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PRP  
#1 Posted : Wednesday, June 17, 2015 6:23:46 PM(UTC)
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Are there any methods to use the 'thicken solid' tool on a complex surface so that the resulting part has a constant thickness, common requirement for molded plastic parts?

My surface is very complex in 3 dimensions and results in a variety of error messages. No doubt I have curvature radii less than the desired thickness of the solid. All features have typical draft as required in molding the part.

Thanks,

Paul


MacPro, ViaCad Pro 9, Shark LT 8
Tim Olson  
#2 Posted : Thursday, June 18, 2015 1:24:20 PM(UTC)
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Hi Paul

Have you tried a negative thickness? I first try positive then negative on complex surfaces.

Are you able to offset the surface?

Tim

Edited by user Thursday, June 18, 2015 1:29:43 PM(UTC)  | Reason: Not specified

Tim Olson
IMSI Design/Encore
PRP  
#3 Posted : Friday, June 19, 2015 11:07:45 AM(UTC)
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Hi Tim,

This is a very complex surface. It's made from about 32 control point splines, straight lines, and interpolate splines using skin surface. I can get offset edges but not offset surface positive or negative (except once partial offset surface, jpg attached) nor positive or negative thicken solid. Three jpgs are attached to show the complexity of the surface. The file size with just the surface is less than 1MB. All the profiles have the same 'direction'.

To create a 0.060 thick part I have to copy of the profiles and move down 0.060 and then adjust each profile in many directions to avoid thin or thick areas of the part (several hours at least).

Edited by user Friday, June 19, 2015 11:23:31 AM(UTC)  | Reason: Not specified

PRP  
#4 Posted : Friday, June 19, 2015 11:11:27 AM(UTC)
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Here are the attachments…

Edited by user Friday, June 19, 2015 11:24:44 AM(UTC)  | Reason: Not specified

File Attachment(s):
Surface Test 2.slt (3,499kb) downloaded 10 time(s).
PRP attached the following image(s):
Partial offset surface.JPG (102kb) downloaded 8 time(s).
surface with profiles.JPG (256kb) downloaded 10 time(s).

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Tim Olson  
#5 Posted : Saturday, June 20, 2015 5:50:19 PM(UTC)
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Paul
Would an approximation work?
Tim
Tim Olson
IMSI Design/Encore
PRP  
#6 Posted : Saturday, June 20, 2015 7:26:24 PM(UTC)
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Hi Tim,

Yes, an approximation might work, to the extent that molded plastic parts like constant wall thicknesses. What do you have in mind? Somehow going to meshes and back? I've done many 3D prints (stl files) on this as it has evolved. Attached is my latest surface, an even more ridiculous surface… Oops, can't seem to upload, file size is 7.3MB, the surface alone.

Uploaded an IGIS file of the surface.

Thanks so much,

Paul

Edited by user Sunday, June 21, 2015 7:27:12 AM(UTC)  | Reason: Not specified

File Attachment(s):
ML41-45.igs (3,592kb) downloaded 9 time(s).
PRP attached the following image(s):
Screen Shot 2015-06-20 at 6.29.08 PM.JPG (165kb) downloaded 9 time(s).

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Tim Olson  
#7 Posted : Monday, June 22, 2015 3:53:31 PM(UTC)
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Hi Paul

So I don't think it mathematically possible to precisely offset this surface into a single G2 surface at 0.06. It self intersects. That is why in some offset cases you are only getting a partial surface.

I used a command in PowerPack to create a grid surface from a reference surface. I used a 40 x 40 grid. It more or less rebuilds the surface to a grid resolution you specify. The more grids the closer it is to the original surface so this is a loose approximation.

I then offset the approximated grid surface -0.06, added ruled surfaces to the edges, and then stitched into a solid which is attached.

This was using the .slt file you attached. Not sure how valid this file is for your task as it took liberty with the constant wall thickness tolerance.


Tim

Edited by user Monday, June 22, 2015 3:55:33 PM(UTC)  | Reason: Not specified

File Attachment(s):
SurfaceThick.vcp (2,335kb) downloaded 8 time(s).

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Tim Olson
IMSI Design/Encore
PRP  
#8 Posted : Monday, June 22, 2015 5:55:55 PM(UTC)
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Hi Tim,

Thanks for all of your attention to this issue!

Unfortunately I think the grid pattern results in much the same solid as copy/paste a 2nd surface 0.060 below the first, creating Offset Face Edges close to the edges (0.001") giving 8 edges, Then doing Skin Surface for each pair of edges leading then to 6 surfaces that Stitch into a solid.

But inspecting the solid, you get very thin and some very thick wall thicknesses in both x and y directions. Note the attached jpgs of "Viewport Layouts/Two" with two infinite planes used as clip planes to inspect the wall thickness. I move both infinite planes through the device and get results seen, shown at a particularly troublesome cross-section that can't even be 3D printed.

That is my basic approach, but instead I copy/paste my profiles down 0.060" and shift them in one direction, then cut each lower profile many times and move the pieces in/out and rejoin, to try to get an approximate 0.060 thickness along the normal vectors throughout, then do a skin surface for the lower surface (all extremely time consuming). But in this way I avoid large wall thickness variations.

I'm looking into now trying a thin "Thicken Solid" such as -0.003", getting an under-surface from that to do the same, do this 20x and then Add Solid 20x., but may have to go thinner yet ….

Thanks again for the interest, I'm sure many plastics molder folks are interested. Also those designing things such as automobile shells, etc. I'd be interested in those doing boat shells and their methods, although those surfaces don't have the extreme shapes I have.

Paul
PRP attached the following image(s):
Clip planes.JPG (34kb) downloaded 5 time(s).
Thin spot.JPG (53kb) downloaded 5 time(s).

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Tim Olson  
#9 Posted : Tuesday, June 23, 2015 1:06:52 PM(UTC)
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[ Unfortunately I think the grid pattern results in much the same solid

Yikes, the cross section is revealing!


>>I'm looking into now trying a thin "Thicken Solid" such as -0.003", getting an under-surface from that to do the same, do this 20x and then Add Solid 20x., but may have to go thinner yet ….

Very interesting. Let me know how that goes, maybe something I could automate.

Tim
Tim Olson
IMSI Design/Encore
thanks 1 user thanked Tim Olson for this useful post.
PRP on 6/24/2015(UTC)
PRP  
#10 Posted : Wednesday, June 24, 2015 1:46:09 PM(UTC)
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Thanks again Tim,

0.003 thicken solid crashed, but 0.001 resulted in a solid. Probably unrealistic to do 60X because the thicken solid took several minutes. Too bad we can't use 6 processors, 5 of which are just watching..

Paul
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