How to Model a Beer Bottle Cap in SolidWorks (Quick and Easy Tutorial)

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In this tutorial, you will learn how to model a realistic beer bottle cap in SolidWorks. This exercise demonstrates sketching, revolve, multi-radius fillets, lofts, circular patterns, and shelling. A great practice for beginners exploring plastic or sheet metal cap designs.↳

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Downloads

👉 Download the SolidWorks Part File (2023.SLDPRT)
👉 Download STEP File (.STEP)↳

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Skills You Will Practice

• Creating precise revolved profiles with sketch dimensions

• Applying multi-radius fillets for smooth transitions↳

• Using Loft feature with split arcs↳

• Applying Circular Pattern for repeating features

• Shelling thin-walled parts for plastic design

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Step-by-Step Instructions

1. Front Plane Sketch

• On the Front Plane, draw the bottle cap profile.

• Use Smart Dimensions (25, 27) with vertical line and centerline.↳

• Move mouse to left side of centerline to constrain.

  
  
  

2. Revolve

• Perform Revolve Boss/Base to form the basic cap shape.

  
  
  

3. Multi-Radius Fillets

• Apply Multi-radius Fillet, radii = 2 mm and 3 mm.

  
  
  

4. Top Plane Sketch

• On Top Plane, sketch and Convert Entities from existing edges.

• Trim circle, add Midpoint relation, and apply fillet radius = 0.5 mm.

  
  
  
  
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5. Create Reference Plane

• Create a new Plane, offset = 3.5 mm from Top Plane.

  
  
  

6. Sketch on Plane 1

• Sketch geometry using Convert Entities from circle or arc below.

• Draw vertical line, trim the circle.

  
  
  
  
  

7. Loft Feature

• Attempt a Loft between top and bottom sketches.

• Start constraint: Normal to Profile.

• Check Merge Tangent Faces.

  
  
  

8. Fillets

• Add fillets radius = 0.5 mm to edges.

  
  
  

9. Circular Pattern

• Apply Circular Pattern with 2 features, quantity = 18.

• ⚠ Do not check Bodies Pattern, otherwise shell will fail.

  
  
  
  
  

10. Shell

• Use Shell with thickness = 0.1 mm.

  
  
  
  
  

11. Final Model

• The beer bottle cap is now complete!

  
  
  

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Tips

💡 Use Split Entities when lofting between different arc conditions.
💡 Always choose Feature Pattern instead of Body Pattern to ensure compatibility with shell.
💡 Thin shells (0.1 mm) are common in bottle cap design, but adjust based on manufacturing process.

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Related Exercises

How to Model a Complex Patterned Part in SolidWorks (Step-by-Step Tutorial)

How to Connect Rectangular Tubes in SolidWorks

How to Model a Squatting Chair in SolidWorks (Step-by-Step Tutorial)