our first hands-on modeling lesson. We’ll create real geometry, name and organize bodies, and use parametric workflows that mirror professional robotics design practices.

Starting a New Project

We begin by launching FreeCAD and creating a new file.

Steps covered in this lesson:

• Starting a new FreeCAD project

• Saving the file and naming it properly

• Switching to the correct workbench

• Preparing the workspace for modeling

Getting this setup right early helps keep projects clean and organized as they grow.

Creating the First Body

Next, we create our first Body, which represents a single solid object in FreeCAD.

In this step, we:

• Create a new Body

• Rename it for clarity

• Change the body color to orange

• Set transparency to 50%

Using color and transparency makes it much easier to work with multiple parts and understand how components relate to each other in a robot assembly.

Creating the First Sketch

With the Body ready, we move on to sketching.

In this lesson, we:

• Create a new Sketch

• Define a rectangular shape

• Set precise dimensions (200 x 250)

• Apply rounded corners where needed

• Ensure the sketch is fully constrained

Sketches are the foundation of parametric modeling. Accuracy here saves time later.

Extruding the Sketch (Pad)

Once the sketch is complete, we turn it into a 3D object.

Steps include:

• Creating a Pad from the sketch

• Setting the extrusion depth

• Reviewing the resulting solid

• Making adjustments as needed

This transforms the 2D sketch into a usable physical part.

Creating a Second Body Using a Shape Binder

To create a related part, we introduce a powerful FreeCAD feature:
Shape Binders.

In this lesson, we:

• Create a second Body

• Use a Shape Binder based on the first body

• Reuse geometry instead of redrawing it

• Extrude the bound sketch into a second solid

This technique keeps parts aligned and ensures design consistency across components.

Result So Far

By the end of this lesson, you will have:

• Two properly named Bodies

• Clean, parametric geometry

• Consistent dimensions between parts

• A solid foundation for building additional components

These first two bodies form the starting point for the rest of the robot design.

What’s Next

In the next lesson, we’ll continue building additional bodies and start layering the robot structure piece by piece.

Take your time here — precision matters more than speed.