🧩 Building the EROS Oxygen Panel in Fusion 360 – Part 1 & 2

Karl Clarke
Sep 9, 2025
2 min read

Posted by Karl | 737DIYSIM | September 9, 2025

Hello Sim Builders!

I think we’ve just taken another massive leap forward on the 737 Sidewall project. Last night, I pulled an all-nighter at work to finish the oxygen panel, and I genuinely believe this might be a work of art. I don’t think anyone has poured this much effort into replicating the real thing.

Thanks to access to a digital scan of the real unit, I was able to understand precisely how it feels and operates. That scan made things both easier and harder! Easier because I knew where every part belonged and its precise dimensions, but harder because working with mesh data is a beast of its own.

I got so deep into the design that I clocked around 72 hours just on this single panel. Let me walk you through what’s working:

🫁 Both mask flaps open

🔘 Test switch is fully operational

🚩 Oxygen ON flag moves via a mini servo

💡 Oxygen flow light illuminates

🎛️ Mask grip simulates harness inflation

🔄 Knob rotates with built-in stops and a potentiometer

🔁 Emergency/Normal flow switch clicks into detents

This panel has been a real brain-bender, and I’ve documented the entire design process in two video parts for anyone curious (or brave enough) to follow along.

🔹 Part 1: From Scan to Sketch

In this first video, I take a digital scan of the panel and begin the design process in Fusion 360, preparing it for 3D printing. It’s a real-time walkthrough showing how I interpret the scan, build the geometry, and start shaping the part.

📺 https://www.patreon.com/posts/creating-eros-1-90000000📝 Blog: Creating the EROS Oxygen Panel from a Digital Scan in Fusion (Part 1)

🔹 Part 2: The Long Haul

This second video is a 3-hour edit of 10 hours of design work. It’s not flashy; in fact, it might be the most tedious video I’ve ever made, but it shows every step of how I got the design to work. You’ll see my thought process, problem-solving, and the final working version (minus the 9 out of 10 failed attempts I cut out).

📺 https://www.patreon.com/posts/oxygen-panel-pt2-90000001📝 Blog: Oxy2 – The Longest and Most Tedious Video Yet

🛠️ What’s Next?

Once this panel is complete, I’ll shift my focus to the front windows and overhead, and I’m genuinely excited about starting the new overhead build. Version 3 of the sim has been a huge success, and this panel is pushing my design skills to their peak in 2025.

Thanks for following along, and as always, I appreciate your support!

Kind regards, Karl