How to Model a Bottle Prototype in Fusion: A Step-by-Step Surface Modeling Guide
In this tutorial, you'll learn how to create a sleek bottle prototype using surface modeling techniques in Fusion. Surface modeling gives you greater control over curves and contours—perfect for creating refined, organic shapes like bottles.
To help you learn even faster, I’ve included a link to the full video tutorial at the end. That video takes a slightly different approach to solving the same problem and is worth watching once you’ve gone through this walkthrough.
Let’s get started by following the golden rule of Fusion: create a new component.
The full video is linked at the end of the tutorial.
Step 1: Sketch the Bottle Profile
Begin with a sketch on the horizontal construction plane. Use the center diameter circle tool and place your circle directly at the origin. This keeps your model centered and symmetrical. Set the diameter to 100 mm if you'd like to match the example.
Draw a straight line through the center of the circle. Convert it into a construction line and trim one half of the circle—we’ll work on just one side and mirror it later.
Next, sketch the bottle’s profile curve using the Fit Point Spline on the vertical construction plane. Start the spline at the origin and shape it to curve upward and outward. Don’t worry about getting it perfect—the green spline handles make it easy to adjust later. In this demo, the spline extends 50 mm.
Step 2: Create the Main Surface
Use the Surface Sweep command to generate the initial surface. Select the half circle as the profile and the spline as the path. Since this is an open profile, make sure you’re using the orange surface Sweep.
Once it’s created, rotate your view using the ViewCube, and then switch to the Left view to sketch the next features.
Step 3: Add and Offset Arcs
Sketch a 3-point arc on the vertical plane so it slightly overlaps your existing surface. Use the Dimension tool if needed to dial in the curve. This arc will help define the bottle’s shape and structure.
Use the Offset tool to create a second arc, 10 mm away from the first. These two arcs will be used to shape and split the surface.
Use the Surface Extrude tool to extrude both arcs. They should extend far enough to fully pass through the existing surface. There’s no need to match the original geometry precisely—these are tools we’ll use for splitting.
Step 4: Split and Offset the Surface
Now use the Split Face command:
Set the original surface as the Face to Split.
Use the extruded arcs as the Splitting Tools.
After the split, you’ll have four surfaces. Delete the one created by the cut and hide the two extruded surfaces.
Select the smaller visible surface and Offset Face it inward by -5 mm. This will serve as the inner surface for the bottle.
Then use the Surface Loft command to connect the original surface and the offset one. Use the G0 option for a straight connection.
Step 5: Add More Cuts
Return to the Left view and create a new sketch on the vertical construction plane behind the model. Use the Project command to bring in the top edge of the model, then Offset it by 20 mm and again by 25 mm.
Extrude both offset lines using Surface Extrude, and make sure they fully intersect the model with some margin.
Attempt to Split Face using these surfaces. If you get an error, check that the extruded lines extend far enough. Adjust the sketch if needed. Once corrected, the split should work as expected.
Offset the new surface inward by -2 mm, and add a subtle 2 mm Fillet to soften the edge.
Step 6: Mirror and Close the Model
Save your work, then use box selection (click and drag left to right) to select all surface bodies.
Use the Mirror command and mirror across the central construction plane. Set the operation to Join.
To close the shape, use the Patch command to seal the top and bottom of the model. Now you have an enclosed shape.
Use Stitch to join all the surfaces into a single solid body. If everything is sealed properly, Fusion will convert it into a solid.
Step 7: Add Grip Details
Create a new sketch on the central vertical plane.
Project the edge of the solid bottle body and sketch a center diameter circle on the projected line. Set the diameter to 10 mm and position it 27 mm from the top.
Use Extrude Cut, set to Symmetric, to cut through both sides. Over-extrude to ensure it captures any changes to the bottle’s shape.
Use Pattern on Path to repeat this grip feature along the curve of the bottle. Set:
Orientation to follow path direction,
Compute Type to Optimized,
Quantity to six.
This adds both grip and flexibility to the design.
Chapters:
00:08 Create a New Component with Keyboard Shortcuts in Fusion
00:19 Start the First Sketch for the Bottle Prototype
00:30 Draw a Center Diameter Circle in Fusion
00:44 Trim the Circle to Prepare for Surface Modeling
01:05 Sketch a Path for the Sweep Command
01:27 Create and Adjust a Fit Point Spline
02:15 How to Sweep a Surface in Autodesk Fusion
02:48 Sketch the Bottle’s Profile Design
03:08 Create, Move, and Dimension a 3-Point Arc
03:46 Offset the Arc for Bottle Wall Thickness
04:08 Surface Modeling: Extrude to Create Trimming Tools
04:32 Split a Surface Model with the Split Face Tool
05:15 Use Offset Face to Push or Pull Surfaces
05:37 Loft Between Surfaces to Connect Sections
05:48 Set Curvature Types: G0, G1, and G2 Explained
06:12 Use the ViewCube and Project Geometry for New Sketches
07:05 Extrude Lines on a Surface Model
07:27 Fix a Failed Split Face Operation in Fusion
07:57 Edit Sketches via the Timeline to Update Surface Geometry
08:22 Split the Surface Body to Refine the Design
09:06 Offset Surface Faces for Thickness Adjustments
09:22 Smooth Edges with Fillet Commands in Surface Modeling
09:52 Mirror a Surface Model to Complete the Bottle Shape
10:19 Close Open Surfaces with the Patch Tool
10:44 Convert Surface Bodies into a Solid with Stitch
11:07 Add a Grip Feature to the Bottle Prototype
11:20 Project Edges Using the Projection Link Tool
11:51 Create a Symmetrical Extrude Cut
12:15 Pattern Features Along a Path in Fusion
13:15 Apply Appearances to Individual Faces for Rendering