FreeCAD Premium Tutorial: Model a Real Mechanical Part Step-by-Step (Beginner to Pro)

Welcome to the ultimate FreeCAD premium tutorial! Learn how to model a real mechanical part from scratch using advanced parametric techniques. FreeCAD is a free, open-source 3D CAD modeler perfect for engineers, hobbyists, students, and professionals. This tutorial equips you to create complex, fully functional mechanical components for production or 3D printing.

Why FreeCAD is the Best Choice

FreeCAD interface overview with toolbars and workspace

  • Free and Open-Source: No licensing costs.
  • Parametric Modeling: Modify dimensions and features easily without breaking the model.
  • Versatile: Supports mechanical design, assemblies, FEM simulation, and CAM workflows.
  • Active Community: Extensive tutorials, forums, and add-ons.
  • Export Options: STEP, IGES, STL, DXF, SVG for manufacturing or 3D printing.

Step 1: Installing FreeCAD and Configuring the Workspace

FreeCAD installation and workspace configuration steps



  • Download the latest FreeCAD version from official site.
  • Set preferred units: millimeters, inches, or centimeters.
  • Choose default workbench; for this tutorial, use Part Design.
  • Create a Body for organized parametric modeling.
  • Enable grid and snapping for precise sketching.

Step 2: Planning Your Mechanical Part

Sketch plan showing dimensions, holes, and features of a mechanical part

  • Identify key dimensions: length, width, height, diameters, thickness.
  • Determine critical features: holes, slots, pockets, fillets, chamfers.
  • Plan symmetry and patterns for repeated elements.
  • Consider manufacturing or 3D printing constraints.

Step 3: Creating the Base Sketch

FreeCAD base sketch with lines, arcs, circles and constraints applied


  • Select a plane: XY, XZ, or YZ.
  • Draw lines, arcs, circles, and rectangles using Sketcher tools.
  • Apply constraints: horizontal, vertical, perpendicular, coincident, and dimensional.
  • Ensure the sketch is fully constrained to avoid errors.
  • Name each sketch clearly for easy identification.

Step 4: Extruding the Sketch (Pad)

Applying Pad feature to convert 2D sketch into 3D solid in FreeCAD
  • Select the sketch and click Pad.
  • Set length, direction, and optional symmetry.
  • For complex parts, use multiple pads sequentially.
  • Tip: Use parametric expressions for pad lengths to allow easy adjustments.

Step 5: Adding Features (Holes, Pockets, Slots)

Adding holes, pockets, and slots to FreeCAD 3D part
  • Create new sketches on relevant faces.
  • Use Hole tool for circular or threaded holes.
  • Pockets remove material; adjust depth carefully.
  • Use Mirror or Pattern for symmetric or repeated features.
  • Tip: Use construction lines for precise alignment of holes and slots.

Step 6: Fillets, Chamfers, and Edge Treatments

Applying fillets and chamfers on edges of FreeCAD part for better design
  • Fillets: round sharp edges to reduce stress.
  • Chamfers: bevel edges for assembly or aesthetics.
  • Tip: Use parametric values to allow easy future adjustments.

Step 7: Advanced Parametric Techniques

Using parametric expressions and reference geometry in FreeCAD
  • Reference planes, axes, and points help align features accurately.
  • Use formulas to link multiple dimensions for dynamic parts.
  • Monitor over-constrained sketches to prevent errors.
  • Save incremental versions for complex projects.

Step 8: Organizing the Model Tree

  • Name sketches and features clearly.
  • Group related features using folders for clarity.
  • Use color or labels for part sections if needed.

Step 9: Exporting and Preparing for Manufacturing or 3D Printing

  • STEP/IGES: CAD interoperability and CNC production.
  • STL: 3D printing.
  • DXF: laser cutting or 2D fabrication.
  • Tip: Always double-check tolerances before export.

Step 10: Full Mechanical Part Example

Completed FreeCAD mechanical part example showing all features and details
  • Create a master sketch with all key dimensions.
  • Add the main pad for thickness.
  • Create pockets for movement and holes.
  • Add fillets and chamfers for strength and assembly.
  • Mirror features for symmetry.
  • Export as STEP for CNC or STL for 3D printing.

Step 11: Pro Tips for Advanced Users

  • Link multiple features using parametric equations.
  • Apply geometric constraints smartly to reduce errors.
  • Use the Assembly Workbench for multi-part designs.
  • Use TechDraw Workbench for production-ready drawings.

Step 12: Troubleshooting Common Issues

  • Sketch fails to pad? Check for under-constrained elements.
  • Over-constrained error? Remove unnecessary constraints.
  • Part deforms unexpectedly? Ensure sketches are fully constrained and feature order is correct.
  • Tip: Monitor the model tree for hidden issues.

Step 13: FAQ

  • Q: Can FreeCAD be used professionally?
    A: Yes, it supports parametric modeling, assemblies, FEM, and CAM.
  • Q: Is FreeCAD beginner-friendly?
    A: Yes, with tutorials and community support.
  • Q: Can I export to other CAD programs?
    A: Yes, STEP or IGES are widely compatible.
  • Q: Can I design for 3D printing?
    A: Yes, export to STL and check tolerances.

Step 14: Additional Learning Resources

Conclusion and Call to Action

This premium FreeCAD tutorial covers installation, sketches, 3D features, parametric techniques, and creating fully functional mechanical parts. Practice regularly and use this guide as a reference for professional-level CAD modeling.