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Sydney, Australia  26 August 2016 - CADDIT announces the simultaneous release of two products: CADprofi for progeCAD 2017 x64 and major progeCAD update 17.0.6.15 for immediate download on CADDIT.net or CADDIT.com.au.CADprofi 12 is a brand new release, now supporting the latest version of progeCAD Professional. progeCAD is a powerful low cost AutoCAD alternative for Windows offering perpetual license, similar commands and interface. progeCAD 17.0.6.15 is an important update including dozens of improvements in areas of user interface, developers API and other aspects.

CADprofi 12 is a full-feature 2D/3D MEP add-on module set for progeCAD 2017 Professional. Each module specializes in major areas of building design: Electrical installation design, HVAC ductwork and hydraulic plumbing systems, Architectural details and Mechanical assembly design. Each module adds domain-specific knowledge to progeCAD's general-purpose CAD environment. CADprofi is also supported on AutoCAD and AutoCAD LT.



The progeCAD 2017 enhancements include many fixes:
- Fixed FLATSHOT and SOLPROF to generate complete projections and create arcs and circles (not elliptical)
- Fixed usage of custom paper size such with HP 500 plotters
- Fixed crash in NVidia Quadro driver
- Fixed crashes using crash reports
- Fixed error using PC3 referring to an unavailable plotter
- Fixed OVERKILL performance
- Fixed regen of blocks after layer thaw
- Fixed deadlock in property palette refresh switching layout
- Fixed SWEEP command in surface mode with closed object
- Fixed direction of extrusion of BOX command
- Fixed set of FONTALT variable for eastern asian languages
- Fixed -ARRAY command with localized default options
- Fixed preview of create table dialog
- Fixed hide of ANNOALLSCALE and ANNOALLVISIBLE status bar panes
- Fixed resize of LAYWALK dialog
- Fixed crash grid zooming out to infinite
- Fixed COPYTOLAYER to show layer dcl
- Fixed second level flyout size
- Fixed crash setting transparency to plot
- Fixed erase of layer DEFPOINTS from layer palette
- Fixed localization of some messages in BOUNDARY command
- Fixed button to choose block destination in FLATSHOT command
- Fixed SECTION command in NWUCS
- Fixed brkline.dwg to avoid warning message in BREAKLINE command
- Fixed elliptical cone option
- Fixed DWGTITLED, DWGPREFIX and last used path after vba SAVEAS
- Fixed Circle 3P option with esnap TAN+TAN+point
- Fixed position of some controls in layer walk dialog
- Fixed HATCH boundary in a drawing
- Fixed TCASE with multiline MTEXT entity
- Fixed crash using TEXTMASK with solid mask
- Fixed rename ribbon tab title.
- Fixed crash in layer palette
- Fixed x64 issues in layer palette
- Develop VBA: Fixed export command called from vba
- Develop VBA: Fixed PrintPreview method of Document object in VBA, now it takes current layout settings
- Develop VBA: Restored StartUp VBA event
- Develop VBA: Fixed Explode method of ActiveX 3dPolyline and Region
- Develop LISP: Fixed lisp fill_image with negative colors and DCL aspect_ratio attribute
- Develop LISP: Fixed COPY command called from lisp or script to ignore multiple mode
---------
Other :
---------
- Changed "read-only" message to System modal
- Removed ESNAP, DYNUCS and SNAP during dragging of entities
- Enlarged buttons in customize dialog
- Added resource to translate Region entity name in QSELECT dialog
- Removed question on OPEN command reopening a currently opened drawing
- Removed "Protect password" checkbox from save dialog
- Changed double click action on MText to start DDEDIT instead of MTEDIT

progeCAD 2017.0.6.15 is a free update for all existing progeCAD 2017 customers and it is highly recommended that users update to this version. For users of ealier versions of progeCAD they can select the appropriate upgrade product from our webstore. A free trial version of progeCAD 2017 (x64 and 32-bit architectures) can be downloaded from this page. CADprofi can be downloaded from CADDIT.net here. Addtional questions regarding CADprofi or progeCAD software can be submitted via the CADDIT contact page.
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Geomagic Design X Basic Training 2016 - English.pdf

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Revision Date: April 2016

Proprietary and Restricted Rights Notice Information within this document is subject to change without notice. No part of this documentation may be reproduced in any form or by any means including photocopying, recording or microfilming or by any information storage and retrieval system including a web site, without written permission of 3D Systems. No liability is assumed by 3D Systems with respect to the use of the information contain herein. While every precaution has been taken in the preparation of this documentation, 3D Systems assumes no responsibility for errors or omissions that may appear in this document. References in this document do not constitute an endorsement of any products or services. © 1996-2015 3D Systems All rights reserved Geomagic Solutions, Geomagic, the Geomagic logo, Geomagic Verify, Geomagic Control, Geomagic Design X, Geomagic Design Direct, Geomagic Design, Geomagic Studio, Geomagic XOS, Geomagic Wrap, Geomagic Freeform, Geomagic Freeform Plus, Geomagic Touch, Geomagic Touch X, Geomagic Phantom Premium, and Geomagic Claytools are either trademarks or registered trademarks of 3D Systems. All other company and product names referenced herein are trademarks or registered trademarks of their respective owners.

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About Us 3D Systems is a leading global provider of 3D content-to-print solutions including 3D printers, print materials and on-demand custom parts services for professionals and consumers alike. The company also provides CAD modeling, reverse engineering and inspection software tools and consumer 3D printers, apps and services. Its expertly integrated solutions replace and complement traditional methods and reduce the time and cost of designing and manufacturing new products. 3D Systems’ products and services are used to rapidly design, communicate, prototype or produce real functional parts, empowering customers to create and make with confidence. More information on the company is available at www.3DSystems.com

Contact Information 3D Systems - Geomagic Solutions 1001 Winstead Dr, Suite 400 Cary, NC 27560, USA Phone: +1 (800) 691-1839 or +1 (919) 474-0122 Fax: +1 (919) 474-0216 Web Sites: Geomagic Solutions Technical Support

http://www.3DSystems.com http://support.geomagic.com

Email Addresses: Technical Support Training

[email protected][email protected]

.

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Contents Introduction ..................................................................................................................................................... 7 Overview .................................................................................................................................................................. 7 Intended Audience ................................................................................................................................................... 7 Prerequisites............................................................................................................................................................. 7 Guide Length ............................................................................................................................................................ 7 Guide Conventions ................................................................................................................................................... 7 Graphical User Interface ................................................................................................................................... 8 ACTIVITY: Getting Started .................................................................................................................................... 8 Ribbon ...................................................................................................................................................................... 9 Upper-Side Toolbar ................................................................................................................................................ 11 Navigation & Selection ................................................................................................................................... 13 Mouse Commands.................................................................................................................................................. 13 ACTIVITY: Using the Mouse ................................................................................................................................ 13 Docks ............................................................................................................................................................. 17 Tree Dock Group .................................................................................................................................................... 17 ACTIVITY: Tree Management ............................................................................................................................. 17 Accuracy Analyzer™ and Properties ....................................................................................................................... 22 ACTIVITY: Check accuracy and properties of a model ....................................................................................... 22 Bottom Toolbar.............................................................................................................................................. 24 Dialogs........................................................................................................................................................... 25 Context Menus .............................................................................................................................................. 26 User Interface Context Menu ................................................................................................................................. 26 Model View Context Menu .................................................................................................................................... 26 Tree Context Menu ................................................................................................................................................ 27 Data Types ..................................................................................................................................................... 28 Point Data ............................................................................................................................................................... 28 Mesh Data .............................................................................................................................................................. 28 CAD Data ................................................................................................................................................................ 29 Scan Preparation ............................................................................................................................................ 30 Overview ................................................................................................................................................................ 30 Mesh Buildup Wizard ............................................................................................................................................. 30 ACTIVITY: Mesh Buildup Wizard ........................................................................................................................ 30 Mesh/Polygon Editing ............................................................................................................................................ 35 ACTIVITY: Clean up mesh data ........................................................................................................................... 35 Auto Surface ........................................................................................................................................................... 42 ACTIVITY: Generate CAD Body ........................................................................................................................... 42 Regions .......................................................................................................................................................... 46 ACTIVITY: Understanding Regions ..................................................................................................................... 46 Align to Coordinate System ............................................................................................................................ 49 ACTIVITY: 3-2-1 Alignment using Regions .......................................................................................................... 49 ACTIVITY: 3-2-1 Alignment using Reference Geometry ..................................................................................... 51 ACTIVITY: XYZ Alignment.................................................................................................................................... 54 2016 3D Systems

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ACTIVITY: Scan to CAD Alignment ...................................................................................................................... 56 Parametric Modeling ...................................................................................................................................... 58 ACTIVITY: Introduction to Sketching .................................................................................................................. 58 ACTIVITY: Basic Concept..................................................................................................................................... 63 ACTIVITY: Mechanical Freeform Surface Modeling ........................................................................................... 80 Advanced Modeling ..................................................................................................................................... 100 ACTIVITY: Hybrid modeling .............................................................................................................................. 100 ACTIVITY: Impeller Workflow ........................................................................................................................... 117 Exact Surfacing ............................................................................................................................................. 129 ACTIVITY: Exact surface .................................................................................................................................... 130 ACTIVITY: Self Exercise ..................................................................................................................................... 137 Appendix I – Mouse and Keyboard Control ................................................................................................... 138 Appendix II - Mesh Editing ............................................................................................................................ 140 ACTIVITY: Mirroring scans ................................................................................................................................ 140 ACTIVITY: Global Mesh Enhancing ................................................................................................................... 144 ACTIVITY: Mesh Editing .................................................................................................................................... 149 Appendix III – Additional Models .................................................................................................................. 154 ACTIVITY: Iterative modeling ........................................................................................................................... 154

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Introduction Overview This guide covers the fundamental commands and workflows utilizing the Geomagic Design X software.  The graphical user interface and navigation  Data types, processing and usage  Standard Geomagic Design X workflows  Various modeling workflows

Intended Audience This guide is targeted to users of Geomagic Solutions products who require an overall understanding of the Geomagic Design X software.

Prerequisites None

Guide Length 3-days

Guide Conventions

Bold Text



Indicates mouse button clicks to locate a command in the user interface in the format of Tab > Group > Command, example: Model> Create Solid > Extrude Model(Tab) > Create Solid (Group) > Extrude (Command) Bold text also may be used to draw attention to or create emphasis for key concepts in activity steps. A dotted bullet indicates an actionable item in the training activities.



This symbol is used to identify additional information within the context of an activity step. Text following this symbol is not actionable within an activity step.



A circled bullet is an information item found outside of an activity.



This symbol is used to strongly advise or convey important information when used.

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Graphical User Interface Introduction to the Graphical User Interface (GUI). ACTIVITY: Getting Started

Objective Locate the primary components of the application user interface.

Training File 01 – Mouse Control.xrl 1.

From the Windows Start button, select Start > All Programs > 3D Systems > Geomagic Design X to start the application.

or 2.

From the Desktop, double-click the Geomagic Design X icon to start the application. The application will start as shown in Figure 1.

 Clicking a Tab will change the current ribbon to display different command Tab Groups.  The Tree displays the commands used and objects that are opened, imported or created.

Figure 1 – Graphical User Interface

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File Open 1.

Click the Open button or select Open from the menu tab.  Use the Open Files dialog to navigate to the training files folder. Choose 01 – Mouse Control.xrl from the Open Files dialog.

 Files in Geomagic Design X format have an .XRL extension.  Click Open. The file is loaded and displayed in the Model View, see Figure 2.  The Open command is for opening native Geomagic Design X files. Other file types need to be Imported.

Figure 2 End of Activity

Ribbon All commands used to create models are stored in the tabs at the top of the interface. Each tab has a different category of commands that are classified into groups. The Model Tab is the default tab, but all tabs can be selected with the left-mouse button.

Figure 3

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Tabs The layout of the new ribbon user interface is shown in Figure 3. Each Tab is broken down into Groups, and the Commands are located within each Group.

The three tabs where the majority of training tools will be found are the Model, Sketch, and Polygons tab. Model – Create and edit solid and surface bodies. The standard CAD creating tools will be located here.

Sketch – Create and edit a 2D or 2D Mesh Sketch using Line, Arc, and other sketching tools.

Polygons – Access tools to improve and edit the polygons/mesh.

Groups Each Group within a tab will hold a set of commands that work similarly or have similar objectives.

Commands Each Command will have its own properties and dialogs. Commands that are similar will have a drop down menu to toggle between the options and save space on the toolbar. All commands not found directly on the Ribbon will be located in the MENU tab. Commands are categorized and stored here. Selecting a command from the MENU tab is the same as selecting directly from the Ribbon.

Figure 4

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Upper-Side Toolbar This toolbar contains data display modes, view options, and selection tools.

Figure 6

Mesh Display Point Set - Display the mesh as only the poly-vertices. Wireframe - Display the mesh as only the poly-edges. Shaded - Display the mesh as shaded poly-faces. Shaded with Edges - Display the mesh as shaded poly-faces with poly-edges visible. Curvature Display Mode - Turn on or off the visibility of the curvature map of the mesh. Region Display Mode - Turn on or off the visibility of the Regions. Geometry Type Display Mode - Change the region display to classify all region types as individual colors.

Body Display Wireframe - Display the bodies as only the edges. Hidden Line – Display the body as edges with the edges in the background displayed as dashed lines. Shaded - Display the bodies as faces with no drawn edges. Shaded with Edges - Display the bodies as faces with edges visible.

Accuracy Analyzer Deviation for Body – Compare the solid or surface body with the used scan data. Deviation for Mesh – Compare the mesh to its previous state. Curvature – Analyze solid or surface for areas of high curvature. Continuity – Display quality of edge continuity. 2016 3D Systems

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Iso Line – Display the iso lines that define the surface. Environment Mapping – Display zebra stripes on the surface to show continuity.

Views Viewpoint - fly out will display the standard views of the Model View. All standard views are listed: Front, Back, Left, Right, Top, Bottom, and Isometric. Rotate View Counter-Clockwise – Rotate the Model View 90° to the left. Rotate View Clockwise – Rotate the Model View 90° to the right. Flip Viewpoint – Change viewing direction 180°. Normal To (Ctrl+Shift+A) – Orient the view perpendicular to a clicked surface.

Selection Tools Toggle between the different selection shape options. Line - Select entities on a user drawn line on the screen. Rectangle - Select entities within a user drawn rectangle on the screen. Circle - Select entities within a user drawn circle on the screen. Polyline - Select entities within a user drawn polyline on the screen. Freehand - Select entities within a freehand drawn curve on the screen. Paint Brush - Select entities on a freehand drawn path on the screen. Flood Selection - Select all polygons connected to a selected polygon. Extend to Similar - Select an area of mesh with polygons connected by similar curvature. Visible Only - Select only visible objects in the current view. Deselect to select through the object.

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Navigation & Selection This section uses a polygon object as an example; all commands in this section work the same for point and CAD objects except where noted.

Mouse Commands ACTIVITY: Using the Mouse

Objective Learn the mouse operations in the Model View. In the upper right corner of the screen, an arrow can be open or closed to display all the functions available with the mouse. This display is dynamic and will only show what is available at the moment. Figure 7 displays the Default mouse options.

Figure 7

Rotate, Pan, and Zoom 1.

Rotate the view by first placing the cursor in the Model View; press and hold the right-mouse button (RMB).  Moving the mouse in all directions performs a spherical (3D) rotation pivoting around the center of the screen.

 Moving the mouse vertically performs a planar rotation, parallel to the current view. 2.

Pan the part. Press and hold down the right-mouse button (RMB) and then the left-mouse button (LMB).  Position the current view by using the Pan command  Move the mouse right or left to pan from one side to the other. Move the mouse away or towards to pan from top to bottom.

 Release to stop the pan operation.

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3.

Change the magnification of the object in the Model View by using the Zoom command.

 Place your cursor in the Model View at a location of interest and use the scrollwheel to zoom in by rolling the scroll-wheel up. To zoom out, roll the scrollwheel down.

 The Zoom defaults to zooming to the center of the screen. This can be changed in Preferences.

Using Selection Tools 1.

Select poly-faces of the mesh.  Click the Rectangle Selection Mode icon.  Place the cursor on the object, click and hold the left-mouse button (LMB).  Drag your cursor to define the second corner of selection zone. As you move the cursor, a rectangle is visible in the area to be selected.

Figure 8

 Release the LMB. The poly-faces in the selection zone are highlighted. 2.

Deselect portions of the previously selected poly-faces. 

Hold down the CTRL key while selecting with the LMB in the same area highlighted area.



Release the mouse button before releasing CTRL.

 Clicking the LMB in empty space in the Model View deselect everything. 3.

Add more poly-faces to the previous selections.



Hold down the SHIFT key while selecting other areas of the mesh.

4.

Delete selected areas by pressing the DEL key

5.

Press CTRL+Z or the undo button on the keyboard to undo the last command.

6.

Figure 9

Figure 10  The brown surface seen is the back face of the mesh. Blue is the default color of the normal side.

Select and delete additional areas using the Line, Circle, Polygon, Freehand, and Paint Brush Selection Modes.  Select the tools from the Upper-Side Toolbar and make selections on the object in the Model View.

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 Press the DEL key to delete selected areas.  The Line Selection Tool is active only on polygon objects.

Remember to hold Shift or Ctrl to add and removed portions of selected data.

Figure 11 - Example of selected areas 7.

Press CTRL+Z to recover (undo) the most recently deleted areas of the object.

 There is one level of undo in the application. 8.

Deselect the Visible Only icon on the Upper-Side Toolbar and select an area on the object using the Rectangle Selection Tool.  Rotate the object around to view the other side of your selection. Notice that turning off Visible Only causes the current selection tool to affect all areas within the selection boundary, not just those visible on screen, see Figure 12 and Figure 13.  Click in empty space to clear all selections.

Figure 12 - Initial Selection 9.

Figure 13 - Result of Selection

From the Upper-Side Toolbar, select the Polyline Selection Tool to create a polygonal selection.  Click a set of points as shown in Figure 14. As you click, a boundary line will appear from click to click.  To define the last point in your Polyline Selection, move your cursor to the last location and press the right-mouse button (RMB) or double click the LMB to end the process and make your selection.

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 Rotate the object slightly to review the selected data.  Double click in space to clear the selection.

Figure 14 10. Choose the Extend to Similar Selection Tool to select adjacent triangles that meet have a similar curvature.  Click on the area as shown in Figure 15.  Adjacent triangles in the polygon mesh that have a small degree difference between them will be selected as shown in Figure 16.

Figure 15

Figure 16

11. Press Esc to remove the selection.  Certain tools will not clear selections when clicking the mouse in space.



The majority of commands in the application operate using the following selection syntax:  If nothing is selected when a command is activated; the command will affect the entire active object or all active objects.  If a selection is present when a command is activated; the command will affect the selected area only.

End of Activity

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Docks Docks contain the properties for many different application needs. Important Design X options are contained within these docks. Docks can be positioned anywhere on the screen. They can also be pinned, hidden, and closed completely.

Tree Dock Group ACTIVITY: Tree Management

Objective Explore the different available docks. 

If a dock is closed, make it visible again with a RMB click on the bottom toolbar and select the dock from the list that appears.

Training File 02 – User Interface.xrl

Tree The Tree dock on the left side is essential to the modeling process. The top half is the Feature Tree, and the bottom half is the Model Tree. The Feature Tree can be compared to a history tree since it lists the steps taken to create a model. The Model Tree lists entities that are still present in the model. The visibility of these objects is controlled here as well. 1.

Click the Open icon on the Quick Access Toolbar.  Use the Open Files dialog to navigate to the folder where the training files reside. Choose 02 – User Interface.xrl from the Open Files dialog and press Open.

 This XRL file is a partially modeled scan file.

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2.

The Feature Tree tracks the parametric history modeling progress. Each step to create an entity is tracked in chronological order, and can be edited.  Find Extrude 1 in the Feature Tree. Click on the + sign next to it to view the associated entities.  RMB click on Extrude 1 to pull up the context menu.

 A right-click context menu is available on entities in the tree. The commands available from the context menu change depending on the type of object selected.

Figure 19

 Select Edit from the menu, as seen in Figure 19.

 Press the ESC key to cancel the edit.

Figure 18 – Feature and Model Tree 3.

Geomagic Design X is a parametric history based modeler, meaning steps can be edited. Certain points in the modeling history can be accessed, and the steps in the Feature Tree can be reordered.  LMB click one time on the Mesh Fit 1 entity. Then click and hold the LMB on Mesh Fit 1 and drag it to be above Extrude 1.

 The Mesh Fit surface can now be used in the Extrude step since it comes first in the tree.  RMB on Cut 1 in the tree and select Rollback.

 The model can now be viewed as if the Cut and all steps after have never been performed.  RMB on an entity in the tree and select Roll to End to go back to last step.

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Figure 20

Geomagic Design X 2016

4.

The Model Tree lists all entities existing in the model. Practice controlling the visibility in the part.  Click on the + next to Ref. Planes to view all Planes in the Model.  Click on the Eye Icon next to the + to turn off visibility for all Planes.  Click on the Closed Eye to turn the planes back on.  Click on and off the Eyes next to the Front, Top, and Right Planes to hide the planes individually.

 Turn on and off visibility for other entities in the model.

Figure 21 Figure 22

Display The Display dock is defaulted as a tab next to the Tree. Display contains display options for the scan data and the bodies. It also contains additional ways to view and display data in the Model View. 1.

Click on the Display Tab next to Tree.

2.

Place/remove a checkmark next to World Axis & Scale, Scene Grid, Gradient Background and Label to toggle visibility of each item in the Model View.

Figure 23

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3.

The General group has options for controlling the way the overall data is displayed, including Transparency, Lighting, and View settings.

4.

The Mesh/Point Cloud group lists all the different ways to view the scan data.

5.

The Region group gives the option to view the geometry of the selected or all regions.

6.

The Body group lists the ways to view a surface or solid body and it allows for control of the resolution of the bodies.

7.

The Sketch & 3D Sketch group has specific visibility options for components of sketches.

 Be cautious changing options without changing them back where they started. The General>Lock option will disable all mouse rotation ability.

Figure 26

Figure 27 Figure 28

Figure 25 Figure 24

Help The Help Tab contains a list of contents and commands to find additional information about each topic. The Index tab is searchable. The content of each help will explain what the tool is, the benefits of using it, how to use the tool, and then all of the options of the tool in detail. Figure 29 shows an example of the layout for the Help tab.  F1 will access the Content Help menu for the command that is currently being used.

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Viewpoint The Viewpoint Tab creates and edits capture states of the current view of the model. The views can be accessed later to remember set, non-standard, views of the part. 1.

Create a Viewpoint of the model.  Rotate, Zoom and Turn on/off Visibility of the model to get a view approximately like Figure 30.  Click on the Add Viewpoint button.  Rotate and Zoom the model to a different orientation.  Select the Apply Viewpoint button to return to the state of Viewpoint1.

Figure 30 2.

Use the Reassign Viewpoint command to change the Viewpoint1.  In the Model Tree, turn off visibility of the Solid Bodies.  Select Reassign Viewpoint.

 Viewpoint 1 is now reassigned to the same view but with the Solid Bodies turned off.

End of Activity

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Accuracy Analyzer™ and Properties ACTIVITY: Check accuracy and properties of a model

Objective Explore the different deviation displays for checking accuracy of a model. Also, explore the different information that can be displayed in the Properties dock.  Docks can be pinned to the screen using the push pin located in the corner.

Accuracy Analyzer™ The Accuracy Analyzer™ allows the user to check the accuracy of their part throughout the entire process. The CAD body can be compared to the base scan data with its deviations displayed in a color map. Different ways to display the quality and continuity of the surfaces are also found here. Deviations between meshes can be analyzed. The dock is where calculation options can be set. Once deviations are applied, a Color Bar will appear to control the tolerance values. 1.

View the deviations between the solid body and the mesh.  Select the radio button next to Deviation for Body.

2.

Adjust the tolerance range of the part  Double click on the 0.1 in green, as shown in Figure 31, to alter the value.  Change the value to 0.15.

 Changing the upper tolerance will automatically change the lower value.

Figure 31

Figure 32 3. 2016 3D Systems

Turn the Accuracy Analyzer off by selecting None at the top of the dock.

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Properties The Properties dock displays information about any selected entities. Some properties can be changed, visibility can be turned on or off, and more information can be calculated inside Properties. 1.

Calculate the Volume of the mesh.  Select the 3DS Partifact mesh from the Feature Tree or Model Tree.

 In the Properties

dock, click Calc. next to Volume.

 If the mesh is not fully closed, Design X will calculate the volume of the assumed closed shape.

Figure 33 2.

Change the color of the mesh.  In the Upper-Side Toolbar, change the Mesh Display Mode to Shaded.  In the Model Tree, turn the eye off next to Solid Bodies. The part should look like Figure 34.  Select the blue bar next to Material in the Properties dock. Then select the three dots on the right (Figure 35).  Change the mesh color by selecting one of the colored circles.  Press OK to accept.

Figure 35 Figure 34

Figure 36 End of Activity

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Bottom Toolbar This toolbar contains a second location to hide and show entities, filter tools, and measuring tools.

Visibility

Filter

Turn on and off the visibility of groups of entities.

Activate selection filters. User can only select the allowed entity types.

Meshes (Ctrl+1)

Meshes/Point Clouds

Regions (Ctrl+2)

Regions

Point Clouds (Ctrl+3)

Poly-Faces

Surface Bodies (Ctrl+4)

Poly-Vertices

Solid Bodies (Ctrl+5)

Mesh Boundaries

Sketches (Ctrl+6)

Bodies

3D Sketches (Ctrl+7)

Faces

Ref. Points (Ctrl+8)

Loops

Ref. Vectors (Ctrl+9)

Edges

Ref. Planes (Ctrl+0)

Vertices

Ref. Polylines

Ref. Geometries

Ref. Coordinate

Sketches

Measurements

Constraints Dimensions Clear All Filters

Measure Find dimensions between any entities in the Model View. Distance – Measure a linear distance between two entities. Angle – Measure an angular dimension between two entities. Radius – Find a radius using 3 points or a circular entity. Section – Create a dimension on a 2D section of an object. Mesh Deviation – Measure deviations between separate scan data.

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World Axis and Scale The World Axis displays the orientation of the global coordinate system. The Scale below shows the size of the part.

Dialogs Geomagic dialogs have several controls in common with each other; this section describes the most commonly used controls and conventions. The majority of Geomagic Control commands are dialog based. OK button – A checkmark that accepts any changes made while in the dialog and exits the dialog. A subset check can also mean Apply. Cancel button - Discards any changes made while in the dialog and exits the dialog. Don’t Quit Command with OK button – When the option is selected, the user will remain in the command after clicking OK to be able to use the command again. Preview button – Allows the user to see what changes will be made after the command is run. Next Stage button – Only available in some commands, when another stage of options is needed. Generally the next stages have calculation options. Previous Stage button – Go back a stage to make changes. User Break – Cancel a command before it finishes. Estimate – Estimate various quantities in options by reading the surrounding mesh. Entity Selection – The yellow box frame around an entity type means the user can select objects, such as scan data, ref. geometry, and CAD faces, to complete the command. Multiple selections can be made in one command.  If there is a vertical red stripe on the left side, an entity is required for completion.

Select None – Remove all entities listed. Deselect Last – Remove the last selected entity. Roll-Up Groups - when rolled up, an arrow in the group title points downward. Clicking anywhere on a rolled up group title will expand the group and reveal additional dialog.

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Context Menus Geomagic Design X has several context menus activated by right-clicking in one of three locations; at the top of the screen on a user interface element, on an object in the Model View tab and in the Tree Dock.

User Interface Context Menu  Quickly add and reorder any command to the Ribbon.  Hide the ribbon; reappears when a tab is clicked.

Model View Context Menu Right click on any object or blank space in the Model View will activate an action menu. Different selected entities produce different menus.  Immediately enter a Sketch mode.  Quickly start a Wizard command.  Toggle through common sketching tools.  Accept and Cancel commands with ease.

Figure 38

Figure 37

Context Menu – Sketch Mode

Dynamically changing menu

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Tree Context Menu Right Click on any entity in the Feature or Model Tree to open a context menu about the entities. Generally, this is the easiest way to find a step to edit or change the visibility state.  Edit a command or sketch.  Suppress an entity in the modeling history.  Rollback and Roll Forward to a certain point of time in the model.  Hide and Show object visibility.  Export individual entities as a more generic file format.

Figure 39

Figure 40

Context Menu – Feature Tree

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Data Types Meshes, or Polygons, are common data types which consist of thousands of triangles derived from a large point cloud. The application can import several hardware device native file formats. Plug-ins are provided for several hardware devices, enabling direct input of scan data into the application.

Point Data  Raw point data is a collection of points, each having an X, Y, Z location. When viewed up close, raw point data is displayed as simple colored points, as shown in Figure 41.  Shading point data enables a better view of the shape. Raw data is unshaded due to its lack of Normal Information.  Data collected using a scanner in LiveScan is automatically contains the Normal Information.

 For best use with Design X, Points can be triangulated and merged to generate a Mesh.

Figure 41 - Raw Point Data

Figure 42 - Shaded Point Data with Normal Information

Mesh Data A Mesh, or polygon, is a group of triangles, formed by triangulating point data to create the appearance of a surface for the data. Mesh data can be generated automatically when the option is selected inside of LiveScan in Design X. When a mesh object is generated the normal faces are colored blue by default, the back face or opposite side of the normal face is colored brown. The back faces of all meshes are the complementary color of the front face. The front and back face are determined by the direction of the normal of the points.

Figure 43 – Default mesh appearance

Figure 44 – Back faces of mesh

Clicking the Display Panel tab and toggling on Edges in the Geometry Display roll-up group will reveal the mesh construct of any mesh object. 2016 3D Systems

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CAD Data CAD data is a collection of faces or bounded surfaces created in Design X, or imported in from other software. Design X uses two different types of CAD bodies. Design X designates if a body is a Solid or Surface body. Solid bodies are grey, and surface bodies are yellow.

Figure 46 Figure 45 Solid Bodies – A collection of connected surface elements resulting in a manifold body.

Surface Bodies – A non-manifold area in 2D or 3D space with defined boundaries.

CAD data is typically the primary result of using the Geomagic Design X software. It occurs by:  Generating sketches, extrudes, revolves, lofts, etc. inside of Design X.  Importing external CAD files, IGES, STEP or CAD neutral file exchange formats  Directly opening or importing supported native CAD file formats

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Scan Preparation Overview On many occasions, the scan data will require post scanning processing. Design X has the capability to align multiple scans, merge scans into one cohesive mesh, and then edit and enhance the mesh. After a mesh is generated, there are many options for output. A clean mesh can be exported to be 3D Printed, or a CAD body can created and sent for other forms of manufacturing.

Mesh Buildup Wizard The Mesh Buildup Wizard (MBW) is a collection of tools to quickly create a single mesh. The scan data can be aligned and cleaned up in the MBW. ACTIVITY: Mesh Buildup Wizard

Objective Create a single mesh from multiple scans of points.

Highlighted Commands  Mesh Buildup Wizard o

Align Between Scan Data

o

Merge

Training File 03a – Mesh Buildup Wizard.xrl 1.

Open training file 03a – Mesh Buildup Wizard.xrl  Click Open icon in the top left corner.  Use the Open Files dialog to navigate to the folder where the training files reside. Select file 03a – Mesh Buildup Wizard.xrl in the Open Files dialog.  Click Open to open selected file.

 Both scan objects should be visible when the file is opened. If they are not turn them on in the Point Clouds group of the Model Tree.

Figure 47 2.

Begin the Mesh Buildup Wizard, located in the POINTS Tab>Wizard Group>Mesh Buildup Wizard.

 The first stage of the MBW, 1/5 – Data Preparation, is for selecting the data and

options for the wizard. If not listed under Select already, select the target scan data.

 Under Set Scanner Type, choose Unknown.  Using Unknown will display all options in each stage.

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 The data is not aligned already and we want to remove unwanted data.

The dialog box should now read 1/5 – Data Preparation indicating all 5 stages are used.

Figure 48  This dialog box has the standard set up used in the software. o

Select entities section

o

Multiple roll-up groups of options

o

Multi-stage command

Figure 49 3.

The Entity Thumbnails dock, below the Model View, allows for an organized way to view and select all the data available at the current stage.  Click the checkmark next to Setup1 in the Entity Thumbnails. The visibility of Setup1 is now off.  Replace the checkmark to turn the visibility back on.  Hover the mouse over the image of Setup1 in the Entity Thumbnails. A small, independent, window will pop up. This view can be rotated separately from the other scans to view scan quality and completeness.

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Figure 50 4.

Go to the Next Stage of the Mesh Buildup Wizard.

5.

Remove any unwanted points in the 2/5 - Data Editing stage.  Set the Max. Poly-Vertices/Faces Count Per Noisy Cluster to 100.  Click on Find Noisy Cluster radio button

 Any groups of points, 100 or less, which are distanced from the main body, will be selected.  Inspect which points are selected, then press the Delete key or icon.

Figure 52

Figure 51 6.

Click the Next Stage button in the Mesh Buildup Wizard dialog.

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7.

Use Stage 3/5 – Data Pre-Aligning to align the two scans.  Change the Method to Local Based on Picked Point.

 The Model View will be divided into 3 view ports. The upper left view port is the Fixed view port and the upper right view port is the Floating view port. The wide frame at the bottom serves as a preview after registering the object in the Floating view port to the object in the Fixed view port.  With proper scanning technique, the Auto Guess method should align the scans.  With Reference highlighted in yellow, choose one of the scans. Notice the scan now appears in the top right box labeled Reference.  Manually select the Moving option and select the other scan.  One scan should be set as Reference, and one scan should be set as Moving.  Setting one scan as Reference will keep it static. Scans that are pre-aligned during LiveScan should be set as Reference.  Orient each scan in the Reference and Moving boxes to have approximately the same positioning.  Click on a point on the Reference scan that also exists on the Moving scan. A red point should appear.  Click on the same point on the Moving scan. The red points should match.  Repeat with at least two more points on each scan.  The order of points is Red, Green, and Blue. At least 3 points are needed to align scans.  Select the Apply check next to the 3/5 – Data Pre-Aligning line.

Figure 53

Figure 54 8.

Go to the Next Stage of the Mesh Buildup Wizard.

9.

Stage 4/5 – Best-Fit Aligning will refine the alignment between the scans.  Use a rectangular selection to highlight both scans for the Moving group.  Sampling Ratio controls the percentage of data being used. Press the Estimate wand to see the amount used when set to Auto.

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 Click the Apply check to complete the fine alignment of the scans.

Figure 56 Figure 57

Figure 55

10. The Best-Fit Aligning can be run multiple times at different Sampling Ratios. When satisfied with the alignment, press the Next Stage button. 11. Stage 5/5 – Data Merging will combine and triangulate the point clouds.  The MBW has two different merging options. Select Mesh Construction.  Place a Check next to Reduce Noise.  Click the Apply check to create a single mesh out of the scan data. 12. Inspect the mesh, then press the overall OK (Apply All and Finish) check to finish the Mesh Buildup Wizard.

Figure 58 End of Activity

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Mesh/Polygon Editing Design X now allows for the mesh to be selected and deleted without entering any edit mode. All of the tools used to edit, optimize, enhance, and heal the mesh are in the POLYGONS tab. ACTIVITY: Clean up mesh data

Objective Create one clean, watertight, closed mesh using a variety of tools.

Highlighted Commands  Decimate  Fill Holes  Rewrap  Enhance  Healing Wizard

Training File Continue from previous or Open 03b – Mesh.xrl

Reduce Polyface Count After the Mesh Buildup Wizard, the resulting mesh may have more polyfaces, or triangles, than needed. The Decimate command can intelligently remove and merge polyfaces to have the lowest amount possible. This will allow for future processing times to be significantly reduced. Saved file sizes will also be smaller. 1.

Select the POLYGONS tab to easily access all of the mesh editing tools.

2.

Click on the Decimate command located in POLYGONS>Optimize>Decimate and progress through the dialog menu from top to bottom.  Select the mesh as the Target Mesh.  Change the Method to Allowable Deviation.

 This method will remove as many polyfaces as possible without allowing the mesh to change at a greater distance than the set value.  Under Options set the value to 0.0254 mm.  Press the OK check to Decimate the scan.  The total triangles now should be under 1,000,000.

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Figure 59

Geomagic Design X 2016

Create Manifold Mesh Downstream applications, such as 3D printing, require a well cleaned mesh. A watertight mesh will produce best results for 3D printing applications. Geomagic Design X has tools that can fill in individual holes, and it can also wrap an entire part to fill in all the holes at once. 1.

Navigate and zoom in to approximately the view shown in Figure 60.

Figure 60

Fill Holes 1.

Select the Fill Holes command located in POLYGONS>Repair Holes/Boss.

Figure 61 – Fill Holes Dialog Layout 2.

Choose the large boundary shown above in Figure 61. Once the command is accepted, this hole will fill in.

3.

Edit the boundary to make a cleaner perimeter. Select Fill Gulf from the Editing Tools rollup group.

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 Left click one time on the top, left-most point of the gap shown below in Figure 62.  Left click again on the opposite side of the gap to immediately fill in a portion of the hole.  Before making the second selection, a preview of the area to be filled will be shown.

Figure 62 – Fill Gulf 4.

Use Remove Peninsula to quickly delete excess, indented data. Edit the boundary to make a cleaner perimeter.  Left click one time on the top, left corner of the area shown in Figure 63.  Left click again on the opposite end to instantly delete this portion of data.

Figure 63 – Remove Peninsula 5.

Select the Remove Island Editing Tool to delete floating areas of data.  Left click on the boundaries of any islands to delete them.

Do not click on any boundary of the main mesh. The entire mesh will delete. To Undo any Editing Tools, click on the left-pointing arrow at the end of the Editing Tools rollup menu.

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Figure 64 – Remove Island 6.

Select Add Bridge to split the boundary into smaller sections.  Left click and hold the mouse button down on one edge of one polyface.

 The polyface edge will highlight when selected.  While holding the LMB, select a triangle on the opposite side of the boundary.  The original selected boundary is now listed as two boundaries.

Figure 65 7.

Adjust the More Options settings to match the previous Figure 66.  Add a check next to Smooth Boundary in the More Options rollup group.

8.

Accept the Fill Holes command by pressing the OK check.

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Rewrap Instead of having to select every boundary in the part, the Rewrap command can extend all boundaries until there are no holes in the scan. 1.

In the dropdown from POLYGONS>Optimize>Global Remesh, select Rewrap.  Under Fitting Options, slide the Geometry Capture Accuracy bar over to Tight. Move the Overall Smoothness bar to Min.

 This will preserve the organic shape of the scan as much as possible.  Place a check next to Extended Boundaries in the More Options group.  Extend Boundaries on will fill in every size hole. If it is deselected, the very large holes will not fill.  Click OK to run the command.

Figure 68

Figure 67

Optimize Mesh For higher quality printing, the scan data should be enhanced and optimized further. For parametric modeling, the following steps are not generally needed. A higher quality mesh will create higher quality surfaces. 1.

In the POLYGONS tab, select the Enhance Shape command in the Optimize group.  Increase the Sharpness to Max.  Decrease Overall Smoothness to Min.  The Enhance Level can be set to the halfway point.

 The Enhance Level can be altered in the second stage.

Figure 69

 Go to the Next Stage by clicking the arrow.

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2.

Adjust the Enhance Level to find optimal result.  Decrease the slide bar to Min.  Check the mesh to see the results.  Increase the slide bar to Max.  View the difference in the mesh.  Adjust the slide bar to the third mark.

Figure 70

Figure 71 – Min Enhance Level

Figure 72 – Max Enhance Level

 Accept the Enhance Shape command with the OK check. 3.

Select the Healing Wizard in POLYGONS>Wizard>Healing Wizard to remove the last erroneous triangles. This command finds these triangles automatically, and after accepting the command, they are removed.

4.

Accept or Cancel the Healing Wizard to exit.

 The Healing Wizard will find any small groups of floating triangles, small polyfaces, or dangling, folded, or crossing poly-faces automatically. The parameters for each of these categories can be modified as needed.

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Figure 73  The Mesh is now ready for 3D printing, surfacing, or other production methods.  Additional mesh editing exercises can be found in the Appendix. Design X also has built in Tutorials.

End of Activity

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Auto Surface A quick, easy, non-parametric way to generate an IGES or STEP file from a cleaned Mesh is the Auto Surface. The mesh is analyzed and surface contours are automatically generated to create extremely accurate surfaces to the scan. ACTIVITY: Generate CAD Body

Objective Create an accurate CAD body to the scan data. The resulting body can be exported as a STP, IGS, x_t file, or other generic file types.

Highlighted Commands  Auto Surface

Training File Continued from previous or Open 03c - AutoSurface.xrl 1.

Open training file 03c - AutoSurface.xrl or continue from previous exercise.

2.

Enter the Auto Surface command located in the SURFACING tab.  Select Organic in the first option for patch structure.

 The Organic method creates a curve network as evenly distributed as possible, and is good for models that have non geometric faces and with few distinct feature shapes. The Mechanical method will create a curve network more uniform and grid like.  Leave the Patch Count in Patch Network Option at Auto Estimate to let the software decide the amount of patches needed for surfacing.  Slide the Geometry Capture Accuracy bar one away from Max.  Change the Tolerance to 0.1285.  Go to the Next Stage in the command.  The first stage of the Auto Surface command sets how the software will construct its NURBS network. The Auto Surface command applies to the entire mesh.

Figure 74 – First Stage

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Figure 75 – Second Stage 3.

The second stage allows for editing of the generated patch network.  Select the Deform option.  Zoom in to the area shown in Figure 76.  Click and drag the center node of multiple patches to manipulate the form of all 5 quadrilaterals.

 If a patch is not in a clear enough four-sided shape, the software might not fit a surface. Occasionally patches need to be edited and reshaped in order to build a better surface body.

Figure 76

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4.

Edit the form of a single edge of a patch with the Deform option.  Click and drag a node on a single spline to adjust the edge of a patch.

 Straightening out a patch edge can help create better quality connections between the patches.

Figure 77 5.

Press the OK checkmark to accept the Auto Surface.

 If the resulting body is a manifold network of surface patches, the body will become a Solid.  Editing the network is generally only needed in the Organic method when patches fail. The Auto Surface can be edited after completion to go correct any failed patches.

Figure 78

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Inspect Accuracy The Auto Surface creates an extremely accurate CAD body in relation to the scan data. Use the Accuracy Analyzer to verify the resulting body. 1.

The Accuracy Analyzer is located in an unpinned dock on the right side. Open the Accuracy Analyzer dock.  Turn on the radio button for Deviation for Body.

2.

Change the tolerance on the color bar to 0.05mm. The default tolerance is set to 0.1mm.  On the color bar, double click on the green 0.1.  Set the value to 0.05.

3.

Hover the mouse over various areas of the mesh to see the deviations.

Figure 79 End of Activity

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Regions Regions classify areas of the mesh based on curvature and geometry features. An automatic segmentation of the scan data into regions is one of the first steps in the modeling processes for most standard workflows. Regions can assist with many processes, including:  Aligning  Quick Selection  Wizard Tools

ACTIVITY: Understanding Regions

Objective Create and edit regions on a mesh to assist in modeling.

Highlighted Commands  Auto Segmentation  Merge  Split

Training File 04 – Regions.xrl 1.

Open training file 04 – Regions.xrl

 No mesh editing will be necessary for the part.

Figure 80

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2.

In the REGION tab, select the Segment>Auto Segment command.

 Press the F1 key to read more about the Auto Segment  Set the Sensitivity to 5.  Click the OK button.  The sensitivity option classifies a shape as being round or prismatic. To make smoothly connected areas in a single region, move the slider to the left. To make strictly separated regions, move the slider to the right.

Figure 81 Figure 82

Editing Regions 1.

Change the Selection Type to Paint Brush Selection Mode in the Upper-Side Toolbar.

 To resize the paint brush tool, hold down the Alt key while left-clicking and moving the cursor. 2.

Paint across the regions shown below to select many regions with one click.

3.

The REGION>Edit>Merge option will now be active. Select the Merge to combine the painted regions.

 The Paint Brush can quickly select multiple smaller regions to merge together.

Figure 83 4.

Figure 84

Change the Selection Type to the Rectangular Selection Mode.

 The Rectangular Selection will allow for single click selections of entire regions. 5.

The Merge tool can combine regions that are not physicallly touching.  Click on the five top Sphere regions show in Figure 85.  Select the Merge command in the REGION tab.

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Figure 85

Figure 86

 Non-adjacent, single regions can be separated back apart by selecting the region and then choosing the Edit>Separatecommand in the REGION tab. 6.

Select the Edit>Split tool to convert single regions into multiple separated regions.  After selecting Split, the Limit to Region is automatically activated. Select the region shown in Figure 87.  Switch the Selection Type to the Paint Brush again.  Paint across multiple regions, including the previously selected.  Accept the command.

7.

Figure 87

Use the Insert command to manually create a region.  Select the Extend to Similar Selection Mode in the Upper-Side Toolbar.  Click on the marked area to select the entire area in a single click.  With the command now active, select REGION>Edit>Insert to create a region independent of the previously merged regions.

Figure 88

Figure 89 End of Activity

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Align to Coordinate System Scan data should be moved and aligned to a more useful position with the general coordinate system. Geomagic Design X has multiple ways to move ACTIVITY: 3-2-1 Alignment using Regions

Objective Learn the basics of aligning scans to the coordinate system using the regions of a mechanical part.

Highlighted Commands  Interactive Alignment

Training File 05a – Align 321.xrl

Scan Setup 1.

Open training file 05a – Align 321.xrl.

 No mesh editing will be necessary for the part.

Figure 90 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 65.  Click the OK button.

Figure 91

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Interactive Alignment 3.

Start the Interactive Alignment in the Alignment>Scan to Global group.  Click the Next Stage button.

4.

Create a 3-2-1 alignment using three planar regions.  The Plane option will set the Front Plane, and therefore the XY Plane and the Z Axis direction. Choose the large Plane Region on the bottom of the part.

Figure 92

 The Vector will set the Top Plane and the Y Axis direction. Choose the pink long thin Plane Region pointed at in Figure 93.  The Position will set the Right Plane and the location along the X Axis. Select the Plane Region shown in Figure 94.

Figure 93

 Click OK to accept.  The origin will be located at the intersection of the three planes selected above.

Figure 94

Figure 95 End of Activity

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ACTIVITY: 3-2-1 Alignment using Reference Geometry

Objective Learn how to create other types of reference geometry to use for an Interactive Alignment.

Highlighted Commands  Ref. Plane  Interactive Alignment

Training File 05a – Align 321.xrl

Scan Setup 1.

Open training file 05a – Align 321.xrl.

 No mesh editing will be necessary for the part.

Figure 96 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 65.  Click the OK button.

Figure 97

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Reference Planes 3.

Create a Ref. Geometry>Plane down the center of the part two directions.  Select the Lock icon to stay inside the command and make multiple planes.  Change the Average.  Select two long planes shown to find the mid plane between them.  Click the OK button to accept.

Figure 98 Figure 99 4.

Create a symmetry plane going down the center of the part in the other direction.  Change the Method to Draw Line.  Draw a line roughly in the orientation shown in Figure 100 to create a plane.  Click the OK button to accept.  Change the Method to Mirror.  In the Model Tree, hold the Ctrl key and select the Mesh (Align1) and Plane2.  Click OK to accept.

 A plane representing the center of the mesh in the direction of the drawn plane will be found.

Figure 101

Figure 100

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Interactive Alignment 1.

Start the Interactive Alignment in the Alignment>Scan to Global group.  Click the Next Stage button.

2.

Create a 3-2-1 alignment using the generated reference planes and a region plane.  The Plane option will set the Front Plane, and therefore the XY Plane and the Z Axis direction. Choose the large Plane Region on the bottom of the part.  The Vector will set the Top Plane. Choose Plane1 to set the Y Direction normal to the plane.  The Position will set the Right Plane and the location along the X Axis. Select Plane3.  Click OK to accept.

 The origin will now be set to the middle of the part along the bottom face.

Figure 103

Figure 102 End of Activity

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ACTIVITY: XYZ Alignment

Objective Learn how to create other types of reference geometry to use for an Interactive Alignment.

Highlighted Commands  Ref. Vector  Interactive Alignment

Training File 05b – Align XYZ.xrl

Scan Setup 1.

Open training file 05b – Align XYZ.xrl.

 No mesh editing will be necessary for the part.

Figure 104 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 50.  Click the OK button.

Figure 105 2016 3D Systems

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3.

Create a Ref. Geometry>Vector down the center of hub of the fan.  Set the Method to Find Cylinder Axis.  Choose the two large cylinder regions around the central hub.  Finish the Vector by right-clicking and selecting the checkmark from the context menu.

 Design X version 2016 and newer has many new rightclicking capabilities.

Figure 106

Interactive Alignment 1.

Start the Interactive Alignment in the Alignment>Scan to Global group.  Click the Next Stage button.

2.

Create an XYZ alignment using the generated reference planes and a region plane.  The Position will set the location of the Origin. Select the Vector1 and Region Plane representing the top of the middle hub.

 The intersection of a vector and plane represents a point, which can be used for position.  To set the directions of the coordinate system, select Axis Z and choose the Vector1.  Click the Flip Direction arrow to adjust the positive Z in the desired direction.  Axis X and Axis Y do not need to be set. The blue circle can be twisted to manually clock the part to any location.  Click OK to accept.  The origin will now be set to the middle of the hub of the propeller with the Z Axis going through the middle.

Figure 107 End of Activity

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ACTIVITY: Scan to CAD Alignment

Objective Learn how to import a CAD body and align the scan data to the CAD body.

Highlighted Commands  Quick Align  Best Fit Align

Training File 05a – Align 321.xrl 05 – Align CAD.igs

Scan Setup 1.

Open training file 05a – Align 321.xrl.

2.

Import the IGES file, 05 – Align CAD.igs, by selecting HOME>Open/Import>Import.

 Importing a file will place it in the same open file.

Figure 108 3.

Choose the ALIGNMENT>Scan to CAD>Quick Fit command to align the scan data to the CAD data.  Set the Target Body to be the CAD body.  The Align1 scan should be automatically set as the Moving Entities.  Click the OK button to accept.

 The Run Best Fit Alignment should be checked under More Options.

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Figure 109

Geomagic Design X 2016

4.

The Best Fit Alignment will automatically start and have all of the options populated. Press the OK key to accept.

 The Best Fit Alignment will always need to be run after a Quick Fit. This will make a much better registration between the files.

Figure 110 Aligning a scan to an already built CAD file can be used for multiple reasons, including:  Check the accuracy of the scanned part to the CAD.  Add features to a Solid Body that were not in the original file. End of Activity

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Parametric Modeling The strength of Geomagic Design X is in its sketch based modeling. Any model can be created regardless of the scan quality. Design X utilizes sketches and standard CAD operations, such as Extrude, Revolve, Sweep, and Loft, to generate a parametric model. ACTIVITY: Introduction to Sketching

Objective Learn how to set up a Sketch and the basic principles of creating sketches. Creating sketch entities, constraining entities, and dimensioning are all introduced in this lesson.

Highlighted Commands  Setup Sketch  Rectangle  Parallelogram  Fillet

Sketch Entities 1.

Create a New File by selecting the icon on the top-most toolbar.

2.

Click SKETCH>Setup>Sketch to begin a 2D sketch.  Select the Front Plane from the Model View.

 The sketch will start immediately after selecting the base plane.

Figure 111

 If a plane is already selected, choosing Sketch would directly start a sketch on that plane.  The Sketch button has now changed to Exit in order to complete the sketch. 3.

Create a Rectangle using the SKETCH>Draw>Rectangle tool.  Left-click in the top-left corner of the origin, as seen in Figure 113, to begin the Rectangle.  Left-click the bottom-right corner to finish the Rectangle.  Finish the Rectangle by right-clicking in the Model View and selecting the Checkmark from the context menu.

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Figure 113

Figure 112 4.

Drag a Line or a Point of the Rectangle to modify its size until it is roughly centered at the Sketch Origin (red U and green V axis).

 By dragging a Line of the Rectangle you can alter one dimension (Length or Width of the Rectangle) at a time, while dragging a Point would let you alter both dimensions at the same time.

Constraints 5.

Double-click on the top-left Point of the Rectangle. The Constraint and information for that single point is now shown.

 A Coincidence Constraint is applied on the end point of the two lines forming the corner.  To see Constraints of another entity, only single left-click on the entity without leaving the Properties Dialog.

Figure 114 6.

Show and add Common Constraints of multiple sketch entities.  LMB Click on the bottom line of the Rectangle to view the Constraints.

 A Horizontal Constraint should be shown.  Shift+LMB Click on the other horizontal line of the Rectangle (Figure 116).  Both lines will be selected to show the Common Constraint between all selected entities.  Select the Independent Constraint Horizontal and click the button Delete Constraint to remove.  Select Parallel to set the Common Constraint.  Repeat with Vertical lines.

Figure 117

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Figure 115 Geomagic Design X 2016

 Alternatively, a Parallelogram could have been chosen from the beginning by clicking the small triangle next to the “Rectangle” tool in the SKETCH Ribbon and selecting the “Parallelogram” in the tools list to produce the same result.  The Ribbon always remembers the last method of a tool button, for quicker repeatability. 7.

Apply a Perpendicular Constraint to the lower left corner of the Rectangle.  Close the Constraints Dialog Tree with a RMB click check or the dialog checkmark.  LMB click anywhere in the Model View background to deselect all entities.

 After most operations, selections will persist after the dialog is closed.

Figure 118 8.

Create a pivot point for rotating the sketch by constructing two intersecting Centerlines with the SKETCH>Draw>Centerline tool below the Line tool.

 The Line tool could have been used with the option For Construction selected.  Move the cursor over the middle of the left line, and LMB click at the Mid-Point Constraint to start the Centerline (Figure 119).  After clicking to make the point, move the cursor back over the left line to activate the Parallel and Perpendicular assist axes.  LMB click to place the Centerline when the yellow Perpendicular and white Vertical symbol are visible.  Creating the centerline perpendicular to the base will keep it related ta rotatable rectangle.  RMB click to finish the line.  Move the cursor over the middle of the bottom line, and LMB click at the Mid-Point Constraint to start the Centerline.  Finish the line at the end point of the first centerline, Perpendicular to the Mid-Point.

Figure 119

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9.

LMB Click and Hold on the intersection point of the two Centerlines and drag it onto the intersection of the red and green Sketch U/VAxis to place the Coincident Constraint.

 The center point should turn black signifying it is fully defined.  Click and drag a mid-point of the rectangle lines and the rectangle will rotate and resize.

Figure 122

Dimensioning 10. Select the Smart Dimension tool from the SKETCH>Draw ribbon to apply the Linear and Angular dimensions as shown.  LMB Click one line and then select the parallel entity. LMB Click in space to set the linear dimension.  Repeat for the other set of parallel lines.  Select the inferred horizontal horizon line and one of the created Centerlines. LMB Click in space to set the angular dimension.  Sketch entities will turn black when they are fully constrained by dimensions and constraints.  Click OK to accept the command.

Figure 124

Figure 123 11. Edit the Dimensions by double-clicking on each value.  Set the two linear dimensions to size the box.

 Change the angular dimension to rotate the box to a specific angle from the horizon. 12. Click the Exit button to finish the sketch. 2016 3D Systems

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Figure 125  This sketch can be easily controlled and updated for future uses in CAD. End of Activity

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ACTIVITY: Basic Concept

Objective Learn the basics of sketching and extruding to create and cut solid bodies.

Highlighted Commands  Mesh Sketch  Extrude  Fillet

Training File 07 – Basic Concept.stl

Scan Setup 1.

Import training file 07 – Basic Concept.stl.  Click the Import button on the Quick Access Toolbar.  Or choose MENU>Insert>Import from the dropdown.  Navigate to the file then choose Import Only.

 Design X requires importing files that are not native Design X file types.  No mesh editing will be necessary for the part.

Figure 126 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 50.  Click the OK checkmark to accept.

Figure 127 Figure 128

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Interactive Alignment 1.

Create a Plane through the middle of the part to use for alignment using the MODEL>Ref. Geometry>Plane command.  Change the Method to Mirror.  In the Feature Tree, hold the Ctrl key and select the Right plane and Basic Concept mesh.  Click OK.

 The Mirror method will read the selected mesh and find the symmetry plane of the scan based on the given direction of the selected plane.

Figure 129 Figure 130 2.

Begin the alignment by selecting Interactive Alignment from ALIGNMENT>Scan to Global.  Go to the Next Stage.

3.

Change the Moving option to X-Y-Z.  Set the Position as the region Plane on the bottom of the part and the region Cylinder of the central hole.

 The Origin will now be set to the point where the cylinder axis would intersect the plane.

Figure 131 Figure 132

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 Click on Axis Z, and then select the same region Plane as before to set the Z direction.  Select the Flip button next to Axis Z to point the Z Axis through the part.  Click on Axis X, and then select Plane1. 4.

Click OK to accept the alignment based around the central hole.

Figure 134

Create Main Body 1.

In the SKETCH tab, choose Setup>Mesh Sketch.  Select the Front plane as the Base Plane.  Set the Offset Distance From Base Plane to 5mm.  Click the OK button to begin sketching.

 The Offset Distance From Base Plane is only to set a cross-section distance of the model to be projected back to the originally selected Base Plane. All sketches will still be created on the Base Plane, regardless of the height of the Offset Distance.

Figure 135

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2.

Use the Model Tree to Hide the Mesh.

3.

Select the Draw>Line tool.  Click on the top-most solid pink line. A line will be best fit to the entire segment.  Click the OK button to accept the line.

4.

Select the Draw>CenterPoint Arc command.  Click on the left-most solid pink line. An arc will be best fit to the entire segment.  Click on the Accept Fitting check.  Double click the right-most solid pink line. This will create and accept the arc while still staying inside the command.

5.

Use the Centerpoint Arc to create the lower, segmented arc.  Single click on the five segments to create one best fit arc between the segments.  Double click anywhere in space to accept the fitting.  Click the OK button to accept.

Figure 136 6.

Open the Accuracy Analyzer on the right side toolbar to display all points of an open loop.  Place a checkmark next to the Disjoined Ends box.

 Disjoined Ends will add a green end point to any point of opening in a sketch chain. 7.

Using commands from the Tools group allows for quick ways to close open sketch loops. Select the Tools>Trim command to close endpoints to a sharp corner.  Change the option the Corner Trim.

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 Locate the two open ends shown in the picture below.  Zoom in to one corner. Left click on one line segment surrounding one corner.  Select the other line segment to join the two ends.  This command uses the sketch segments, not end points. The Trim will be directed based which side of the segment is selected.  Repeat on the other corner.  Click the OK button to accept.  If the OK is greyed out, clicking the Cancel button will keep the Trim and exit the command.

Figure 138

Figure 137 8.

Use the Tools>Fillet command to close the other two open points with smooth, tangent arcs.  Left click on one sketch segment near the missing arc segment.  Click and HOLD the LMB on the second segment.  While still holding the LMB, move the mouse around to adjust the size of the fillet.  Release the mouse button when the arc is best fitting the pink polyline.  Repeat to create the second arc.  Click OK to accept.

Figure 139 9.

Figure 140

Figure 141

Double click on a dimension to edit the value.  Using a design intent approach, change each dimension to 88 mm.

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10. Verify there are no openings in the sketch loop, then press the Exit button in the top toolbar.

Figure 142 11. In the MODEL tab, select the Create Solid>Extrude command to generate the body.  Turn on the Mesh and Region visibility by pressing Ctrl+2.  The Base Sketch should automatically be selected as Sketch1 (Mesh).  Change the Method to Up to Region. The Sub Method should automatically set to Trim with Region Fit Surface.  For the Up To option, select the top, Freeform region.  Click the OK to accept.  The Up to Region>Trim with Region Fit Surface method will automatically fit the extrusion to the shape of the region.  Press F1 to see all the different methods of Extruding.

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Figure 144 12. Turn on Deviation for Body inside of the Accuracy Analyzer dock.  Rotate the body to inspect the accuracy of the model.  The Bottom View will display the area of high deviation. This face shows the solid body is both too small in areas and too large.  Select None to turn the deviations off.

Figure 145 13. To fix the inaccuracies of the model, Edit the base sketch.  RMB on Sketch1(Mesh) in the Feature Tree.  Select Edit from the dropdown menu. 14. Press the Normal To button on the Upper-Side Toolbar, or Ctrl+Shift+A. This will align the sketch back normal to the screen. 15. Select the lower sketch arc and press Delete.

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16. Using the Draw>Line command, reconnect the loop by clicking on one endpoint and then the other.  Click the OK to accept.  A yellow and black concentric circle symbol will appear when selected on the end point. 17. Click and HOLD the LMB on the new line and drag it below the pink polyline.

Figure 146 18. Click the Exit button to exit and accept. 19. Make sure the Regions are still visible, but HIDE the Solid Bodies using the Model Tree, or by pressing Ctrl+5. 20. Create an accurate, form-fitting surface along the back face of the mesh with the MODEL>Wizard>Mesh Fit command.  Select the Revolution region that represents the inaccurate face.  With the Resolution set to By Allowable Deviation, limit the Max. No. of Control Points to 20.  Click OK to accept the Mesh Fit surface.  A Mesh Fit surface will be created accurately to any mesh surface. This surface is not directly editable since it is not based off of a sketch. If changing the Mesh Fit parameters does not create the desired surface, the mesh itself can be optimized and editing to make a better fitting surface.

Figure 147

Figure 148

21. Turn back on the Solid Body visibility.  This surface will be used to cut off the excess solid body. 2016 3D Systems

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22. Select the MODEL>Edit>Cut command to cut a solid body using a surface body.  Select the Mesh Fit1 surface as the Tool Body.  Select the Extrude1 solid as the Target Body.  Click on the Next Stage arrow. Notice the OK check is not available until the next stage is completed.  Click on the main portion of the Solid Body to select as the Target Body. This is the portion that will be kept.  Select the OK check to accept the cut.

Figure 149

Figure 150 23. Turn the Deviation for Body back on in the Accuracy Analyzer dock to see the new resulting body.

Figure 151  It is recommended to turn the deviations back off after viewing. This will speed up processing time for all proceeding steps instead of making the software rerun the analyzer.

Extrude Cut 1.

Turn on and off visbility of entities until only the Mesh and Regions are visible.

2.

Right Click on the Plane region shown below.  Select the Mesh Sketch icon to immediately enter the Mesh Sketch Setup up with the region as the Base Plane.

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Figure 152  Set the Offset Distance From Base Plane to 2 mm, or drag the thin, blue arrow up until the outline of the cutout shown is visible.  Place a Check next to Draft Angle.  Select the Measure Angle button then click on the two planar regions shown in Figure 154.  Set the Draft Angle to 1°.  The total angle will be displayed. This will show if there is any draft from the base plane. The Mesh Sketch Setup can compensate for the draft when projecting the poly-lines back to the base plane.  Click the OK check to begin sketching.  Hiding the Mesh can make it easier to see the underlying polylines.

Figure 153 3.

Figure 154

Sketch the inner cutout using the Line and 3 Point Arc tools.  RMB Click in the Model View. An array of common sketch tools will immediately appear.  Select the Line icon and sketch the two vertical lines by double clicking the LMB on each polyline.  Draw a Line between the bottom end points to close the loop.  RMB Click and select the Check to accept the line command.  RMB Click. Select the 3 Point Arc icon. Click on both end points and then the height of the pink polyline radius.  RMB Click and select the Check to finish the command.

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Figure 155

4.

Figure 158

Figure 157

Figure 156

Edit and adjust the sketch for a better overall model.  Double Click on one of the vertical sketch lines.  A dialog box will appear with the editing and constraint options. Select Vertical from the Constraints box.  Hold Shift and select the other vertical line. Select Parallel from the Common Constraint options.  Double Click on the arc. Hold Shift and select one of the vertical lines. Select Tangent from the Common Constraint options. Repeat the process on the other line to create tangency with the arc.  Adjust the sketch entities until the sketch looks like Figure 160.  RMB Click and select the Exit button.

Figure 160

Figure 159

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5.

RMB Click in space on the Model View and select Solid Extrude.  Turn on the Mesh and Solid Body visibility.  Check Sketch2 (Mesh) is selected as the Base Sketch.  Change the Method to Through All.  Place a Check next to Draft and input the 1° measured earlier.

 Check the direction of the draft is correct. Use the Flip Direction arrow next to the Draft input.  Set the Result Operator options to Cut.  Click the OK check to accept.

Figure 161

 The sketch must still be highlighted, and the RMB click must not be on a plane to give the Extrude options. 6.

Hide the Solid Bodies, then RMB Click on the plane shown and start a Mesh Sketch.  Set the Offset Distance From Base Plane to 2 mm.  Click the OK check to accept.

Figure 162 7.

RMB Click on the Model View and select the Auto Sketch command.  With the option set to Make Selected Only, select only the inner loop sketch.  Click the OK check to accept.  RMB Click and select the Exit button to finish the sketch.

Figure 164

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8.

RMB Click in space on the Model View and select Solid Extrude.  Turn on the Mesh and Solid Body visibility.  Check Sketch3(Mesh) is selected as the Base Sketch.  Change the Method to Through All.  Set the Result Operator options to Cut.  Click the OK check to accept.

Figure 165

Revolve Cut 1.

Create a Vector in the MODEL>Ref. Geometry group.  Select the Right and the Top Planes.  If not done automatically, set the Method to Intersect 2 Planes.  Click the OK to finish.

2.

Right-Click on the Right Plane and select the Mesh Sketch icon to start sketching.  The sketch setup will already be located in the correct location. Click the OK to accept and begin sketching.

Figure 167

Figure 166

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3.

Use the Model Tree to Hide the Mesh and Solid Bodies.

4.

Select the Draw>Line tool.  Use a box select method to create the 3 lines from the polylines.  Draw a vertical line starting from the vector to create a complete sketch.  Right-Click in space to select the Check and accept the command.

5.

Right-Click on the Vector and select Convert Entities.

6.

Select the Draw>Trim command.  Check it is set to Corner Trim.  Click on all of the lines surrounding each open connection to close.  Right-Click in space to select the Check and accept the command.

7.

Set constraints and dimensions then Right-Click in space and Exit the sketch.

Figure 168

Figure 169

 Only half of the figure needs to be sketched for the Revolve command.

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8.

Choose the MODEL>Create Solid>Revolve command to cut out the section.  With the previous sketch populating the Base Sketch and Profiles, chose Axis and select Vector1.  Under Result Operator, select Cut.  Click the OK to cut out the area.

Figure 170

Create Fillets 1.

Choose the Fillet command in the MODEL>Edit group.  Create a Constant Fillet by selecting the edge shown in Figure 171.

 The Tangent Propagation option will select all edges of the solid tangent to the first choice, reducing the need to manually select all edges.  Next to the Radius box, press the Estimate Radius From Mesh magic wand button.  Adjust the value to 1.5mm.  Click the OK to finish.

Figure 171

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2.

Repeat the process on the fillet around the outside of the mesh. Add all edges belonging to the same size fillet.

Figure 173 3.

Right-Click the solid edge of the other cut out in Figure 174, and choose the Fillet icon.  Change the type to Variable Fillet.

 The Profile View will appear below the Model View. This will be used to figure out the varying radius.  Manually select all 3 edges used for the variable fillet then click the Estimate Radii From Mesh Button.  Look at the predicted fillet radius down in the Profile View. 4.

Adjust the end points to match the pink polyline.  Set the R(adius) value to 4mm at each end point.

Figure 174

 Click on the middle section to re-zoom around this segment. Click again to place a new point in the approximate middle of the line.  Drag this point up to tallest peak of the pink polyline.  Click OK to finish.

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Figure 175 Figure 176

Figure 177 5.

Insert any additional fillets to the model.

End of Activity

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ACTIVITY: Mechanical Freeform Surface Modeling

Objective Create a surface body using Modeling Wizard and Model Surface Features, and then combine the surfaces using 3D sketches and surface trimming tools. Analyze modeling result with Accuracy Analyzer™.

Highlighted Commands and Concepts  Surface Fitting  Surface Editing  Surface Loft  3D Sketching

Training File 08-Mech Freeform Surface.xrl

File Open 1.

Open training file 08 – Mech Freeform Surface.xrl.  Navigate to the file from the Open Files dialog and press the Open button.

 The data is already aligned and classified with regions.

Figure 178

Upper Surfaces 1.

Select the Mesh Fit button in the MODEL>Wizard group on the ribbon to create a surface on the large, upper face.  Select the large, upper target Region shown in Figure 179.  Set the Resolution type to By Allowable Deviation, and the Allowable Deviation to 0.1mm.  Rotate the preview plane with a manipulator node until it is parallel to the x-axis.  Click the OK to accept the command.

 The orientation of the preview plane will be the same as the finished surface. Having the surface more square to the part will allow for higher quality surfaces in the end.

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Figure 179 Figure 180 2.

Hide only the Mesh Fit(1) surface body using the Model Tree.

3.

Select the Mesh Fit button in the MODEL>Wizard group on the ribbon to create the adjoining surface on the upper face.  Select the target Region shown in Figure 181.  Click the OK to accept the command using the previous options.

Figure 182 Figure 181

Join Surfaces 1.

Click the 3D Sketch button in the 3D SKETCH > Setup group on the ribbon.

2.

Select the Spline tool in the Draw group.  Draw a Spline from edge to edge of the Mesh Fit(1) surface body, as shown in Figure 183.  Right-Click to end the first spline.

3.

Repeat Step 2 for drawing a Spline on Mesh Fit(2) as close to parallel as possible to the first spline, then Accept the Spline.

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Figure 184 – Mesh Fit(2)

Figure 183 – Mesh Fit(1) 4.

Click the Split button in the 3D SKETCH>Edit group on the ribbon.  Split the first curve by clicking on two points near the edges of the Mesh Fit(2) surface.  Accept the command.

Figure 185 5.

Click the Exit button in the top left corner to finish the 3D Sketch.

6.

Hide Meshes and Mesh Fit(2), and Show Mesh Fit (1).

7.

Select the MODEL>Edit>Trim Surface command to trim the surfaces with the 3D Splines.  Select the first Spline in 3D Sketch(1) as the Tool Entities.  Select Mesh Fit(1) as the Target Entities.  Click the Next Stage button to continue.  Chose the correct larger portion of the surface as the Remaining Bodies.  Click the OK button to accept.

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8.

Repeat Step 7 using the second drawn Spline as the Tool Entities, and the Mesh Fit(2) as the Target Entities.

Figure 188

Figure 189 9.

Figure 190

Turn on visibility for both Trim Surface(1) and Trim Surface(2), and turn off visibility for 3D Sketch(1).

10. Select the MODEL>Create Surface>Loft command to join the surfaces.  Double check the Surface Loft command has been selected.  Select the Edge1 of Trim Surface1, and Edge2 of Trim Surface2 as the Profiles.  Set the Start Constraint and End Constraint to Tangency To Face. This will apply tangency to the lofted surface where it connects to the original surfaces.  Click the OK button to create the lofted surface.

Figure 193 Figure 192 Figure 191

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11. Finish joining all the surfaces into one body with the Sew command, found in the MODEL>Edit group.  Select all three surfaces as the Surface Bodies.  Click the Next Stage button.  Click the OK button to accept the result.

Figure 194  Alternatively, the Sew step can be skipped if the “Merge Tangent Faces” option is selected during the Loft command.

Reasoning for splitting the spline When trimming a surface by a curve, the split points on the curve will create a separate edge along the surface. Therefore, the surface edge length can be adjusted for lofting by editing the split points. If the edge lengths are of similar size when lofting, the resulting surface will be smoother and of higher quality.

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Figure 195 – 3D Sketch with Split

Figure 196 – 3D Sketch without Split

Figure 197 – Loft with Split

Figure 198 – Loft without Split

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Figure 199 – Deviation with Split

Figure 200 – Deviations without Split

Create Side Surfaces 1.

Hide Surface Loft1 to view the Mesh with Regions on.

2.

Choose the Loft Wizard command in the MODEL>Wizard.

3.

In the 1st stage of the Loft Wizard, set the location and orientation of the Loft.  Choose the three regions, shown in Figure 202, as the Regions/Poly Faces.  Change the Section option to By No. Of Sections, and set the value to 5.  Check the options match Figure 201.

Figure 202

Figure 201 4.

Rotate and adjust the manipulator to stretch the preview planes the long way across side body.

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5.

Click the Next Stage button to continue. A preview of the flow of the fitted surface body will be displayed.

Figure 204 6.

Turn on the Deviation for Body in the Accuracy Analyzer™, and use these deviations to add and move sections for a higher quality surface.

 Sections can be moved by clicking and dragging. Sections can be added by holding Ctrl and clicking and dragging the section planes.  These sections cannot be easily added and moved once the Loft Wizard has be completed.

Figure 205 7.

Figure 206

Click the OK button to finish the lofted surface.

Figure 207

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8.

Create the adjacent surface with a Mesh Fit surface. Select MODEL>Wizard>Mesh Fit on the ribbon.  Select the region shown in Figure 208 as the Target Regions/Poly-Faces.  Click the OK button to accept the surface using the previous settings.

Figure 208

Figure 209

Join Side Surfaces 1.

As done previously, enter into a 3D Sketch to create clean trim lines for lofting between surfaces.

2.

Hide Surface Loft1 and Surface Loft2 to only show the new Mesh Fit surface.

3.

Select the Spline tool in the 3D Sketch>Draw group.  Draw a Spline on the Mesh Fit3 surface body (Figure 210).  Hide the Mesh Fit3 surface and Show Surface Loft2.  Draw a second spline on the Surface Loft2 body (Figure 211).

Figure 210 Figure 211

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4.

Select the Split button in the 3D SKETCH>Edit group on the ribbon.  Turn on visibility of the Mesh Fit3 surface to see where the split points should be located.  Click on two points on the second spline to split the line.

5.

Click the Exit button in the top left corner to finish.

6.

Turn on the visibility for Mesh Fit3 and Surface Loft2.

7.

Select the MODEL>Edit>Trim Surface command on the ribbon.

Figure 212

 Select the first spline in 3D Sketch3 as the Tool Entities, and Mesh Fit(3) as the Target Entities.  Click the Next Stage button to continue.  Choose the correct Remaining Bodies.  Click the OK button.

Figure 214 Figure 213 8.

Repeat Step 7 using the second spline as the Tool Entity and Surface Loft2 as the Target Entity to Trim the lofted surface.

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Figure 216 Figure 215 9.

Hide 3D Sketch3, and Show Trim Surface3 and Trim Surface4.

10. Create a Surface Loft with the MODEL>Create Surface>Loft command to join the surfaces.  Select the Edge1 of Trim Surface3, and Edge2 of Trim Surface4 as the Profiles.  Set the Start Constraint and End Constraint to Tangency To Face. This will apply tangency to the lofted surface where it connects to the original surfaces.  Place a check next to Merge Tangent Faces in the Options rollup.  Click the OK button to create the lofted surface.

Figure 218 Figure 217

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Finish Side Surfaces 1.

Create the next with a Mesh Fit surface. Select MODEL>Wizard>Mesh Fit on the ribbon.  Select the region shown in Figure 219 as the Target Regions/Poly-Faces.  Click the OK button to accept the surface using the previous settings.

Figure 219

Figure 220

2.

Enter into a 3D Sketch to create clean trim lines for lofting between surfaces.

3.

Hide all surfaces except the new Mesh Fit surface.

4.

Select the Spline tool in the 3D Sketch>Draw group.  Draw a Spline on the Mesh Fit4 surface body (Figure 221).  Hide the Mesh Fit4 surface and Show Trimmed Surface3.  Draw a second spline on the Trimmed Surface3 body (Figure 222).

Figure 221 5.

Figure 222

Select the Split button in the 3D SKETCH>Edit group on the ribbon.  Click on two points on the second drawn, and longer, spline at approximately the length of the first spline.  Click OK to accept the Split.

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6.

Exit 3D Sketch with the button in the top left corner.

7.

Turn on the visibility for necessary surfaces.

8.

Select the MODEL>Edit>Trim Surface command on the ribbon.  Select the split spline in 3D Sketch4 as the Tool Entities, and Trim3 as the Target Entities.  Click the Next Stage button to continue.  Choose the correct Remaining Bodies.  Click the OK button.

Figure 224

Figure 225 9.

Figure 226

Select the MODEL>Edit>Trim Surface command on the ribbon.  Select the other spline in 3D Sketch4 as the Tool Entities, and Mesh Fit4 as the Target Entities.  Click the Next Stage button to continue.  Choose the correct Remaining Bodies.  Click the OK button.

Figure 227

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Figure 229

Figure 228 10. Hide 3D Sketch4 and show all the side surfaces.

11. Create a Surface Loft with the MODEL>Create Surface>Loft command to join the surfaces.  Select the Edge1 of Trim Surface5, and Edge2 of Trim Surface6 as the Profiles.  Set the Start Constraint and End Constraint to Tangency To Face. This will apply tangency to the lofted surface where it connects to the original surfaces.  Place a check next to Merge Tangent Faces in the Options rollup.  Click the OK button to create the lofted surface.

Figure 230

Figure 231

12. Click the Sew button in the MODEL > Edit group on the ribbon.  Select all the side surface bodies as the target Surface Bodies.  Click the Next Stage button to continue.  Check the previewed result and then click the OK button.  This step is only necessary if there are multiple side surfaces.

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Figure 232

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13. Click the Environment Mapping button in the Accuracy Analyzer™. Check continuity of the surface bodies.

Figure 233

Combine Upper and Side bodies 1.

Turn on the visibility of the upper and side surfaces (Surface Loft1 and Surface Loft4).

2.

Select the MODEL>Edit>Trim Surface command on the ribbon.  Select the Loft1 and Loft4 as the Tool Entities.  Deselect the Target checkbox.

Figure 234

Figure 235

 Click the Next Stage button to continue.  Choose the correct Remaining Bodies, as shown in the image below.  Click the OK button.

Figure 237

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Add Fillet 1.

Add a rounded, fillet edge to the connection of the two surfaces. Click the Fillet button in the MODEL > Edit group on the ribbon.  Change the method to Variable Fillet.  Select the edges between the two surfaces for the Entities, as shown in the image below.

Figure 239 Figure 238  Set R to 10-11mm for each edge.  These values can be directly edited by clicking them in the Profile view or in the graphic window.  Click the OK button.

Figure 241

Figure 240

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Finishing Features 1.

Begin a 3D Sketch by Right-Clicking in space in the Model View, and select the 3D Sketch icon.

2.

Draw a spline along either side of the fillet with the Draw>Spline tool.  Draw the first spline at the edge of the Fillet1 surface body to the first seam. (Figure 242).  Draw a second spline below the crooked fillet (Figure 243).

Figure 242 3.

Figure 243

Click the Split button in the 3D SKETCH > Edit group on the ribbon.  Select a point on the top spline near where the side surface ends.  Click the OK button to accept the command.

Figure 244 4.

Right-Click and select the Exit button to finish the 3D Sketch.

5.

Hide the Mesh. Show the Surface Body and 3D Sketch 5 only.

6.

Click the Split Face button in the MODEL>Body/Face group on the ribbon.  Select the split spline as the Tool Entities.  Select the upper surface face as the Target Entities, as shown in the image below.  Click OK button to accept the command.

7.

Repeat Step 6 using the lower spline and the side surface face. (Figure 246).

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Figure 246

Figure 245 8.

Remove the newly split area with the Delete Face command found in the MODEL>Body/Face group on the ribbon.  Select the Faces, as shown in Figure 247.  Click the OK button to remove the area between the splines. (Figure 248)

Figure 247 9.

Figure 248

Hide 3D Sketch5.

10. Create a Surface Loft with the MODEL>Create Surface>Loft.  Select Edge 1 and Edge 2 as the Profiles.  Apply the Start and End Constraint as Tangency To Face.  Select the small Edge 3 as the Guide Curve to create better connections with the surrounding surfaces.  Click the OK button and a lofted surface will be created.

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Figure 251 Figure 249

Figure 250

11. Repeat all of the previous steps on the other side where the fillet becomes unsmooth.

 3D Sketch on either side of the fillet with a spline to connect  Split Face of the surface using the 3D Sketch  Delete Face  Surface Loft

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Figure 252 – 3D Sketch

Figure 253 – 3 Splines with Split Point

Figure 254 – Split Face

Figure 255 – Split Face

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Figure 256 – Delete Face

Figure 257 – Removed Face

Figure 258 – Surface Loft

Figure 259 – Finished Surface

12. Sew the remaining surfaces together with the MODEL>Edit>Sew command.  Select all the surface bodies as the target Surface Bodies.  Click the Next Stage button to continue.  Check the previewed result and then click the OK button to accept.

 The model has more surfaces created and joined the same way the lesson demonstrated.  Continue creating surfaces or move to the Advanced Modeling section.

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Figure 260 13. Click the Deviation for Body and the Environment Mapping buttons in the Accuracy Analyzer™.

Figure 261

Figure 262 End of Activity

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Advanced Modeling ACTIVITY: Hybrid modeling

Objective Create a model by combination of automatic and parametric modeling. Hybrid modeling allows for quickly creating a model which has accuracy and parametric features. The resulting model is helpful for checking assembly and analyzing.

Highlighted Commands  Global Remesh  Enhance Shape  Optimize Mesh  Auto Surface  Sketch  Extrude - Cut

Training File 09-Knuckle.stl

Scan Setup 1.

Import training file 09-Knuckle.stl.  Click the Import button or select Import from Menu>Insert.  Use the Import Dialog to navigate to the training files folder. Choose Knuckle.stl from the Import dialog.  Click Import only. The file is loaded and displayed in the Model View.

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1.

Select the Auto Segment command located in REGION tab.

 The Auto Segment command can be activated by RMB context menu after selecting the mesh with a double click.  Set the Sensitivity to 10.

Figure 264  Press the OK button to finish the Auto Segment.

Figure 265 2.

Click the Knuckle from Feature Tree and select Copy from MENU>Edit (Ctrl+C).  Click the OK button to copy the selected mesh data.

 After editing a mesh to create a better Auto Surface, the original mesh will still be needed to show where cuts and features belong.

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Figure 266  Select Paste from MENU>Edit (Ctrl+V) and paste the Copied Mesh in Feature Tree.

Figure 267

Edit and Optimize Mesh 1.

Select Knuckle in Feature Tree to edit.

 For a higher quality Auto Surface, details can be removed from the mesh and smoothed over. The Copied Mesh can still be used to track these features and shapes to use for sketch based modeling.  When there are multiple meshes, a mesh needs to be selected before editing with the POLYGONS tab. 2.

Select Offset command located in POLYGONS>Edit group on the ribbon.

 Create thickness beforehand to cut to plane.  2016 3D Systems

Select ~8 regions while holding the Shift key (Figure 268).

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Figure 268  Change the Distance to 1mm.

Figure 269  Press the OK to finish the Offset.

Figure 270 3.

Select Global Remesh command located in POLYGONS tab.

 Recalculate the entire mesh to make watertight, and improve the mesh quality.  Verify the mesh is still selected in the Tree if the command is not available.  Change the Target Average Edge Length to 0.5mm.  Place a check next to Make Clean And Manifold Solid Mesh. 2016 3D Systems

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Figure 271  Press the OK check button and finish Global Remesh.

Figure 272  It is easier to see the mesh quality without Regions. Ctrl+2 will toggle Regions on and off.  Select Shaded With Edges (F8) from MENU>View>Mesh Display Mode to show the mesh edges. 4.

Select Enhance Shape command in POLYGONS>Optimize group on the ribbon.

 Improve the quality of the mesh by sharpening corners and smoothing flat or rounded areas.  Change the options like the figure below.

Figure 273  Press the OK check button and finish Enhance Shape.

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5.

Select Optimize Mesh command located in POLYGONS>Optimize>Global Remesh dropdown.

 Optimizes a mesh based on its feature shapes and improves the quality of the mesh. This command also offers advanced options to control the size of poly-faces and the effects of smoothing a model.  Change the Method to High Quality Mesh Conversion.

Figure 274  Press the OK check to finish Optimize Mesh.

Figure 275

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Create Solid Body 1.

Select the Auto Surface command located in SURFACING tab.  Select Knuckle for Mesh and click Organic button.

Figure 276  Press the OK check button and finish Optimize Mesh.

Figure 277

Create Cutting Planes Create reference planes which are used as base sketch. These planes should be located at original mesh not on offset mesh. 1.

Click Copied Mesh in Feature Tree.

 Hide the visibility of the Mesh Knuckle.  Select the Auto Segment command located in REGION tab.  Use the previous settings.  Press the OK check button and finish Auto Segment.

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Figure 278 2.

Select the Plane command located in MODEL>Ref. Geometry tab and group.  Select the Don’t Quit Command With OK Lock button to remain in the command after accepting.  Select both the regions like the figure below.  Verify the Method is set to Average.  Press the OK check button.

Figure 280

Figure 279 3.

Immediately create a new Plane.  Select the region as shown Figure 281 below.  Press the OK check button.

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4.

Select the region shown in Figure 283.  Press the OK check button.

Figure 284

Figure 283 5.

Select the region like Figure 285.  Click the OK check button.

Figure 286

Figure 285 6.

Select the region like Figure 287.  Click the OK check button.

Figure 288

Figure 287

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7.

Select the region like Figure 289.  Click the OK check button to create the sixth plane.

Figure 290

Figure 289  Press the Cancel button and finish the Plane command.

Create Sketches 1.

Create sketches to cut off redundant parts from solid model for machining.  Click Knuckle in Feature Tree.

2.

Select Mesh Sketch command in Setup group located in SKETCH tab.  Select Plane1 for Base Plane and press the OK check button.  Draw a sketch similar to Figure 291.  Press the EXIT button and finish the Mesh Sketch.

Figure 291 3.

Click Knuckle in Feature Tree and select Mesh Sketch in the SKETCH>Setup tab.  Select Plane2 for Base Plane and press the OK check button.

4.

Draw circular sketch line like the figure.  Press the Exit button and finish Mesh Sketch.

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5.

Click Knuckle in the Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane3 for Base Plane and press the OK check button.  Draw sketch similar to shown in Figure 293.

Figure 293  Press the EXIT button and finish Mesh Sketch. 6.

Click Knuckle in the Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane4 for Base Plane and press the OK check button.  Draw sketch line like the figure.

Figure 294  Press the EXIT button and finish Mesh Sketch.

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7.

Click Knuckle in the Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane5 for Base Plane and press the OK check button.  Draw sketch line like the figure.  Press the EXIT button and finish Mesh Sketch.

Figure 295 8.

Click Knuckle in the Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane6 for Base Plane and press the OK check button.  Draw sketch line like the figure.  Press the EXIT button and finish Mesh Sketch.

Figure 296 9.

Show only Solid Bodies and Sketches in the Model View.

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Cut Solid Body by Extruding Sketches 1.

Extrude each sketch with the MODEL>Create Solid>Extrude command to cut the Solid Body.  Select Sketch1 (Mesh) for Base Sketch.  Set the Method to Blind with a Length of 20 mm.  Place a check in the Cut box in Result Operator.

Figure 298  Press the OK check button and finish Extrude.

Figure 299

Figure 300

 Repeat operation to cut the body. 2.

Select the Extrude command.

 Use Ctrl+Space bar to execute previous command.  Select Sketch2 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button. 2016 3D Systems

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Figure 301 3.

Figure 302

Select the Extrude command.  Select Sketch3 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 304

Figure 303 4.

Select Sketch4 (Mesh) in the Feature Tree, then Right-Click in space and select the Extrude (Solid) icon.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 306

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5.

Select the Extrude command with any method.  Select Sketch5 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 308

Figure 307 6.

Select the Extrude command with any method.  Select Sketch6 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 310

Figure 309

Make a Hole for Assembly 1.

Select the Vector command located in MODEL>Ref. Geometry tab.

 Create the axis of the Cylinder.  Select Top plane and Right plane for Entities and create a vector which will intersect both Planes.

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Figure 311  Press the OK check button and finish Vector. 2.

Click Copied Mesh in Feature Tree.

3.

Right-Click in space, then select the Mesh Sketch icon.  Select Right plane for Base Plane.  Click the Apply check button.  Draw sketch line as shown in Figure 312.

Figure 312  Press the EXIT button and finish Mesh Sketch. 4.

Select the Revolve command from Create Solid group located in MODEL tab.  Select Sketch7 (Mesh) for Base Sketch,  Select Vector1 for Axis.  Select the Cut check box in Result Operator.

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Figure 313  Press the OK check button and finish Revolve.

Figure 314

End of Activity

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ACTIVITY: Impeller Workflow

Objective Create an impeller using surfacing and solid tools.

Highlighted Commands  Revolving Silhouette Mesh Sketch Setup  Loft Wizard

Training File 10-Impeller.stl

Scan Preparation 1.

Import training file 10-Impeller.stl.  Click the Import button or select Import from Menu>Insert.  Use the Import Dialog to navigate to the training files folder. Choose Impeller.stl from the Import dialog.  Click Import only. The file is loaded and displayed in the Model View.

Figure 315 2.

In the POLYGON tab, use the Fill Holes and Smart Brush command to clean and smooth a single vane of the impeller.

 Assuming all blades are the same, only one will need to be edited for the modeling. The single modeled vane can be patterned.  With the Repair Holes/Boss>Fill Holes command, select all the holes on one vane to fill in with Curvature.  Use the Wizard>Smart Brush command and the Smooth option to paint the specific areas that are rough. 2016 3D Systems

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Figure 316 3.

Figure 317

In the Tree dock, change the tab to Viewpoint.  Orient the part to focus on the edited vane.  Select the Add Viewpoint button to save the view.  Toggle back to the Tree dock.

Figure 318

 The Viewpoint can be saved for later use to be able to quickly move back to the edited vane. 4.

After editing the mesh, use the Optimize>Decimate command to reduce the triangle count.  Select the Allowable Deviation method with a value of 0.01 mm in the Options.  Accept the command to see the new triangle count.

Figure 319 Figure 320

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5.

Select the Auto Segment command located in REGION tab.  Set the Sensitivity to 5 then accept.

6.

Use the Edit>Merge command to merge the the regions on either side of the cleaned vane.  Hold Shift and select the multiple regions on a single face.  The Merge button is now active. Select.  Repeat process on other side face of vane.

Figure 321

Align To Coordinate System 1.

Create Ref. Geometry>Vector to more accurately align the scan.  Select the Revolving Axis method.  Select all regions where the central axis would be the same as the center of the impeller.  Preview and then Accept the Vector.

Figure 322 2.

Align the scan to the coordinate system using ALIGNMENT>Scan to Global>Interactive Alignment.  Verify the mesh is selected then go to the Next Stage.  Change the Method to XYZ.  For Position, select the Vector1 and a Plane Region on the bottom of the scan.  Set Axis Z to Vector1. If needed, Flip Direction of the positive axis.  Use the Blue Circle of the Manipulator to clock the part about the Z Axis. Rotate until the X Axis (Right Plane) is passing through the edited vane.  Check the alignment is in position on the right half of the screen then Accept.

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Figure 324

Figure 323

Main Body 1.

Create a Mesh Sketch on the Right Plane.  Change the method to Rotational Method.  Use the Offset Angle From Base Plane or the Green Circle to rotate the base plane to find the best sketch angle for the main body of the impeller.  Accept the sketch setup.

Figure 325 2.

Sketch the inner profile shown in Figure 326.  Use Arc and Line tools to create a sketch of the inside profile of the impeller.  Exit the sketch when finished.

 The bottom post is not rotational and does not need to be sketched.

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Figure 326 3.

Create the body with Create Solid>Revolve.  Set the previous sketch as the Base Sketch and Profile.  Select the Centerline of the Sketch as the Axis.  Accept the command.

Figure 327

Figure 328

Vane 1.

Create a surface on either side of the cleaned vane with a Loft Wizard or Mesh Fit command.

Option 1  RMB on the region of one side of the cleaned vane scan and choose the Loft Wizard icon.  In Section, select By No. Of Sections, then set the No. Of Sections to 7, and increase the smoothness.  In Profile Types, select Ref. Planes and Mesh Sketches. 2016 3D Systems

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 Adjust the size of the bounding box of the surface with the red, green, and blue dots to be much larger than the mesh, then go to the Next Stage.  Turn on the Deviation From Body.  LMB and hold on the planes to readjust the position of the planes.  Ctrl+LMB on a plane will add a new plane. Readjust the planes to reach the desired accuracy then accept the command.

Figure 329

Figure 330

Option 2  RMB on the region of one side of the cleaned vane scan and choose the Mesh Fit icon.  Make any desired adjustments to the settings, or press the OK button to accept the command.

Figure 331

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Figure 332

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2.

Repeat either option on the other side of the vane.

3.

Edit any sketches created by the Loft Wizard to smooth and better the surface.  RMB on Sketch 5(Mesh), or any other sketch created by the loft wizard, and choose Edit.  Select the generated spline.  In the Rebuild Spline>No. Of Interp. Pts box, enter 20 then press Enter.  Look at the spline, then edit the value again but to 10.

Figure 333

Figure 334

 Exit the sketch to see how much smoother the surface is in one spot. 4.

Repeat Step 3 on the other sketches as desired.

 Reducing the spline points is one way to edit the loft wizard to change the resulting surface.  Other ways could be to completely remove the spline and remake the sketch using lines and arcs.

Figure 336- Edited Surface

Figure 335- Original Surface 5.

Create a Mesh Sketch on the Right Plane to capture the outer profile of the vane.  Change the option to Rotational Method for the sketch setup.  Pull the Green Arrow or change the Silhouette Range to encompass the entire cleaned vane, then accept the command.

 The Rotational Silhouette Range will create a wedge to contain the desired area, and then project by rotating about an axis.  The Offset Angle can also be adjusted for a better cross section.  Create the sketch of the outside vane profile using Line and Arc tools.  Use Figure 338 to create the sketch then Exit. 2016 3D Systems

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 An open profile sketch can be used only for surfaces. Close the sketch to create a solid revolve.

Figure 337 6.

Figure 338

Use the Create Surface>Revolve to revolve the surface the necessary amout to enclose the surfaced vane.

 The Sihlouette command will place the sketch near the vane or on the opposite side of the impeller.  A small rotation in both directions could be needed, or a large rotation to encompass the entire vane.

Figure 339 7.

Create an Edit>Surface Offset of the original rotated body to completely enclose an impeller vane.  Select all faces along the top of the solid.  Change the Offset Distance to 0 mm then accept.

 An offset at 0 is duplicating and creating a surface on the solid face to use in more commands.

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Figure 340 Figure 341– Enclosed Vane 8.

Select MENU>Insert>Surface>Solidify to create a solid from the selected surfaces.  Select the four surface bodies needed to enclose a vane and accept the command.

 If an error occurs or a surface does not extend fully through the other surfaces, use the Extend Surface tool to lengthen the surface before repeating the Solidify command.  Check the Visibility of the Solid Bodies is on to view the main body and single vane. 9.

Use the MODEL>Edit>Fillet command to place a small fillet on the top edges of the vane.

Figure 342

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Figure 343

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10. Select Pattern>Circular Pattern to create the remaining vanes.  Choose the Vane as the Bodies.  Select Vector1 as the Rotation Axis.  Set the No. Of Instances to 16.

Figure 344

Edits and Shaft 1.

Merge all solid bodies to one body with the Edit>Boolean command.  Set the Operation Method to Merge.  Select all 17 solid bodies as the Tool Bodies then accept to have a single solid body remaining.

2.

Create the lower shaft using a Mesh Sketch on the Front Plane or any plane normal to the shaft.  Offset the Offset Distance From Base Plane to cross through the triangular shaft and accept the set up.  Use Arc and Fillet tools to create the sketch then Exit when completed.

Figure 345 2016 3D Systems

Figure 346

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3.

Create Solid>Extrude the sketch to create and merge the shaft.  Use the Up to Region method with the Max Position sub method.  Select the lower region of the scan shaft.  Check the Merge option is selected under Result Operator, then Accept.

Figure 347 4.

Create a Mesh Sketch on the top face of the shaft to cut out the top hole.  Select the top solid face as the Base Plane.  Offset the sketch profile down slightly to see the inside circle then accept the Mesh Sketch Setup.  Sketch the inside Circle then Exit the sketch to cut out the hole.

Figure 348

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Figure 349

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5.

Cut out the hole with the Create Solid>Extrude command.  Set the Method to Blind and cut down about 25 mm in to the mesh.  Set the Result Operator to Cut.  Accept the command.

Figure 350 6.

Repeat process for lower hole in shaft.

Figure 351 7.

Add Fillets where needed on the model.

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Exact Surfacing Exact Surfacing is a workflow designated to create a very accurate surface on a complex scan. The new SURFACING toolbar walks through the steps needed to create a good patch network to generate the surfaces. The Create/Edit Patch Network group in the SURFACING tab has all the tools needed to create the surface. Step 1: Extract Contour Curves –Detect and automatically extract 3D contour curves for the area of high curvature on a mesh. These curves can be edited and adjusted manually to create a better Patch Layout.

Figure 354

Step 2: Construct Patch Network – Automatically construct the patch network within the patch layout.

Figure 355

Step 3: Shuffle Patch Groups – Reorient the patches within the panels in a 3D patch network for better continuity.

Figure 356

Step 4: Fit Surface Patches- Create NURBS surfaces inside each patch of the 3D patch network. An accurate freeform surface body will be created.

Figure 357

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ACTIVITY: Exact surface

Objective Learn about exact surfacing. This exercise converts a polygon object to an exact surfaces object and activities the remainder of the exact surfaces tab. This workflow generates surfaces match the object exactly as it is constructed.

Highlighted Commands  Extract Contour curves  3D curves  Construct Patch Network  Shuffle Patch Groups  Fit Surface Patches

Training File 12-Exact Surface.xrl

Import file 1.

Open training file 11-Exact Surface.xrl  Click the Open button or select Open from Menu>File>Open.  Use the Open Dialog to navigate to the training files folder. Choose 11-Exact Surface.xrl from the Open dialog.  Click Open. The file is loaded and displayed in the Model View.

Figure 358

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Extract counter network 1.

Go to the SURFACING tab to begin the Exact Surfacing workflow. the Extract Contour Curves and set the curvature Sensitivity Potion to 60 and then click to next stage  Select the Extract Contour Curves command in the Create/Edit Patch Network group.  Set the Curvature Sensitivity Position to 60 then select the Next Stage button.

 The Extract Contour Curves command automatically places red separators between regions of relative flatness. The Next Stage allows adjustment of those region separators and then places 3D contour lines inside the regions.

Figure 359

Figure 360 2.

In the Next Stage, click the Enable Real Time Preview option to have live feedback of the editing of the separators.  Use the Paint Brush Selection Mode to add, remove, and clean regions.

 Best practice will be to extend all separator regions to a scan boundary, similar to Figure 457.  Edit the Contour Curves regions as shown in Figure 362.  Hold Ctrl when selecting to remove separator regions.  Other selection modes, such as the Line, Rectangle, and Circle can be used to edit separators.

Figure 361 - Before Editing

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Figure 362 - After Editing

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Figure 363 – Edited Separators

Edit Contour Curves on a Mesh 1.

The generated contour curves are now a 3D Sketch. Go to the 3D SKETCH tab to edit.  Select all of the Contour Curves by pressing Ctrl+A or box selecting the part.  In the ribbon, find the Rebuild Toolbar. Change the value of No. of Interp. Pts to 10 then click the OK button.

 Each curve will now have 10 points; therefore, the contour curves are more easily controlled.

Figure 365

Figure 364 2.

Select a junction point on the contour curves and swing the point back and forth so that the connected curves are smoothed.

3.

Adjust all contour curves to be continuous and four sided. The Edit>Trim tool can remove extra segments.

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Figure 367 - After Editing

Figure 366 - Before Editing 4.

Select all of the Contour Curves and Rebuild them again.  In the ribbon, find the Rebuild Toolbar. Change the value of No. of Interp. Pts to 20 then click the OK button.

5.

Verify all lines are straight and the patches seem continous.

 Each of these four sided figures is a panel. The panels will dictate the layout of the patch network.

Figure 368

Constructing a 3D Patch Network 1.

Allow the software to automatically construct a patch network from the panels created previously with the Construct Patch Network step. This is found in the Create/Edit Patch Network group.

 Note that Construct Patch Network command can be found in the 3D SKETCHING and the SURFACING tabs. In both of these tabs, the command is located within the same group.

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Figure 370

Edit 3D Patch Network 1.

In the 3D SKETCH or SURFACING tab, choose the Create/Edit Patch Network>Shuffle Patch Groups command.  Click on a panel as shown in the Figure 371.

2.

Select Add/Del 2 Paths in the Action roll up, and select the Auto Fill Neighboring Panels option in the More Option roll up.

 The Auto Fill will match the number of paths in the adjacent panel when paths are added or removed.  Select a point along the lower side of the panel to increase the number of paths along the edge until the edges match.  To decrease the number of paths in a panel, hold Ctrl when clicking on the panel edge.

Figure 372

Figure 371 3.

Click the Deselect Current Planel next to Action in the top roll up to clear the previous selection and make choose a new panel to edit.  In the More Option roll up, click the Next arrows to navigate through patch panels and find the ones needing rearranging.

4.

Select a panel that needs to be shuffled and repeat steps 2 and 3 until all panels have equal patch sides.

 While the define option is selected in Action, check the vertices of each panel is properly placed in each corner of the panel. If not, click the vertex to redefine and Accept.

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Figure 373

Create a NURBS Surface 1.

In the SURFACING tab, choose the Fit Surface>Fit Surface Patches command.  Select the 3D Sketch1(Mesh) as the Mesh Curves base.  Select the Adaptive option as Fitting Method.

Figure 374

 Adjust the slider of the Geometry Capture Accuracy option to one notch away from Max to improve the accuracy of the fitting surface patches.

Figure 375

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Figure 376 End of Activity

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ACTIVITY: Self Exercise

Objective Create a propeller using the skills learned throughout the training course.

Highlighted Commands  Interactive Alignment  Mesh Sketch – Silhouette  Loft Wizard/Mesh Fit  Revolve

Training File 12-SelfExercise.stl

Figure 377

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Appendix I – Mouse and Keyboard Control Mouse Control The default Right-Hand Mouse is shown.  Selection Button o Change tabs in ribbon o Activate commands o Select and activate entities

LMB

o Make individual or box selections

 Scroll Wheel o Zoom in and out of center of screen. Roll the mouse up and away to increase magnification; roll the mouse down to decrease magnification.  Toggle Button

MMB

o Activate second level of mouse buttons. Most buttons will rotate the part.

 Rotate Button o Hold to rotate the view of the part about the center of the screen.  Context Menu

RMB

o Activate common commands based on the entity selected. o Accept and Exit Commands

 Pan o Move the part laterally on the screen.

LMB and RMB

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Shortcut Keys Listed in the table are the commonly used default Shortcut Keys. These shortcut keys will allow quicker access to certain functions quickly without selecting the function from the Tool Bar.

Command

Shortcut Key

Menu New Open Save Select All Select Inverse Undo Redo Repeat Last Command

Ctrl+N Ctrl+O Ctrl+S Ctrl+A, Shift+A Shift+I Ctrl+Z Ctrl+Y Ctrl+Space

Zoom Fit Meshes Visibility Regions Visibility Point Cloud Visibility Surface Bodies Visibility Solid Bodies Visibility Sketches Visibility 3D Sketches Visibility Ref. Points Visibility Ref. Vectors Visibility Ref. Planes Visibility Normal To

Ctrl+F Ctrl+1 Ctrl+2 Ctrl+3 Ctrl+4 Ctrl+5 Ctrl+6 Ctrl+7 Ctrl+8 Ctrl+9 Ctrl+0 Ctrl+Shift+A

View

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Appendix II - Mesh Editing ACTIVITY: Mirroring scans

Objective This training course is designed to show how to mirror half a scan and edit the mesh of a bottle scan to prepare it for either 3D printing or modeling.

Highlighted Commands  Mirror  Thicken

Training File Bottle.stl

Import Scan Data 1. Import the Scan Data found at:

(~/Appendix/Bottle.stl)

Figure 379

Add a Reference Plane 1. Hold down the Ctrl button and click-drag the Right plane to the neck of the bottle by 105mm.

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2. Click the Visibility icon next to the Top Plane and Right Plane entities in the Model View to hide them, leaving on the Front Plane and Plane1 visible.

Figure 381

Figure 382

Splitting the Mesh 1. Click the POLYGONS>Edit>Split button in the ribbon.  Select the By Entity method.  Choose Plane1 as the Tool Entity.  Do not use the Cap Section Ends option and toggle the Don’t Quit Command With OK button to turn it off.

Figure 383 2. Click the Next Stage button. 3. Select the region to remain and click the OK button.  Make sure to select the larger section of the bottle and de-select the smaller section.

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Figure 384

Figure 385

Mirror and Thicken 1. Click the Mirror button in the MENU>Tools>Mesh Tools>Mirror option.  Select the Front base plane as the Position.  Enable the Trim & Merge with the Remesh Poly-Faces Around Mirror Plane option enabled.

Figure 386

Figure 387

2. Click the OK button. The mesh will be identically mirrored across the Front base plane.

Figure 388

Figure 389

3. Click the POLYGONS >Edit>Thicken button on the ribbon. This command creates a constant thickness along the walls of the model.  Choose the Surface method, set the Thickness to 2mm and choose the Direction2 option.

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Figure 390

Figure 391

4. Click the OK button and the mesh will now have a thickness of 2mm.

Figure 392

Figure 393

5. The mesh of the bottle is now complete and thickened and ready for the modeling process.

Figure 394 End of Activity

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ACTIVITY: Global Mesh Enhancing

Objective This training course is designed to show how to optimize and enhance messy scan data.

Highlighted Commands  Optimize Group  Decimate  Enhance Shape

Training File Grasshopper.stl

Import 1. Import the Scan Data found at: (~/Appendix/Grasshopper.stl)

Figure 395

Hide Reference Planes 1. In this training the Ref. Planes will not be utilized, so they can be hidden from the Model View by pressing the Ctrl + 0 keyboard shortcut or by clicking the visibility icon next to the Ref. Planes entity in the Model Tree.

Figure 396

Change Mesh Color 1. Click the Right Mouse Button (RMB) on the Grasshopper entity in the Model Tree and select Properties from the pop-up menu if it is not already visibile on the right side toolbar.

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 

Click the Material option in the Appearance options. Change the color to the green material.

Figure 398 3. Click the OK button. The color of the mesh material for the model will change to green.

Figure 399  Changing the color of the mesh is used to help in recognizing the mesh in the application. It does not change the color information of the mesh file.

Global Remesh 1. Click the Global Remesh button in the POLYGONS>Optimize group.  Set the Edge Length Multiplier to 1 to create similar edge lengths for the entire model.  Enable the Make Clean And Manifold Mesh option to generate a clean and closed mesh.

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 Click the OK button.  The mesh will now be globally remeshed by regenerating mesh structures and removing defects from the curvature flow of the mesh. All poly-faces will be remeshed to have the same edge length, resulting in a more uniform mesh.

Figure 401 – Before Remesh

Figure 402 – After Remesh

Decimating the Mesh Show Edge 1. Enable the Edge option under the Mesh section in the Display tab, or press the F8 key on the keyboard.

Figure 403

Decimate 1. Click the Decimate button in the POLYGONS>Optimize group.  Click the Don’t Quit Command With OK button to continuously use the comm and without exiting it.  Set the Reduction Ratio to 70%.  Click the OK button to apply the command without exiting it.

Figure 404

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2. Apply the command again by clicking the OK button, then click the Cancel button.  The mesh will be reduced by 70% again to further reduce the poly-face count.

Figure 405

Figure 406

Optimize Mesh 1. Click the Optimize Mesh button in the POLYGONS>Optimize>Global Remesh dropdown group.  Select the High Quality Mesh Conversion Method.  Set the Min Edge Length Multiplier to 0.5 and the Max Edge Length Multiplier to 8.

Figure 407  This method creates regular sized triangles from the original mesh by generating more triangles in high curvature regions and fewer triangles in low curvature regions. 2. Click the OK button. The mesh will now be optimized.

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Enhance Shape 1. Click the Enhance Shape button in the POLYGONS>Optimize group.  Change the Overall Smoothness to Mid and the Enhance Level setting to Max.

Figure 410 2. Click the OK button. Areas of high curvature will become sharper than the original shape. Apply this command again with the same options to emphasis sharper areas even more.

Smooth 1. Click the Smooth button in the POLYGONS>Optimize group.  Change the Smoothness Level to Max.

Figure 411 2. Click the OK button. The mesh will be smoother globally.

magic Design X ning

Figure 412

Figure 413

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ACTIVITY: Mesh Editing

Objective This training course is designed to show how to edit the mesh of a phone scan to prepare it for the modeling process.

Highlighted Commands  Defeature  Fill Holes  Edit Boundaries  Healing Wizard

Training File Phone.stl

Import Scan Data 1. Import the Scan Data found at:

(~/Appendix/Phone.stl)

Figure 414

Defeature 1. Click the Defeature button in the POLYGONS>Repair Holes/Boss group.  Click-drag and release around an area near the top of the phone as shown in the image below.

Figure 415  The defeature command is useful for models where small irregular features exist that may hinder the modeling process. 2016 3D Systems

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2. Click the OK button. The feature will be removed.

Figure 416

Fill Holes 1. Click the Fill Holes button in the POLYGONS>Repair Holes/Boss group.  Toggle on the Don’t Quit Command With OK button to continuously use the command without exiting it.  Select the microphone hole boundary on the bottom of the phone (Figure 417) using the default settings.  Click the OK button.

Figure 417

Figure 418

Add Bridge 1. Click the Add Bridge button in the Editing Tools.  Click on hold the LMB on the edge of one triangle on one side of the gap seen below.  Drag the mouse to the other side and release one an edge is highlighted.

Figure 419  Adding bridges is useful for filling in complicated holes or boundary areas that are irregular in shape.

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2. Click the Boundaries button and  Select the boundary created by the bridge shown in Figure 420.  Toggle off the Don’t Quit Command With OK button to disable it and then click the OK button to complete the command.

Figure 420

Figure 421

Edit Boundaries 1. Click the Edit Boundaries button in the POLYGONS>Edit group. This command enhances boundary shapes on a mesh.  Toggle on the Don’t Quit Command With OK button.  Select the Fit method and change the Fit Option to Circle.  Select the largest circular boundary in the middle of the model shown in Figure 423.

Figure 422 

Figure 423

Figure 424

Click the OK button. The boundary will be changed to a circle.

2. Change the Method to Smooth and select the outer boundary of the mesh. Set the Select N-Depth Boundary to 3.

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Figure 425 

Click the OK button. The boundary will be smoothed by 3 poly-faces from the original boundary. 3. Click the Cancel to exit.

Figure 426

Figure 427

Healing Wizard The wizard will remove unwanted and irregular poly-faces using an automated wizard process.

Remove Dangling Poly-Faces 1. To remove any remaining dangling poly-faces on the mesh boundary, click the Healing Wizard button in the POLYGONS>Wizard group.  De-select all options except for the Dangling Poly-Faces option.

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Figure 429 2. Click the OK button. The dangling poly faces on the mesh will be removed.

Figure 430

 Dangling Poly-Faces are edges that are not connected to neighboring poly-faces.

2 Sides Open

3 Sides Open

End of Activity

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Appendix III – Additional Models ACTIVITY: Iterative modeling

Objective Reinforce common skills, such as importing scan data, region segmentation and editing, and 2D sketching and basic modeling concepts to create a parametric model. Reverse model a casting and iterate the model to the desired result by modifying the parametric features.

Highlighted Commands and Concepts  Mesh Sketch Setup (Advanced)  Convert Entities  Iterative Modeling

Training File A1-Iterative Model.stl

Scan Setup 1.

Import training file A1-Iterative Model.stl.

 The model is not a complete scan, but all the information required to model is available.

Figure 431 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 65.  Click the OK checkmark to accept.

3.

Switch to the Geometry Type Display Mode from the Upper-Side Toolbar.

 Each specific geometry will have a specific assigned color. For example, all Planes will be blue.

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Method 1: Extracting Geometry 1.

While still in the REGION tab, Hold Ctrl and select all three regions of the curved top face.  Select the Edit>Merge command to merge the regions.

 Certain commands in the extracting geometry workflow require the selection of a single region.

Figure 433 2.

Use the Extrusion Wizard to quickly create a base body.  RMB click on the recently merged region and select Insert/Merge.  Click the Select None next to Sides then Top.

3.

The automatically selected regions were not appropriate for the desired outcome.  For Top, select the Freeform, merged region on the mesh, and for the Bottom select the Ref. Plane Front plane.  For Sides, select the three Plane walls.  Set the Custom Extrusion Direction to the Ref. Plane Front to be able to select Fix Sketch Plane With Selection.

 The extracted 2D Sketch for the upcoming Extrusion will be placed on the Front Plane.  Uncheck the Draft Angle option.

Figure 435 Figure 434

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4.

Select the Next Stage arrow to view and edit the generated sketch and extrusion.  Slide the Resolution slide bar all the way to Min to avoid the noise of the scan data in the final sketch. It should appear as a rectangle.  Set the Geometry Capture Accuracy all the way to Loose to allow for constraint (Perpendicular, Tangent, etc.) entities to be assigned to the sketch.  Accept the Extrusion Wizard as long as the created body is previewed.

Figure 436 5.

RMB click on the Sketch1(Mesh) that has been created in the Feature Tree, and select Edit.

 Wizard parameterscannot be edited after acceptance because editable, parametric features are created in the Feature Tree.  Select the Front Viewpoint from the Upper-Side Toolbar.  Adjust the right-most line to better fit the model.  Exit the sketch to re-extrude the base.

Figure 438

Figure 437

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6.

Inspect the quality of the surface by checking different Surface Analyzing Modes.  From the Upper-Side Toolbar, or Accuracy Analyzer dock, select Deviation For Body. The majority of the surface is green so within our desired tolerance.  Change the option to Iso Line. This will show the curvature of the freeform surface.

 Although this is a quick way of extracting the actual situation of the scan data, it is not always the desired method. The top, freeform surface is not editable in CAD. The surface is not easily reusable because its flow cannot be controlled by the user.

Figure 439

Figure 440

Method 2: Creating Geometry  Looking and investigating the nature of the top surface, it is a surface that consists of two differently tilted areas that are blended between. Do not delete or undo the previous body. It can still be utilized in the next method. 1.

Create a Mesh Sketch on each of the side faces of the solid body.  Select the actual face of the side wall shown in the Figure as the Base Plane.  Set the Offset Distance From Base Plane to 1 mm inward on the part.  Click OK to begin sketching.

 Tilted surfaces should ideally get a zero offset, but some cases require a slight offset to capture better data.

Figure 441

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2.

Set the left and right edges of the base by converting the extracted base.

 Turn the visibility of the Solid Bodies ON and the visibility of the Meshes OFF.  RMB click on the left-most vertical edge and select Convert Entities.  Repeat on the right-most vertical edge. 3.

These lines have a Converted Constraint. Change the lines to Construction Lines.  RMB click on each line and select the Make As Construction Line symbol.

 Hide the Solid Bodies to avoid selecting when finishing the sketch.

Figure 444 Figure 443 4.

Finish the sketch with the Line and Corner Trim tools.  With the Line tool, double click on the long diagonal pink profile line.  Use the Corner Trim command to connect the diagonal to the vertical lines.

5.

Add Dimensions using the Smart Dimensions command.  Select the end point of the diagonal top line, vertically down to the U Axis to define the height.  Repeat on the other vertical line.  Turn on the Deviation from the Upper-Side Toolbar to adjust the best assumed heights.

 In the Accuracy Analyzer dock, increase the Vector Multiplier to view the deviation easier.  Change the dimensions to the best fit height, or adjust to match Figure 445.  Exit the sketch.

Figure 445

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6.

Repeat the same process for the opposite face.

 Mesh Sketch on the solid face, offset 1mm inward.  Convert the vertical edges and make as construction.  Dimension to match Figure 446.

Figure 446 7.

The other two sides needs to be created using Mesh Sketches and the previous sketches.  Set up the Mesh Sketch on a remaining face, offset inward 1 mm.  Create a Line on a straight stretch of the pink profile line by using the rectangular selection method of drawing a line (Figure 447).  Double-click on the end point then Shift+LMB on the grey line of the previous sketch.  Select the Pierce Constraint from the Common Constraints List.  Repeat on the other side of pink profile lines.

Figure 447

Figure 449

Figure 448

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8.

Use a Spline tool and only two points to connect the open entities.  Add Tangent constraints to the connection of the spline and each line. This will allow the spline to bend and better fit the polylines.  Use Smart Dimensions to define the sketch as shown in Figure 450.

Figure 450 9.

Repeat this process on the other side.

 Mesh Sketch on the face with the profile offset 1mm inward.  Create two lines and Pierce them to the previous sketches.  Use a spline to connect the two lines.  Constrain and Dimension.

Figure 451 10. Create the top surface using the MODEL>Create Surface>Loft command.  For the Profiles, select both sketch chains with the splines.  The Surface Normal depends on the order the profiles are selected. Choosing the profiles from right bottom to left bottom, or left top to right top, will create a surface normal pointed in the desired direction.

Figure 453

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11. Use the MODEL>Body/Face>Replace Face command to use the newly lofted surface.  For Target Faces, choose the extracted, curved top face of the solid body.  For Tool Entity, select Loft1 from the Model Tree.  Accept the command to finish the solid.

Figure 454

12. Check the changes in the different deviations between the Extracted geometry and the geometry created with sketches and dimensions.

Figure 455 – Extracted Deviation

Figure 456 – Extracted Iso-Line

Figure 457 – Extracted Design Quality

Figure 458 – Created Deviation

Figure 459 – Created Iso-Line

Figure 460 – Created Design Quality

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Casting Body Features 1.

Find the position and orientation of the rib feature.  Method 1: Create Ref. Geometry>Vector, and select the Cylinder region shown and the Front plane.  Change the Method to Projection then accept the command.

 This method is most accurate to the scan data, but unable to change parameters of the vector. The created vector will not be used.

Figure 461

 Method 2: Create a Ref. Geometry>Polyline, and select the top fillet regions of the rib feature.  Change the Method to Fillet then accept the command.  Polylines can be inserted into Mesh Sketches and sketch entities will snap to the lines to give full control of the shape and form. 2.

Figure 462

Create a Mesh Sketch on the Front Plane with 0 offset.  Bring the Ref. Polyline into this sketch using MENU>Tools>Sketch Tools>Insert Polyline.  Sketch a Line on the inserted polyline.  Convert the intersecting edges of the solid base and Make as Construction Geometry.  Use the Edit>Extend tool to extend the sketched line to the converted edges.  Dimension the endpoints and angle of the line to the vertical V Axis.

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3.

Create a Ref. Geometry>Plane on the sketch line.  Choose the Right Plane and Sketch (Curve 1) as the Entities.  Change the Method to Projection and accept.

 A plane, orthogonal to the Front Plane, will now be set on the sketch line to use to create the rib. 4.

Create a Mesh Sketch with the new plane, Plane 1, as the Base Plane.  To capture the maximum height and profile of the rib, set the Silhouette Range to be wider than the rib, about 38 mm and accept the sketch setup.

 The upper and lower boundaries of a volume around the section plane will be projected to the base plane.

Figure 465 5.

Sketch the profile of the rib as shown in Figure 466.  Use the Auto Sketch tool to quickly extract sketch entities from the poly-lines.  Adjust the Resolution slide bar to find the appropriate poly-line segments.  With Make Selected Only, choose the top profile of the rib and accept the dialog.

Figure 466 6.

Use Convert Entities to bring in the lower line of the rib sketch profile.  Select the line from the previous sketch.

7.

Trim the profile to close the sketch loop.

8.

Smart Dimension the sketch to define the rib, then Exit the sketch.

 A 4.5° draft between the vertical and side lines of the sketch were added for manufacturing purposes.

Figure 467

 For better maintainability, sharp corners were created. Dimensions on the corner points, rather than the arc centers, will allow for easier radii changes. 2016 3D Systems

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9.

Select Create Solid>Extrude from the previous sketch to generate a solid model.  Select all three closed sketch loops for the Profiles.  Set the Method to Mid Plane. Drag the arrow until it snaps to the upper boundary of the planar side region.  Change the Length value to a round number.  Remove all checks under Result Operator, and then Accept the Extrude.

 A draft is still needed for the extruded sides, but it will be added at a later step.

Figure 468

Figure 469

10. In the MODEL tab, select Edit>Fillet.  In Constant Fillet, select the corner edge of the extruded rib.  Use the small Measure Radius button next to the Radius input field.  Click on the larger radius sketch entity.  Verify the Radius is now set to 75 mm.  Accept the command.

Figure 470 11. Apply the Edit>Draft command on the rib.  Set the method to Parting Line Draft.  Select the planar, top face of the rib as the Pull Direction.  For Parting Lines, select 4 planar and 2 round edges along either side of the top rib face, with their respective arrows pointed down, in to the part.  Adjust the draft Angle to 4° with this arrow pointing up and away from the part.  Accept the Draft.

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Figure 471 12. Apply a Fillet to the smaller edge of the rib, the same was as in Step 9.  In Constant Fillet, select the corner edge of the extruded rib.  Use the small Measure Radius button next to the Radius input field.  Click on the larger radius sketch entity.  Verify the Radius is set to 20 mm then Accept the command.

Figure 472

13. Press the Ctrl+Space keyboard keys to repeat the previous command of Fillet.  Change the type to Full Face Fillet to round the entire rib face.  Select one of the large side faces as the Left, and the other large face as Right.  Select the top rib face as the Center and Accept.

Figure 473

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Adjustments and Deviation Checking 1.

Turn on the Deviation for Body to see how the solid model matches the scan. Make adjustments as needed.  The four sketches (Sketch2-5(Mesh)) guiding the lofted face can be edited to minimize deviation of the top freeform loft face.  To edit the Spline Tangent Lengths, double-click on the Spline inside of the Sketch to enter the Properties Dialog Tree. Click, hold, and drag the Tangent Arrow around to create a smoother tangent transition. (Figure 475)  Edit the Extrusion width to fit the scan width better.  Adjust the position and angles of the rib with Sketch6(Mesh) and Sketch7(Mesh).

Figure 474

Figure 475

Figure 476 - Extracted

Figure 477 - Extracted

Figure 478 - Extracted

Figure 479 - Created

Figure 480 - Created

Figure 481 - Created

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Cone Features 1.

Generate an editable axis for one of the cone features by creating a Mesh Sketch.  Select the Right Plane as the Base Plane.  Offset the Section Poly-line until it is in the cone region (Figure 482), about 60 mm.

2.

Use the Draw>Circle tool to find a center point of the central cone axis.  Double click on the pink arc line to create the circle.  Use Smart Dimension to fully define the center point.

 The Cone could be quickly and easily made with the RMB Insert/Merge command to extract from the scan data. Accurate to the scan geometry would be generated, but it would not be easily editable.

Figure 483

Figure 482 3.

Create a Ref. Geometry>Vector for the central axis of the cone.  Select the Sketch Circle Center and the Right Plane.  Change, if not done automatically, the Method to Pick Point and Line.

4.

Quickly generate the cone body with the Revolution Wizard.  RMB click on the Cone Region and select the Insert/Merge icon.  Add the fillet region and the planar face region to the Target.  Place a Check next to Get Partial Shape then go to the Next Stage.

5.

The second stage allows for slight editing of the revolution and base sketch.  Modify the angle of revolution with the green and grey arrows.  Lower the Resolution slide for clean faces of the cone and no fillet in the sketch.

Figure 485

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6.

After accepting the wizard, investigate the revolved shape by looking from the Front Viewpoint. A gap between the cone and the rib is revealed.  RMB click on Sketch9(Mesh) in the Feature Tree and select Edit.  Click and drag the right edge further in to the rib section, then Exit the sketch.

Figure 486 7.

Figure 487

Figure 488

The previous cone was perpendicular to the ref. coordinate system. Create the axis of the second cone by again using a Mesh Sketch.  Use the Front Plane as the Base Plane, and offset the section until it crosses through the entire conical face. They polylines will look like Figure 489.  Accept the sketch setup and create the dimensioned sketch shown in Figure 490.  Start with the Parabola tool found under Draw>Ellipse. Four points are needed to create the parabola.  Use best judgement to choose the center point of the parabola. It should be near the apex. Use Figure 489 to help place the other points of the parabola.

 Just try to get the parabola close to the pink poly-lines. Dimensions and constraints will edit and move the entity.  Use the Centerline tool to draw a line between the center point and the apex point of the parabola. This line will be used to set angles and begin other dimensioning.  Use the Smart Dimension to manipulate and find the central axis of the parabola.

Figure 490

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8.

Create a Ref. Geometry>Plane with this center line.  Select the Top Plane and the Center Line of parabola as the Entities.  Change the Method to Projection if it does not change automatically.

Figure 491 9.

RMB click and select Insert/Merge on the Cone Region.  Change the view to the Bottom Viewpoint.  Notice the extracted axis generated by the Revolution Wizard is at about the same height as Vector 1.

 This assumption can be used when manually generating this axis. The Revolution Wizard can show how the cone should be made, but it will be difficult to edit.  Cancel the wizard command. 10. Create a new Mesh Sketch on the new Plane 2.  RMB click on Vector 1 and select Convert Entities.  The center line is constrained to the first cone. Edits to this axis will change the axis of this cone.  To edit the center line independently, delete the Converted constraint and add a dimension and horizontal constraint.

Figure 492 11. Create a Ref. Geometry>Vector on the center line from the previous sketch using the Extract Method.

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12. Right-Click on the Cone Region and select the Insert/Merge icon.  Check the Revolution Wizard has automatically found Plane 2 and the Vector 2 to use for the sketch and the revolution.  Adjust the Auto Sketch Options to find the best fitting Cone.  Increase the degrees of revolution by pulling on the arrows.  Accept the wizard command.

Figure 493

Figure 494

13. Right-Click on Sketch12 (Mesh) and select Edit.  Adjust the length of the sketches to ensure it is long enough and extends in to the rib.  Dimension the part to constrain the sketch and make it easier to edit in the future.

Figure 495 - Example of dimensioning 14. If needed, adjust any sketch or center lines of the first cone axis or parabola to fit better deviations.  Turn on Deviation for Body to check how each edit can affect the overall part.  If entities are converted or tied to a previous entity, one edit could change multiple parts.

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Figure 497

Figure 496

Figure 498

Pin Feature 1.

Investigate the final pin feature.  This feature has the least amount of information available from the scan.  From the Right Viewpoint, the two different angles of the pin are visible.

2.

Create a Mesh Sketch on the Front Plane.  Offset the section to about 62.5 mm; above the fillet in an area with the most possible amount of data.  Create a sketch on the slot cross section. Draw the Center Line of the slot.  Exit the sketch.

 The information of the slot cross section can allow for the assumption that it is perpendicular to the Top plane.

Figure 499

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3.

Select the Ref. Geometry>Plane tool to create the sketch plane for the side of the pin.  Select the Center Line of the slot sketch, and the Right Plane.  Change Method to Projection if necessary.  Accept the command.

4.

Create a Mesh Sketch on this new Plane 3 and begin sketching.  Since the left and right sides of the sketch have different draft angles, the best approach would be to create half the sketch and then mirror it about a center line.  Create half of the sketch with the Line tool, and fully constrain with the Smart Dimension.  Use the Center Line command and find the center of the feature.

 This sketch will control the position of the pin, the tilt of the top and side faces, and the draft of the side faces.

Figure 501 5.

Create the sketching plane for the top shape of the pin by generating a new Ref. Geometry>Plane.  Turn on the Visibility of Sketch 14(Mesh).  Select the Front Plane and the top Line of the last sketch.  Change the Method to Projection.

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6.

Create a Sketch on the new Plane 4.  Use the Circle command to create a circle from the center point of the line from the last sketch to the end point of the sketch.  Use the Pierce and Converted commands to constrain the sketch and pull in points needed for constraining.  Use the Center Line and Offset commands to create split points for the circle.

 The two arcs should be separate so different extrusions can be made to account for different draft angles.  Accept the sketch when it looks similar to Figure 503.

Figure 503 7.

Insert a Create Surface>Extrude to generate one side face of the pin at a time.  Sketch 15 will be the Base Sketch, but only have one Sketch Chain as the Profile at a time.  Select Custom Direction and choose the angled centerline from Sketch 14(Mesh).  Place a check next to Draft and set the angle to 4.5°, as calculated in the sketch, so the extrusion will match up with the solid line.  Set the Method to Up To Vertex and select the end point of the line used for Custom Direction.  Accept the Extrude.

8.

Repeat Step 7 to the other profile from Sketch 15.

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Geomagic Design X 2016

Figure 505

Figure 504 9.

To join the two open surfaces, use the Create Surface>Loft command.  The two facing edges will be the Profiles.  Apply a Curvature To Face, Start and End Constraint.  Add a Check to Add Side Curve Influence.  Accept the Loft.

Figure 506 10. Use the Edit>Fill Face command to close the top and bottom faces of the pin and create a solid body.  Select the four edges of the circular opening for Edges.  Apply a check next to both options in More Options to create a closed entity.  Accept the command. 11. Repeat Step 10 to the slot shaped opening of the pin.

2016 3D Systems

Figure 507

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Geomagic Design X 2016

Fillets 1.

Use the Edit>Boolean command to create a single solid body.  Set the Operation Method to Merge.  Select all solid bodies as Tool Bodies then accept the command.

 In the Model Tree, only one Solid Body should remain. 2.

Turn on the Deviation for Body to see where all the Fillets are needed.

Figure 508 3.

Choose the MODEL>Edit>Fillet command to generate the rounded edges.  Use a Constant Fillet on each of the fillets around the cones.  Select an edge of the Solid Body, then press the Magic Wand button to Estimate the Radius from the Mesh. This found value can be adjusted to the nearest round number.  Press the Add Radius plus sign button to insert a different size fillet in the same command.  Select a different edge and press the Magic Wand button again to read this fillet.  Repeat on the other cone fillets then accept the Fillet command.

4.

Create a new Fillet for the fillet where the casting body meets the freeform face.  Select an edge then press the Magic Wand to find the value.

 Since this fillet was done after the cone edge fillets, all the edges should be tangent making only a single click to select the edges necessary. Check all needed edges are selected.

Figure 510

Figure 509

2016 3D Systems

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Geomagic Design X 2016

5.

Create one more Fillet around the edges of the pin.

Figure 511 6.

Use a Fillet>Face Fillet to define the top edge of the pin feature.

 A width of the fillet segment would change with the angles of the faces of the pin in a constant fillet. The Face Fillet would keep a constant width even with changes to the face angles.  For the first set of Faces, choose only the top face of the pin.  Select the green based Faces set and click on the side faces of the pin.  Turn the Deviation for Body on to see what Radius would be best.  Change the Radius to 5 mm and accept the Fillet.

Figure 512 7.

Check the different Deviations of the finished solid model.

Figure 514

Figure 513 2016 3D Systems

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Geomagic Design X 2016

Figure 515

Figure 516

End of Activity

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Geomagic Design X 2016

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1 Licensing Guide For All Geomagic Products November, 2013

2 Copyright Notice D Systems, Inc. All rights reserved. Produced in the USA. 11/30/13 The content of this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by 3D Systems, Inc. Any names, places, and/or events in this publication are not intended to correspond or relate in any way to individuals, groups or associations. Any similarity or likeness of the names, places, and/or events in this publication to those of any individual, living or dead, place, event, or that of any group or association is purely coincidental and unintentional. No warranties of any kind are created or extended by this publication. Any products and related material disclosed in this publication have only been furnished pursuant and subject to the terms and conditions of a duly executed agreement to license the Software. Any warranties made by 3D Systems, Inc. with respect to the Software described in this publication are set forth in the License Agreement provided with the Software and printed in this publication. As more definitively stated and set forth in the License Agreement, 3D Systems, Inc. does not and will not accept any financial or other responsibility that may result from use of the Software or any accompanying material including, without limitation, any direct, indirect, special or consequential damages. Individuals or organizations using the Software should ensure that the user of this information and/or the Software complies with the laws, rules, and regulations of the jurisdictions with respect to which it is used. This includes all applicable laws concerning the export of technology and the protection of intangible or intellectual property rights. 3D Systems, Inc. asserts its rights in and will endeavor to enforce all proprietary rights embodied in the Software and this publication including, without limitation, all copyright, patent, trademark, and trade secrets or proprietary information. The only rights given to an individual or organization purchasing the Software are those explicitly set forth in the License Agreement. Other than as explicitly allowed in the License Agreement, copying the Software or this material (including any format or language translation) is prohibited absent the prior written consent of 3D Systems, Inc. 3D Systems, 3D Systems, Inc., Geomagic, Geomagic Capture, Geomagic Design, Geomagic Design X, Geomagic Design Direct, Geomagic Studio, Geomagic Verify, Geomagic Control, Geomagic Wrap, Geomagic Freeform, Geomagic Freeform Plus, Geomagic Sculpt, Geomagic Capture for SolidWorks, Geomagic Capture for SpaceClaim, and all product logos are either registered trademarks or trademarks of 3D Systems, Inc. All other trademarks within this user guide & tutorial are the property of their respective owners and are used for identification purposes only. Other than to identify this Software and publication, individuals or organizations purchasing the software are not entitled to use 3D Systems s trademarks without 3D Systems s prior written consent. Correspondence regarding this publication should be directed to: 3D Systems, Inc. Geomagic Solutions Web:

3 Table of Contents 1. OVERVIEW LICESING QUESTIONS AND SUPPORT GETTING AN EVALUATION LICENSE PRODUCT LICENSING Virtual Dongle (Node Lock) Geomagic License Utility Virtual Dongle with Local Network Sharing (Floating) Geomagic License Server Utility for Server License Geomagic License Utility for Client License USB Dongle LICENSING WITH VIRTUAL DONGLE (NODE LOCK) Product Activation Product Deactivation License Expiration Updating a License Repairing a License LICENSING WITH VIRTUAL DONGLE WITH LOCAL NETWORK SHARING (FLOATING) Product Activation Server Activation Client Activation Checking Server License Information Product Deactivation Server Deactivation Client Deactivation License Expiration Repairing a License... 26

4 6.5. Borrowing a License Borrowing of a License Returning a Borrowed License Changing Port Number Changing Port Number on Server Changing a Port Number on a Client LICENSING WITH USB DONGLE Using USB Dongle Activation and Deactivation Product Maintanece Date Expires Maintenance Date Update Using USB Floating Dongle Install Dongle Driver Check Floating Server Working... 37

5 1. Overview Evaluation License Geomagic products can be used for free for a certain period of time without an activation code for evaluation purposes. Product Licensing Geomagic supports licensing tools to activate, deactivate, update, borrow, or repair a license depending on the license type. Activating and Deactivating a License Licenses should be activated to use products and deactivated when moving licenses or changing PC's. Activation and deactivation methods for licenses differ depending on network connectivity. License Expiration After a license expires, the application will display options that include obtaining a renewal code, reactivation using a previously obtained renewal code, and switching to a floating license from a license server. Updating a License Depending on the type of license received and network connectivity, updating a Geomagic product can be accomplished in multiple ways. Repairing a License When a Geomagic product does not run due to license problems, the license may need to be repaired. Licenses can be repaired using the repair function in the Geomagic License Utility. Licensing Guide Overview 1

6 Borrowing a License When a license type is a virtual dongle with local network sharing (floating) and a user would like to temporarily use Geomagic software on a client PC without accessing the license server system, a license can be borrowed for an assigned period. Changing Port Number If a license conflicts with the port of another application, change the port number. The application uses port by default. Licensing Guide Overview 2

7 2. Licesing Questions and Support If you have any question and problem about licensing or pricing, please contact us using the details below: Phone: Toll-free in the USA: Korea Phone: APAC Phone: China Phone: Japan Phone: EMEA(Europe) Phone: +49 (0) Geomagic Solutions Technical Support Web Sites Technical Support Addresses Training Training Licensing Marketing m Licensing Guide 3

8 3. Getting an Evaluation License Geomagic products can be used for free for a certain period of time without an activation code for evaluation purposes. 1. Install an evaluation version of a Geomagic product and start the application. Note: If this is your first time to execute a trial version of the application, click the Activate Trial button then fill your address in the registration field to register your account. In the next time, you can use the trial version of the application for a certain period by clicking the "Continue Trial" button 2. During the evaluation period, the remaining days until expiration will be displayed in the title bar and the following page in the middle of the application. 3. Once an evaluation period of an application expires, it cannot be used on the same PC again. When the application is opened and the evaluation period is expired, a dialog box will be displayed. It can be used to renew an activation code, or to activate a renewal activation code if one has already been obtained. Licensing Guide Getting an Evaluation License 4

9 Licensing Guide Getting an Evaluation License 5

10 4. Product Licensing Geomagic supports three types of licenses: Virtual Dongle (Node Lock) Is the default license type for Geomagic. You can activate or deactivate licenses to move from PC to another PC. Internet access is required for this license type. Virtual Dongle with Local Network Sharing (Floating) With a Local Network Sharing license; multiple users can access a pool of licenses stored on a local server. This requires the installation and activation of the Geomagic License Server utility on a computer within your local network. At least local network access is required for this license type. USB Dongle Is a physical license key that can execute the application. Licensing tools differ depending on the license type Virtual Dongle (Node Lock) This section explains the Geomagic License Utility license management system Geomagic License Utility The Geomagic License Utility can be accessed by going to Start > All Programs > 3D Systems > Product Name and it also supports manual licensing. Licensing Guide Product Licensing 6

11 License Management License Information: Shows the Expiration Date, Maintenance Date, Status, and Code of a license. Activation: Users can activate a license by going to Help > Activate License. Alternatively, this menu in the Geomagic License Utility can be used. License information Update: updates the license information. Deactivation: Deactivates a license. Licenses should be deactivated when changing PC's. Open File: Opens a.asr file to complete licensing when extending an evaluation license License Support License Repair: Repairs broken licenses. A license needs to be repaired when a system date is changed after receiving the license. License Assistance: Makes a log file. Log files help to solve problems when requesting support. License Setting License Type: Selects any license type of a Virtual Dongle,Virtual Dongle with Local Network Sharing license, or USB Dongle. Help Help: Opens the Licensing Guide Virtual Dongle with Local Network Sharing (Floating) This section explains the Geomagic License Server Utility on a server PC and the Geomagic License Utility on a client PC and how licenses are managed by communication between client and server PC's. Licensing Guide Product Licensing 7

12 Note: For a floating license the License Information option in the Help menu in the application only shows license information. To make changes to a license the Geomagic License Utility must be used Geomagic License Server Utility for Server License The Geomagic License Server Utility found at Start > All Programs > 3D Systems > Geomagic License Server Utility supports server licenses. License Management License Information: Shows licenses that can be managed. Activation: Registers a license. License Information Update: Updates the license information. Deactivation: Deactivates a license. Licenses should be deactivated when changing PC's. License Support License Repair: Repairs broken licenses. A license needs to be repaired when a system date is changed after receiving the license. License Assistance: Makes a log file. Log files help to solve problems when requesting support. Licensing Guide Product Licensing 8

13 License Setting Geomagic License Service: Used for manual activation or deactivation of floating licenses. Change TCP/IP Port Number: Changes the TCP/IP port number between a server and a client. Help Help: Opens the Licensing Guide Geomagic License Utility for Client License The Geomagic License Utility found at Start > All Programs > 3D Systems > Product Name supports client licenses. License Management License Server Registration: Registers a license server by using its server name and TCP/IP port number. Borrowing License: Borrows licenses from a registered license server. Borrowed license can be returned to the license server when a user is using a local network sharing (floating) virtual dongle license and wants to temporarily use the application on a client PC without accessing the license server system. License Support License Repair: Repairs broken licenses. A license needs to be repaired when a system date is changed after receiving the license. Licensing Guide Product Licensing 9

14 License Assistance: Makes a log file. Log files help to solve problems when requesting support. License Setting License Type: Selects any license type of a Virtual Dongle,Virtual Dongle with Local Network Sharing license, or USB Dongle. Help Help: Opens the Licensing Guide USB Dongle License Management License Information: Displays the current maintenance date and contains the option to update the maintenance code if necessary. License Support License Assistance: Makes a log file. Log files help to solve problems when requesting support. License Setting License Type: Selects any license type of a Virtual Dongle, Virtual Dongle with Local Network Sharing license type, or Physical Dongle. Licensing Guide Product Licensing 10

15 Help Help: Opens the Licensing Guide. Licensing Guide Product Licensing 11

16 5. Licensing with Virtual Dongle (Node Lock) This chapter explains how to do the followings: Activate a Product Deactivate a Product Renew an Expired License Update a License Repair a License 5.1. Product Activation When a PC is connected to the internet, all activation codes will be automatically validated. 1. When the dialog is displayed, click the Run License Tool to use Geomagic License Utility. Note: There are another ways to use the Geomagic License Utility: Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility and click the Activation menu to activate a license. 2. Select Virtual Dongle. Licensing Guide 12

17 3. Enter an activation code and address. 4. Click the (Next) button. Note: If you already registered your account, the activation process will be done in this step. If you are a first time user, go to the next step to continue. 5. Fill your information in the fields to create a new user account. Note: Items marked by an asterisk (*) are mandatory. Licensing Guide Licensing with Virtual Dongle (Node Lock) 13

18 6. Click the (Next) button. 7. Click the OK button to confirm information. 8. When the activation process is completed, a confirmation screen will be displayed. Click the (Close) button. Note: Maintain online environment. You will not be able to use the application unless the license information is updated for 30 days. Connect your pc to the internet and run the application to update the license information. Licensing Guide Licensing with Virtual Dongle (Node Lock) 14

19 5.2. Product Deactivation When changing PCs or installing a new OS, existing licenses will need to be deactivated. 1. Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility and click Deactivate License in the menu. 2. Select licenses to deactivate. 3. Click the (Next) button. 4. The deactivation status will be displayed. Click the (Close) button. Licensing Guide Licensing with Virtual Dongle (Node Lock) 15

20 5.3. License Expiration After a license expires, the application will display options that including obtaining a renewal code, reactivation using a previously obtained renewal code, or switching to a floating license from a license server. There are three options: Virtual Dongle An activation page will be displayed depending on network status. Virtual Dongle with Local Network Sharing An activation page will be displayed depending on network status. USB Dongle Guides you to use the USB Dongle. Buy Now Click the Buy Now button to contact the nearest reseller or local office for renewing or purchasing a license Updating a License Generally, the license information is automatically updated, However, the license information can be manually updated by pressing the License Information Update button. Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility and click the Licensing Guide Licensing with Virtual Dongle (Node Lock) 16

21 License Information Update button Repairing a License 1. Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility. 2. Click the License Repair menu. 3. Select licenses to repair. 4. Click the (Next) button. 5. A dialog window showing the repair status will be displayed. Licensing Guide Licensing with Virtual Dongle (Node Lock) 17

22 Licensing Guide Licensing with Virtual Dongle (Node Lock) 18

23 6. Licensing with Virtual Dongle with Local Network Sharing (Floating) This chapter explains how to do the followings: Activate a Product Deactivate a Product Renew an Expired License Update a License Repair a License Borrow a License Change a Port Number 6.1. Product Activation When a PC is connected to the internet, all activation codes will be automatically validated. It is necessary to activate a Geomagic License Server PC and allow it to communicate with client PCs. It is used to manage licenses for a server and clients Server Activation Install the Setup Geomagic License Server Utility.exe file that is located at: C:\Program Files\3D Systems\Product Name\License. A new folder will be created at the following location: C:\Program Files\3D Systems\Geomagic License Server Utility. Licensing Guide 19

24 1. Go to Start > All Programs > 3D Systems > Geomagic License Server Utility > GeomagicLicenseUtility.exe. 2. Click the Activation menu to activate a code. 3. Enter an activation code and address. 4. Click the (Next) button. Note: If you already registered your account, the activation process will be done in this step. If you are a first time user, go to the next step to continue. 5. Fill your information in the fields to create a new user account. Note: Items marked by an asterisk (*) are mandatory. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 20

25 6. Click the (Next) button. 7. Click the OK button to confirm user information. 8. When the activation process is completed, a confirmation screen will be displayed. Click the (Close) button. Note: You can check the log for the license service running by using the Open Service log menu in the Geomagic License Service. If the service failed to run, click the Stop Service and the Start Service in consecutive order to restart the license service. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 21

26 Note: Maintain online environment. You will not be able to use the application unless the license information is updated for 30 days. Connect your pc to the internet and run the application to update the license information Client Activation 1. When the dialog is displayed, click the Run License Tool to use Geomagic License Utility. Note: There are another ways to use the Geomagic License Utility: Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility and click the Activation menu to activate a license. 2. Select Virtual Dongle with Local Network Sharing. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 22

27 3. Enter a Server Name or IP address. 4. Click the Register Server button. 5. Click the OK button to connect to the Geomagic License Server. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 23

28 6. Restart Geomagic products to activate the license Checking Server License Information 1. Go to Start > All Programs > 3D Systems > Geomagic License Server Utility > GeomagicLicenseUtility.exe. 2. Click License Information option in the menu to check license information. 3. A list of all activated licenses will be displayed Product Deactivation When changing PCs or installing a new OS, existing licenses need to be deactivated Server Deactivation Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 24

29 1. Go to Start > All Programs > 3D Systems > Geomagic License Server Utility > GeomagicLicenseUtility.exe. 2. Select licenses to deactivate. 3. Click the (Next) button. 4. A dialog window showing the deactivation status will be displayed Client Deactivation Virtual Dongle with Local Network Sharing (Floating) licenses are not saved on a client PC because client PC's gets the licenses from a server PC. Therefore, there is no deactivation involved for a client PC. If the server is changed, clients will need to change the server name to the correct one when they start the application. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 25

30 6.3. License Expiration After a license expires, the application will display options that including obtaining a renewal code, reactivation using a previously obtained renewal code, or switching to a floating license from a license server. There are three options: Virtual Dongle An activation page will be displayed depending on network status. Virtual Dongle with Local Network Sharing An activation page will be displayed depending on network status. USB Dongle Guides you to use the USB Dongle. Buy Now Click the Buy Now button to contact the nearest reseller or local office for renewing or purchasing a license Repairing a License 1. Go to Start > All Programs > 3D Systems > Geomagic License Server Utility > Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 26

31 GeomagicLicenseUtility.exe. 2. Click the License Repair menu. 3. Select licenses to repair. 4. Click the (Next) button. 5. A dialog window showing the repair statuses will be displayed. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 27

32 6.5. Borrowing a License When a license type is a virtual dongle with local network sharing (floating) and a user would like to temporarily use Geomagic software on a client PC without accessing the license server system, a license can be borrowed for an assigned period Borrowing of a License 1. Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility. 2. Click the Borrowing License option. 3. Select a product to borrow a license for and click the drop-down arrow next to the Borrow button. 4. Set an ending date. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 28

33 5. Click the Borrow button. 6. The Expiration Date will show the final date of the borrowing period Returning a Borrowed License To return a borrowed license, connect to the license server system before the borrowed time period expires and follow the process below: 1. Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility. 2. Click the Borrowing License option. 3. Select a product license to return. 4. Click the Return button. 5. The Expiration Date will be blank after the license has successfully been returned. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 29

34 6.6. Changing Port Number If a license conflicts with the port of another application and the license type is a virtual dongle with local network sharing (floating), the TCP/IP port number can be changed. The application uses port by default Changing Port Number on Server 1. Go to Start > All Programs > 3D Systems > Geomagic license Server Utility > GeomagicLicenseUtility.exe. 2. Click the Change TCP/IP Port Number option. 3. Enter a TCP/IP Port Number. A number from 1024 to except for reserved numbers such as is available but a number between and is recommended. 4. Click the Change TCP/IP Port Number button. 5. The TCP/IP port number will be changed. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 30

35 Changing a Port Number on a Client 1. Go to Start > All Programs > 3D Systems > Product Name > Geomagic License Utility. 2. Click the License Server Registration option. 3. Select a Server Name to change the port number. 4. Click the Remove Server button. 5. Enter a Server Name/IP Address and a new TCP/IP Port Number. 6. Click the Register Server button. 7. The server with the new TCP/IP port number will be registered. Note: The TCP/IP port number between a server and a client must be the same to enable communication. Licensing Guide Licensing with Virtual Dongle with Local Network Sharing (Floating) 31

36 7. Licensing with USB Dongle Geomagic products support two different types of USB dongle license types: USB Dongle - Is a physical USB key that includes license information to be able to use the application on a PC. USB Floating Dongle Is a physical USB key that includes license information to be able to use the application on multiple client PC. This chapter explains how to do the followings: Use USB Dongle Use USB Floating Dongle 7.1. Using USB Dongle This chapter explains how to do the followings with USB dongle: Activate and Deactivate Product Maintenance Date Expires Maintenance Date Update Activation and Deactivation Product Licensing Guide Licensing with USB Dongle 32

37 You can easily activate and deactivate the license for your products by inserting the USB dongle into the USB port on your PC. 1. Insert the USB dongle into the USB port on your PC. 2. Check if the red light is turned on and your products run with the USB dongle Maintanece Date Expires The USB dongle s maintenance date is depending on your license contract with 3D Systems, Inc. Once the maintenance date expired, you will see the popup message on your screen as shown in the image below. If you meet the screen, you need to update the maintenance date of your USB dongle. Licensing Guide Licensing with USB Dongle 33

38 Maintenance Date Update To update the maintenance date of your USB dongle, contact Geomagic Solutions reseller or regional sales manager. 1. Contact Geomagic Solutions regional sales manager or reseller and request them Update Maintenance file. 2. After getting the Update Maintenance file, Insert the USB dongle into the USB port on your working PC 3. Install the Update Maintenance file on the PC 4. Check if the red light is turned on and the application run with the USB dongle Using USB Floating Dongle This chapter explains how to do the followings: Install Dongle Driver Check Floating Server Working Install Dongle Driver To start the floating license service on your server PC using the USB Floating Dongle, you need to first install the dongle driver for the USB Floating Dongle. 1. Find lmsetup.exe and aksmon32_setup.exe by going to License folder following the product installation path. 2. Double click the lmsetup.exe to install the HASP License Manager and USB dongle driver. Licensing Guide Licensing with USB Dongle 34

39 3. Click the Next button to continue the installation. Note: When you meet the installation Type stage as shown in the image below, select the Service option and click the Next button to continue. 4. The installation of lmsetup.exe file is completed. Licensing Guide Licensing with USB Dongle 35

40 5. Double click the aksmon32_setup.exe file to install the monitoring tool on the server PC for USB Floating Dongle. 6. Click the Next button to continue the installation. 7. The installation of aksmon32_setup.exe file is completed Licensing Guide Licensing with USB Dongle 36

41 8. Insert the USB Floating Dongle into the USB port on the server PC. 9. Check if the red light on the USB Floating Dongle is turned on and the products run on the Client PC Check Floating Server Working By using the USB Floating Dongle monitoring tool, you can monitor which clients are currently connected to the server PC and using the products. 1. Go to All Programs > Aladdin > Monitor > AKS Monitor and click the AKS Monitor application. Licensing Guide Licensing with USB Dongle 37

42 2. Go to Control Panel > Administrative Tools > Servicecs and check if the HASP Loader is started. 3. Check which clients are currently connected to the server PC and using the products. Licensing Guide Licensing with USB Dongle 38

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- Fixed FLATSHOT and SOLPROF to generate complete projections and create arcs and circles (not elliptical)
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progeCAD 2017.0.6.15 is a free update for all existing progeCAD 2017 customers and it is highly recommended that users update to this version. For users of ealier versions of progeCAD they can select the appropriate upgrade product from our webstore. A free trial version of progeCAD 2017 (x64 and 32-bit architectures) can be downloaded from this page. CADprofi can be downloaded from CADDIT.net here. Addtional questions regarding CADprofi or progeCAD software can be submitted via the CADDIT contact page.
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Deliver precise digital 3D models and CAD assemblies of physical objects for design, engineering, and manufacturing. Solve complex design and manufacturing challenges with unique sculpting and organic 3D design software that facilitates fast 3D modeling of complex, highly-detailed, organic shapes for prototyping or manufacturing. Prepare and optimize parts for printing quickly and easily.

Print quality parts faster using both plastic and metal materials. Shorten your product delivery time and boost productivity by reducing both programming and machining time with software solutions for both additive and subtractive manufacturing, plastic and metal materials. Bring the power of 3D scan-based inspection to more people in more places with industry-leading metrology software that makes it easy to capture and interpret scan data.

Increase uptime, lower operating costs, and improve production efficiency with fleet monitoring and remote diagnostic applications in the 3D production environment. Software For your entire digital manufacturing workflow.

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Reverse Engineering Deliver precise digital 3D models and CAD assemblies of physical objects for design, engineering, and manufacturing. Geomagic Design X. Highlights Enables faster time to market, better fit, and longer product life cycles Works seamlessly with any CAD software Provides complete toolsets for solids, surfaces, and meshes Combines scan processing and CAD plus real-time feedback Works like your CAD software so you can start using it right away.

Learn More. Geomagic Wrap. Design for Manufacturing Solve complex design and manufacturing challenges with unique sculpting and organic 3D design software that facilitates fast 3D modeling of complex, highly-detailed, organic shapes for prototyping or manufacturing. Geomagic Freeform.

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Highlights Creates sculpted shapes, especially products that precisely fit the human body Lets you add aesthetic and functional details that are difficult or impossible in CAD Ensures designs are ready for additive, subtractive, or formative manufacturing Enables transition from handcrafting to digital design with an intuitive haptic interface Supports primary mesh file formats for scan data import and live scanning for select scanners.

Highlights Provides a single, integrated, dedicated solution for tooling Boosts productivity Handles any geometry Machines any part Has local training and support from tooling experts. Highlights Supports all model preparation steps and various imaging modalities, 3D file formats, and 3D printers Creates 3D models in minutes using automatic segmentation tools Enables pre-operative surgical planning and patient consent Overlays results on patient scan to ensure precision Provides intuitive editing tools and enhanced 3D visualization.

Highlights Programs any CNC machine using a single CAM software solution Offers an easy-to-use, customizable interface designed specifically for NC programming Provides a proven, error-free library of post processors developed in-house Features accurate, industry-leading machine simulation for the most complex machines Enables multi-task machining MTM programming. Highlights Supports every additive manufacturing AM workflow step, from design to post-processing Prepares designs for AM to achieve successful, quality 3D prints Optimizes design structure with lighter weights and enhanced functional properties Streamlines preparation and optimization processes for shorter lead times Reduces print time, material consumption, and post-processing.

Highlights Streamlines time to print with a single, easy-to-use interface Facilitates file preparation with native CAD import Enhances manufacturing efficiency with finely-tuned supports Increases productivity with auto placement Accurately estimates material usage and print time. Inspection Bring the power of 3D scan-based inspection to more people in more places with industry-leading metrology software that makes it easy to capture and interpret scan data.

Geomagic Control X. Highlights Makes it easy to both capture and interpret scan data Enables anyone to get results with little or no training Handles huge data sets quickly and easily with scan-native algorithms built on a CAD kernel Provides all the tools you need for professional-level inspection Works with any 3D scanner or PCMM arm. Management Increase uptime, lower operating costs, and improve production efficiency with fleet monitoring and remote diagnostic applications in the 3D production environment.

Highlights Provides active system management and proactive service alerts to 3D Systems Enables real-time remote diagnosis Automatically creates support cases Offers intelligent preventative maintenance Plans service visits and parts ordering.

Customer Stories. With over twenty years of experience in the point-of-sale POS industry, VAULT combines its industry knowledge with an agile design-to-production workflow to answer the growing need for quality-made, uniquely branded POS stands and enclosures.

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Secure data deletion tools. We show you which tools you can use.Bring the power of 3D scan-based inspection to more people in more places with industry-leading 3D metrology software that makes it easy to capture and interpret scan data. Geomagic Control X empowers everyone to measure, understand, and make decisions about their parts faster, more often, and more completely—from anywhere. Geomagic Control X includes features to help you ensure quality for each stage of your manufacturing workflow including designing, manufacturing, inspecting, and maintaining.

Geomagic Control X gives you simple and powerful inspection capabilities leading to better decision making, improved efficiency for inspection workflows, and lower overall risks and costs.

It focuses on making the inspection process easier, allowing access to everyone who participates in the inspection process, and enhancing features to provide greater productivity in metrology workflows.

Geomagic Control X is available as a standalone software license or bundled software license package:. Learn whether 3D scanning is right for your inspection needs.

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Watch a demonstration by a 3D Systems application engineer of the 3D compare, color bar, and annotations features in Geomagic Control X. We currently show that you have Opted In to email communications. If you wish to wish to manage your preferences, you may click here to visit your Preference Center.

Use Geomagic Control X with comprehensive reverse engineering software to create feature-based, editable solid models compatible with existing CAD software. Use Geomagic Control X with powerful scan processing software to transform 3D scan data and imported files into 3D models for immediate use downstream. We provide professional-grade online 3D printing and manufacturing services that empower designers and engineers with the tools to design, iterate, and produce quality parts directly from digital 3D files.

Request a free trial. Ensure Quality Everywhere. Why Geomagic Control X? Easy to learn. Anyone can get results with little or no training. Fast and easy to use. Handle huge data sets quickly and easily with scan-native algorithms built on a CAD kernel.

Complete solution. Get all the tools you need for professional-level inspection. Compatible with all 3D scanners. What is Geomagic Control X?

Ensure quality everywhere. Bring the power of 3D scan-based inspection to more people in more places with software that makes it easy to both capture and interpret scan data. Scan parts to capture more information and leverage rich data to understand why parts are in or out of tolerance.

Optimize manufacturing processes. Recognize and address issues faster with insights gained from comparing scanned parts to CAD models or golden parts. Design Design for manufacturability.Here you can find details on how to uninstall it from your computer. It is developed by 3D Systems, Inc. Additional info about 3D Systems, Inc. The program's main executable file occupies The executable files below are installed together with Geomagic Verify Viewer They take about This data is about Geomagic Verify Viewer 64 version 5.

You can find here a few links to other Geomagic Verify Viewer 64 releases: 4. Some computer users want to erase it. This is efortful because removing this by hand takes some know-how regarding removing Windows applications by hand.

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Scroll the list of applications until you find Geomagic Verify Viewer 64 or simply activate the Search field and type in "Geomagic Verify Viewer 64". The Geomagic Verify Viewer 64 program will be found very quickly. When you select Geomagic Verify Viewer 64 in the list of programs, some information regarding the application is shown to you: Star rating in the left lower corner. The star rating explains the opinion other people have regarding Geomagic Verify Viewer 64, ranging from "Highly recommended" to "Very dangerous".

Opinions by other people - Click on the Read reviews button. Technical information regarding the program you are about to uninstall, by pressing the Properties button.

Press the Uninstall button. A window asking you to confirm will come up. Press Next to perform the cleanup. All the items of Geomagic Verify Viewer 64 that have been left behind will be found and you will be able to delete them.

Your computer will remain clean, speedy and ready to take on new tasks. Users that installed Geomagic Verify Viewer Get access to such inspection data generated in Verify as deviation color maps, dimensions, and tolerances. Add annotations and perform measurements of distances, angles, and radii. Download Geomagic Verify Viewer 5. The most frequent installer filename for the software is: GeomagicVerifyViewer. The actual developer of the free program is 3D Systems, Inc.

Our built-in antivirus checked this download and rated it as virus free. The most popular versions of the program are 4. This free viewer application, based on Geomagic Verify, lets anyone view the results of inspections created in Verify, including deviation color maps, dimensions and tolerances. You can annotate and measure distances, angles and radii on both Verify inspection results and any point cloud, mesh or CAD model. Windows Mac. Download now. Developer: 3D Systems, Inc.

License: Freeware.

Geomagic Verify Viewer

From the developer: This free viewer application, based on Geomagic Verify, lets anyone view the results of inspections created in Verify, including deviation color maps, dimensions and tolerances. Download Geomagic Verify Viewer. Comments You can also add comment via Facebook. Thank you for rating the program! Please add a comment explaining the reasoning behind your vote.

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Notify me of replies from other users. Subscribe to comments:. Latest update: Dec 19, Related software. Geomagic Verify 3D Design.

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Geomagic Plug-In for Faro Converters. Geomagic Studio 3D Design. Geomagic Qualify Science Tools. Geomagic Design 3D Design. File Viewer File Managers. Downloaded for. Geomagic verify viewer free download.The generation has drastically changed over the previous 10 years. It has advanced in technology so much now that the 3D object can be made and printed digitally. At first, it was not possible for the people to draw a 3D object using their home held device, but now, so many software are available with the help of which, you can create a 3D object in your home.

Although there is a lot of software available, most of the top-ranking software are very expensive and are out of reach of an average person like AutoCAD. This is why we have provided you with a list of free software that will help you create and open any 3D object STEP file with ease.

These free software can be run on most of the devices like Computer, Laptop, Mobile, Tablet, etc. You can easily draw a 3D object in the software and can open any STEP file which was made in any other software. Check out the list given below. GOM Inspect is a simple software which is not heavily loaded with features and is easy to run on low hardware PCs.

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The software can View STEP files and also lets you edit those files in the integrated user interface. This feature allows the user to make some changes to its STEP file.

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This software also allows the user to create STEP files from scratch and can make triangular objects. This is a handy software for veterans.

GOM Inspect is a freeware and can be downloaded free from its official website. Download: GOM for Windows. It has a bunch of features to work with and is very easy to operate.

The software does not only supports and views files of STEP Format, but it also has integrated support for many other file formats.

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The variety of functions in this software exceeds the average range of features and has features like Solid Calculating Data Material. The Solid Calculating Data Material lets you calculate the Mass, Volume, Inertial moment and units like Surface Area of a 3D object and many more useful features are available in this free software.

This software is also used to create stereoscopic 3D projects and hold high functionalities regarding the creation of 3Dobjects. It is also an alternative to AutoCAD and is very rivaling in the competition. In this software, you can perform functions like deviating color maps of objects, dimensions, and tolerances. You can annotate and measure distances, angles, and radii on both Verify inspection results and any point cloud, mesh or CAD model.

Download: Geomagic Verify Viewer for Windows.Geomagic Freeform is the best solution for design and manufacturing of organic shapes, giving you the real sensation of clay modeling but with all the added benefits of digital design.

Now combined with Artec's precise 3D scanners, you can effortlessly capture a large variety Geomagic Wrap Free Activate objects in high detail directly into Geomagic Freeform software in order to easily solve any design and manufacturing challenges. The new scanning integration in Geomagic Freeform allows you to capture organic objects in all shapes and sizes with Artec's lightweight, portable and user-friendly 3D scanners directly into Geomagic Freeform, where you can immediately get up-close and personal with your 3D creations using the software's touch-based 3D sculpting, surfacing, design intent modeling, 3D scan processing, CAD interoperability and mold making tool.

Embrace the freedom and speed to create with Artec's lightweight, portable and user-friendly 3D scanners which exactly capture organic objects in all shapes and sizes. Break free from the limitations of traditional CAD workflow and bring your visions to life with advanced 3D scanning and Geomagic Freeform.

Take full advantage of the software's comprehensive design and sculpting toolset that lets you sculpt, detail and turn virtual clay models into any form you desire. Don't lose touch with your work of art with the use of the advanced haptic device that lets the artist within you control the creative process completely.

Capture any organic shape with Artec's 3D scanners and enjoy the hands on feel of the haptic device, letting you experience and sculpt your model as if it was done by hand with clay. Do even more with the extended toolset of Geomagic Freeform Plus, featuring advanced manufacturing design options, such as automatic conversion of digital clay and polygons to Jixipix Premium Pack 1.2.1 Free Download with Crack surfaces, mold and die design, shelling, draft analysis, as well as parting line and surface creation tools for complex organic shapes.

As a powerful 3D design software, it is purpose-built to seamlessly get your creation straight into production. Freeform Plus supports additional CAD formats. Combine CAD files with sculpted features to create accurate organic solids that are defined by explicit dimensions. With advanced tools, unavailable in most 3D design software, Geomagic Freeform Plus users can identify and correct any potential manufacturing issues quickly and effortlessly.

Detecting these early and retaining full artistic control at the same time, users are guaranteed against costly oversights and unpleasant surprises during production. Pre-printing analysis, featuring powerful and thorough tools, lets you 3D print your design with confidence and get it right from the first time. You can also use Freeform data to quickly 3D print casting patterns for fast, accurate creation of investment casts.

The powerful voxel technology allows you to export watertight models without using additional costly software for model fixing. Users can have various clay models displayed from Geomagic Sculpt and Geomagic Freeform int eh stand-alone Freeform Viewer.

Simple visualization, zoom, rotate, pan, measure and cutaway tools allow others to see the model without having to be proficient in the software. Our low price Please call.

Request Quote. Geomagic Wrap Free Activate Specifications Documents Compatible Products. Unreal Commander 3.57 Build 1496 Crack & Keygen Free Download 2021 Scan-to-Design The new scanning integration in Geomagic Freeform allows you to capture organic objects in all shapes and sizes with Artec's lightweight, portable and user-friendly 3D scanners directly into Geomagic Freeform, where you can immediately get up-close and personal with your 3D creations using the software's touch-based 3D sculpting, surfacing, design intent modeling, 3D scan processing, CAD interoperability and mold making tool.

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Innovative Approach to Design Break free from the limitations of traditional CAD workflow and bring your visions to life with advanced 3D scanning and Geomagic Freeform. Manufacturing Straight From Your Designs With advanced tools, unavailable in most 3D design software, Geomagic Freeform Plus users can identify and correct any potential manufacturing issues quickly and effortlessly. Compatible Products. Artec Micro. More Information. Artec Eva. Perfect for capturing small objects or intricate details.

Artec Eva Lite. Artec Leo 3D Scanner. The first 3D scanner to offer automatic onboard processing.


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Geomagic Design X Basic Training 2016 - English.pdf

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Revision Date: April 2016

Proprietary and Restricted Rights Notice Information within this document is subject to change without notice. No part of this documentation may be reproduced in any form or by any means including photocopying, recording or microfilming or by any information storage and retrieval system including a web site, without written permission of 3D Systems. No liability is assumed by 3D Systems with respect to the use of the information contain herein. While every precaution has been taken in the preparation of this documentation, 3D Systems assumes no responsibility for errors or omissions that may appear in this document. References in this document do not constitute an endorsement of any products or services. © 1996-2015 3D Systems All rights reserved Geomagic Solutions, Geomagic, the Geomagic logo, Geomagic Verify, Geomagic Control, Geomagic Design X, Geomagic Design Direct, Geomagic Design, Geomagic Studio, Geomagic XOS, Geomagic Wrap, Geomagic Freeform, Geomagic Freeform Plus, Geomagic Touch, Geomagic Touch X, Geomagic Phantom Premium, and Geomagic Claytools are either trademarks or registered trademarks of 3D Systems. All other company and product names referenced herein are trademarks or registered trademarks of their respective owners.

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About Us 3D Systems is a leading global provider of 3D content-to-print solutions including 3D printers, print materials and on-demand custom parts services for professionals and consumers alike. The company also provides CAD modeling, reverse engineering and inspection software tools and consumer 3D printers, apps and services. Its expertly integrated solutions replace and complement traditional methods and reduce the time and cost of designing and manufacturing new products. 3D Systems’ products and services are used to rapidly design, communicate, prototype or produce real functional parts, empowering customers to create and make with confidence. More information on the company is available at www.3DSystems.com

Contact Information 3D Systems - Geomagic Solutions 1001 Winstead Dr, Suite 400 Cary, NC 27560, USA Phone: +1 (800) 691-1839 or +1 (919) 474-0122 Fax: +1 (919) 474-0216 Web Sites: Geomagic Solutions Technical Support

http://www.3DSystems.com http://support.geomagic.com

Email Addresses: Technical Support Training

[email protected][email protected]

.

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Contents Introduction . 7 Overview . 7 Intended Audience . 7 Prerequisites. 7 Guide Length . 7 Guide Conventions . 7 Graphical User Interface . 8 ACTIVITY: Getting Started . 8 Ribbon . 9 Upper-Side Toolbar . 11 Navigation & Selection . 13 Mouse Commands. 13 ACTIVITY: Using the Mouse . 13 Docks . 17 Tree Dock Group . 17 ACTIVITY: Tree Management . 17 Accuracy Analyzer™ and Properties . 22 ACTIVITY: Check accuracy and properties of a model . 22 Bottom Toolbar. 24 Dialogs. 25 Context Menus . 26 User Interface Context Menu . 26 Model View Context Menu . 26 Tree Context Menu . 27 Data Types . 28 Point Data . 28 Mesh Data . 28 CAD Data . 29 Scan Preparation . 30 Overview . 30 Mesh Buildup Wizard . 30 ACTIVITY: Mesh Buildup Wizard . 30 Mesh/Polygon Editing . 35 ACTIVITY: Clean up mesh data . 35 Auto Surface . 42 ACTIVITY: Generate CAD Body . 42 Regions . 46 ACTIVITY: Understanding Regions . 46 Align to Coordinate System . 49 ACTIVITY: 3-2-1 Alignment using Regions . 49 ACTIVITY: 3-2-1 Alignment using Reference Geometry . 51 ACTIVITY: XYZ Alignment. 54 2016 3D Systems

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ACTIVITY: Scan to CAD Alignment . 56 Parametric Modeling . 58 ACTIVITY: Introduction to Sketching . 58 ACTIVITY: Basic Concept. 63 ACTIVITY: Mechanical Freeform Surface Modeling . 80 Advanced Modeling . 100 ACTIVITY: Hybrid modeling . 100 ACTIVITY: Impeller Workflow . 117 Exact Surfacing . 129 ACTIVITY: Exact surface . 130 ACTIVITY: Self Exercise . 137 Appendix I – Mouse and Keyboard Control . 138 Appendix II - Mesh Editing . 140 ACTIVITY: Mirroring scans . 140 ACTIVITY: Global Mesh Enhancing . 144 ACTIVITY: Mesh Editing . 149 Appendix III – Additional Models . 154 ACTIVITY: Iterative modeling . 154

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Introduction Overview This guide covers the fundamental commands and workflows utilizing the Geomagic Design X software.  The graphical user interface and navigation  Data types, processing and usage  Standard Geomagic Design X workflows  Various modeling workflows

Intended Audience This guide is targeted to users of Geomagic Solutions products who require an overall understanding of the Geomagic Design X software.

Prerequisites None

Guide Length 3-days

Guide Conventions

Bold Text



Indicates mouse button clicks to locate a command in the user interface in the format of Tab > Group > Command, example: Model> Create Solid > Extrude Model(Tab) > Create Solid (Group) > Extrude (Command) Bold text also may be used to draw attention to or create emphasis for key concepts in activity steps. A dotted bullet indicates an actionable item in the training activities.



This symbol is used to identify additional information within the context of an activity step. Text following this symbol is not actionable within an activity step.



A circled bullet is an information item found outside of an activity.



This symbol is used to strongly advise or convey important information when used.

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Graphical User Interface Introduction to the Graphical User Interface (GUI). ACTIVITY: Getting Started

Objective Locate the primary components of the application user interface.

Training File 01 – Mouse Control.xrl 1.

From the Windows Start button, select Start > All Programs > 3D Systems > Geomagic Design X to start the application.

or 2.

From the Desktop, double-click the Geomagic Design X icon to start the application. The application will start as shown in Figure 1.

 Clicking a Tab will change the current ribbon to display different command Tab Groups.  The Tree displays the commands used and objects that are opened, imported or created.

Figure 1 – Graphical User Interface

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File Open 1.

Click the Open button or select Open from the menu tab.  Use the Open Files dialog to navigate to the training files folder. Choose 01 – Mouse Control.xrl from the Open Files dialog.

 Files in Geomagic Design X format have an .XRL extension.  Click Open. The file is loaded and displayed in the Model View, see Figure 2.  The Open command is for opening native Geomagic Design X files. Other file types need to be Imported.

Figure 2 End of Activity

Ribbon All commands used to create models are stored in the tabs at the top of the interface. Each tab has a different category of commands that are classified into groups. The Model Tab is the default tab, but all tabs can be selected with the left-mouse button.

Figure 3

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Tabs The layout of the new ribbon user interface is shown in Figure 3. Each Tab is broken down into Groups, and the Commands are located within each Group.

The three tabs where the majority of training tools will be found are the Model, Sketch, and Polygons tab. Model – Create and edit solid and surface bodies. The standard CAD creating tools will be located here.

Sketch – Create and edit a 2D or 2D Mesh Sketch using Line, Arc, and other sketching tools.

Polygons – Access tools to improve and edit the polygons/mesh.

Groups Each Group within a tab will hold a set of commands that work similarly or have similar objectives.

Commands Each Command will have its own properties and dialogs. Commands that are similar will have a drop down menu to toggle between the options and save space on the toolbar. All commands not found directly on the Ribbon will be located in the MENU tab. Commands are categorized and stored here. Selecting a command from the MENU tab is the same as selecting directly from the Ribbon.

Figure 4

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Upper-Side Toolbar This toolbar contains data display modes, view options, and selection tools.

Figure 6

Mesh Display Point Set - Display the mesh as only the poly-vertices. Wireframe - Display the mesh as only the poly-edges. Shaded - Display the mesh as shaded poly-faces. Shaded with Edges - Display the mesh as shaded poly-faces with poly-edges visible. Curvature Display Mode - Turn on or off the visibility of the curvature map of the mesh. Region Display Mode - Turn on or off the visibility of the Regions. Geometry Type Display Mode - Change the region display to classify all region types as individual colors.

Body Display Wireframe - Display the bodies as only the edges. Hidden Line – Display the body as edges with the edges in the background displayed as dashed lines. Shaded - Display the bodies as faces with no drawn edges. Shaded with Edges - Display the bodies as faces with edges visible.

Accuracy Analyzer Deviation for Body – Compare the solid or surface body with the used scan data. Deviation for Mesh – Compare the mesh to its previous state. Curvature – Analyze solid or surface for areas of high curvature. Continuity – Display quality of edge continuity. 2016 3D Systems

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Iso Line – Display the iso lines that define the surface. Environment Mapping – Display zebra stripes on the surface to show continuity.

Views Viewpoint - fly out will display the standard views of the Model View. All standard views are listed: Front, Back, Left, Right, Top, Bottom, and Isometric. Rotate View Counter-Clockwise – Rotate the Model View 90° to the left. Rotate View Clockwise – Rotate the Model View 90° to the right. Flip Viewpoint – Change viewing direction 180°. Normal To (Ctrl+Shift+A) – Orient the view perpendicular to a clicked surface.

Selection Tools Toggle between the different selection shape options. Line - Select entities on a user drawn line on the screen. Rectangle - Select entities within a user drawn rectangle on the screen. Circle - Select entities within a user drawn circle on the screen. Polyline - Select entities within a user drawn polyline on the screen. Freehand - Select entities within a freehand drawn curve on the screen. Paint Brush - Select entities on a freehand drawn path on the screen. Flood Selection - Select all polygons connected to a selected polygon. Extend to Similar - Select an area of mesh with polygons connected by similar curvature. Visible Only - Select only visible objects in the current view. Deselect to select through the object.

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Navigation & Selection This section uses a polygon object as an example; all commands in this section work the same for point and CAD objects except where noted.

Mouse Commands ACTIVITY: Using the Mouse

Objective Learn the mouse operations in the Model View. In the upper right corner of the screen, an arrow can be open or closed to display all the functions available with the mouse. This display is dynamic and will only show what is available at the moment. Figure 7 displays the Default mouse options.

Figure 7

Rotate, Pan, and Zoom 1.

Rotate the view by first placing the cursor in the Model View; press and hold the right-mouse button (RMB).  Moving the mouse in all directions performs a spherical (3D) rotation pivoting around the center of the screen.

 Moving the mouse vertically performs a planar rotation, parallel to the current view. 2.

Pan the part. Press and hold down the right-mouse button (RMB) and then the left-mouse button (LMB).  Position the current view by using the Pan command  Move the mouse right or left to pan from one side to the other. Move the mouse away or towards to pan from top to bottom.

 Release to stop the pan operation.

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3.

Change the magnification of the object in the Model View by using the Zoom command.

 Place your cursor in the Model View at a location of interest and use the scrollwheel to zoom in by rolling the scroll-wheel up. To zoom out, roll the scrollwheel down.

 The Zoom defaults to zooming to the center of the screen. This can be changed in Preferences.

Using Selection Tools 1.

Select poly-faces of the mesh.  Click the Rectangle Selection Mode icon.  Place the cursor on the object, click and hold the left-mouse button (LMB).  Drag your cursor to define the second corner of selection zone. As you move the cursor, a rectangle is visible in the area to be selected.

Figure 8

 Release the LMB. The poly-faces in the selection zone are highlighted. 2.

Deselect portions of the previously selected poly-faces. 

Hold down the CTRL key while selecting with the LMB in the same area highlighted area.



Release the mouse button before releasing CTRL.

 Clicking the LMB in empty space in the Model View deselect everything. 3.

Add more poly-faces to the previous selections.



Hold down the SHIFT key while selecting other areas of the mesh.

4.

Delete selected areas by pressing the DEL key

5.

Press CTRL+Z or the undo button on the keyboard to undo the last command.

6.

Figure 9

Figure 10  The brown surface seen is the back face of the mesh. Blue is the default color of the normal side.

Select and delete additional areas using the Line, Circle, Polygon, Freehand, and Paint Brush Selection Modes.  Select the tools from the Upper-Side Toolbar and make selections on the object in the Model View.

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 Press the DEL key to delete selected areas.  The Line Selection Tool is active only on polygon objects.

Remember to hold Shift or Ctrl to add and removed portions of selected data.

Figure 11 - Example of selected areas 7.

Press CTRL+Z to recover (undo) the most recently deleted areas of the object.

 There is one level of undo in the application. 8.

Deselect the Visible Only icon on the Upper-Side Toolbar and select an area on the object using the Rectangle Selection Tool.  Rotate the object around to view the other side of your selection. Notice that turning off Visible Only causes the current selection tool to affect all areas within the selection boundary, not just those visible on screen, see Figure 12 and Figure 13.  Click in empty space to clear all selections.

Figure 12 - Initial Selection 9.

Figure 13 - Result of Selection

From the Upper-Side Toolbar, select the Polyline Selection Tool to create a polygonal selection.  Click a set of points as shown in Figure 14. As you click, a boundary line will appear from click to click.  To define the last point in your Polyline Selection, move your cursor to the last location and press the right-mouse button (RMB) or double click the LMB to end the process and make your selection.

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 Rotate the object slightly to review the selected data.  Double click in space to clear the selection.

Figure 14 10. Choose the Extend to Similar Selection Tool to select adjacent triangles that meet have a similar curvature.  Click on the area as shown in Figure 15.  Adjacent triangles in the polygon mesh that have a small degree difference between them will be selected as shown in Figure 16.

Figure 15

Figure 16

11. Press Esc to remove the selection.  Certain tools will not clear selections when clicking the mouse in space.



The majority of commands in the application operate using the following selection syntax:  If nothing is selected when a command is activated; the command will affect the entire active object or all active objects.  If a selection is present when a command is activated; the command will affect the selected area only.

End of Activity

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Docks Docks contain the properties for many different application needs. Important Design X options are contained within these docks. Docks can be positioned anywhere on the screen. They can also be pinned, hidden, and closed completely.

Tree Dock Group ACTIVITY: Tree Management

Objective Explore the different available docks. 

If a dock is closed, make it visible again with a RMB click on the bottom toolbar and select the dock from the list that appears.

Training File 02 – User Interface.xrl

Tree The Tree dock on the left side is essential to the modeling process. The top half is the Feature Tree, and the bottom half is the Model Tree. The Feature Tree can be compared to a history tree since it lists the steps taken to create a model. The Model Tree lists entities that are still present in the model. The visibility of these objects is controlled here as well. 1.

Click the Open icon on the Quick Access Toolbar.  Use the Open Files dialog to navigate to the folder where the training files reside. Choose 02 – User Interface.xrl from the Open Files dialog and press Open.

 This XRL file is a partially modeled scan file.

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2.

The Feature Tree tracks the parametric history modeling progress. Each step to create an entity is tracked in chronological order, and can be edited.  Find Extrude 1 in the Feature Tree. Click on the + sign next to it to view the associated entities.  RMB click on Extrude 1 to pull up the context menu.

 A right-click context menu is available on entities in the tree. The commands available from the context menu change depending on the type of object selected.

Figure 19

 Select Edit from the menu, as seen in Figure 19.

 Press the ESC key to cancel the edit.

Figure 18 – Feature and Model Tree 3.

Geomagic Design X is a parametric history based modeler, meaning steps can be edited. Certain points in the modeling history can be accessed, and the steps in the Feature Tree can be reordered.  LMB click one time on the Mesh Fit 1 entity. Then click and hold the LMB on Mesh Fit 1 and drag it to be above Extrude 1.

 The Mesh Fit surface can now be used in the Extrude step since it comes first in the tree.  RMB on Cut 1 in the tree and select Rollback.

 The model can now be viewed as if the Cut and all steps after have never been performed.  RMB on an entity in the tree and select Roll to End to go back to last step.

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Figure 20

Geomagic Design X 2016

4.

The Model Tree lists all entities existing in the model. Practice controlling the visibility in the part.  Click on the + next to Ref. Planes to view all Planes in the Model.  Click on the Eye Icon next to the + to turn off visibility for all Planes.  Click on the Closed Eye to turn the planes back on.  Click on and off the Eyes next to the Front, Top, and Right Planes to hide the planes individually.

 Turn on and off visibility for other entities in the model.

Figure 21 Figure 22

Display The Display dock is defaulted as a tab next to the Tree. Display contains display options for the scan data and the bodies. It also contains additional ways to view and display data in the Model View. 1.

Click on the Display Tab next to Tree.

2.

Place/remove a checkmark next to World Axis & Scale, Scene Grid, Gradient Background and Label to toggle visibility of each item in the Model View.

Figure 23

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3.

The General group has options for controlling the way the overall data is displayed, including Transparency, Lighting, and View settings.

4.

The Mesh/Point Cloud group lists all the different ways to view the scan data.

5.

The Region group gives the option to view the geometry of the selected or all regions.

6.

The Body group lists the ways to view a surface or solid body and it allows for control of the resolution of the bodies.

7.

The Sketch & 3D Sketch group has specific visibility options for components of sketches.

 Be cautious changing options without changing them back where they started. The General>Lock option will disable all mouse rotation ability.

Figure 26

Figure 27 Figure 28

Figure 25 Figure 24

Help The Help Tab contains a list of contents and commands to find additional information about each topic. The Index tab is searchable. The content of each help will explain what the tool is, the benefits of using it, how to use the tool, and then all of the options of the tool in detail. Figure 29 shows an example of the layout for the Help tab.  F1 will access the Content Help menu for the command that is currently being used.

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Viewpoint The Viewpoint Tab creates and edits capture states of the current view of the model. The views can be accessed later to remember set, non-standard, views of the part. 1.

Create a Viewpoint of the model.  Rotate, Zoom and Turn on/off Visibility of the model to get a view approximately like Figure 30.  Click on the Add Viewpoint button.  Rotate and Zoom the model to a different orientation.  Select the Apply Viewpoint button to return to the state of Viewpoint1.

Figure 30 2.

Use the Reassign Viewpoint command to change the Viewpoint1.  In the Model Tree, turn off visibility of the Solid Bodies.  Select Reassign Viewpoint.

 Viewpoint 1 is now reassigned to the same view but with the Solid Bodies turned off.

End of Activity

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Accuracy Analyzer™ and Properties ACTIVITY: Check accuracy and properties of a model

Objective Explore the different deviation displays for checking accuracy of a model. Also, explore the different information that can be displayed in the Properties dock.  Docks can be pinned to the screen using the push pin located in the corner.

Accuracy Analyzer™ The Accuracy Analyzer™ allows the user to check the accuracy of their part throughout the entire process. The CAD body can be compared to the base scan data with its deviations displayed in a color map. Different ways to display the quality and continuity of the surfaces are also found here. Deviations between meshes can be analyzed. The dock is where calculation options can be set. Once deviations are applied, a Color Bar will appear to control the tolerance values. 1.

View the deviations between the solid body and the mesh.  Select the radio button next to Deviation for Body.

2.

Adjust the tolerance range of the part  Double click on the 0.1 in green, as shown in Figure 31, to alter the value.  Change the value to 0.15.

 Changing the upper tolerance will automatically change the lower value.

Figure 31

Figure 32 3. 2016 3D Systems

Turn the Accuracy Analyzer off by selecting None at the top of the dock.

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Geomagic Design X 2016

Properties The Properties dock displays information about any selected entities. Some properties can be changed, visibility can be turned on or off, and more information can be calculated inside Properties. 1.

Calculate the Volume of the mesh.  Select the 3DS Partifact mesh from the Feature Tree or Model Tree.

 In the Properties

dock, click Calc. next to Volume.

 If the mesh is not fully closed, Design X will calculate the volume of the assumed closed shape.

Figure 33 2.

Change the color of the mesh.  In the Upper-Side Toolbar, change the Mesh Display Mode to Shaded.  In the Model Tree, turn the eye off next to Solid Bodies. The part should look like Figure 34.  Select the blue bar next to Material in the Properties dock. Then select the three dots on the right (Figure 35).  Change the mesh color by selecting one of the colored circles.  Press OK to accept.

Figure 35 Figure 34

Figure 36 End of Activity

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Bottom Toolbar This toolbar contains a second location to hide and show entities, filter tools, and measuring tools.

Visibility

Filter

Turn on and off the visibility of groups of entities.

Activate selection filters. User can only select the allowed entity types.

Meshes (Ctrl+1)

Meshes/Point Clouds

Regions (Ctrl+2)

Regions

Point Clouds (Ctrl+3)

Poly-Faces

Surface Bodies (Ctrl+4)

Poly-Vertices

Solid Bodies (Ctrl+5)

Mesh Boundaries

Sketches (Ctrl+6)

Bodies

3D Sketches (Ctrl+7)

Faces

Ref. Points (Ctrl+8)

Loops

Ref. Vectors (Ctrl+9)

Edges

Ref. Planes (Ctrl+0)

Vertices

Ref. Polylines

Ref. Geometries

Ref. Coordinate

Sketches

Measurements

Constraints Dimensions Clear All Filters

Measure Find dimensions between any entities in the Model View. Distance – Measure a linear distance between two entities. Angle – Measure an angular dimension between two entities. Radius – Find a radius using 3 points or a circular entity. Section – Create a dimension on a 2D section of an object. Mesh Deviation – Measure deviations between separate scan data.

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World Axis and Scale The World Axis displays the orientation of the global coordinate system. The Scale below shows the size of the part.

Dialogs Geomagic dialogs have several controls in common with each other; this section describes the most commonly used controls and conventions. The majority of Geomagic Control commands are dialog based. OK button – A checkmark that accepts any changes made while in the dialog and exits the dialog. A subset check can also mean Apply. Cancel button - Discards any changes made while in the dialog and exits the dialog. Don’t Quit Command with OK button – When the option is selected, the user will remain in the command after clicking OK to be able to use the command again. Preview button – Allows the user to see what changes will be made after the command is run. Next Stage button – Only available in some commands, when another stage of options is needed. Generally the next stages have calculation options. Previous Stage button – Go back a stage to make changes. User Break – Cancel a command before it finishes. Estimate – Estimate various quantities in options by reading the surrounding mesh. Entity Selection – The yellow box frame around an entity type means the user can select objects, such as scan data, ref. geometry, and CAD faces, to complete the command. Multiple selections can be made in one command.  If there is a vertical red stripe on the left side, an entity is required for completion.

Select None – Remove all entities listed. Deselect Last – Remove the last selected entity. Roll-Up Groups - when rolled up, an arrow in the group title points downward. Clicking anywhere on a rolled up group title will expand the group and reveal additional dialog.

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Context Menus Geomagic Design X has several context menus activated by right-clicking in one of three locations; at the top of the screen on a user interface element, on an object in the Model View tab and in the Tree Dock.

User Interface Context Menu  Quickly add and reorder any command to the Ribbon.  Hide the ribbon; reappears when a tab is clicked.

Model View Context Menu Right click on any object or blank space in the Model View will activate an action menu. Different selected entities produce different menus.  Immediately enter a Sketch mode.  Quickly start a Wizard command.  Toggle through common sketching tools.  Accept and Cancel commands with ease.

Figure 38

Figure 37

Context Menu – Sketch Mode

Dynamically changing menu

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Tree Context Menu Right Click on any entity in the Feature or Model Tree to open a context menu about the entities. Generally, this is the easiest way to find a step to edit or change the visibility state.  Edit a command or sketch.  Suppress an entity in the modeling history.  Rollback and Roll Forward to a certain point of time in the model.  Hide and Show object visibility.  Export individual entities as a more generic file format.

Figure 39

Figure 40

Context Menu – Feature Tree

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Data Types Meshes, or Polygons, are common data types which consist of thousands of triangles derived from a large point cloud. The application can import several hardware device native file formats. Plug-ins are provided for several hardware devices, enabling direct input of scan data into the application.

Point Data  Raw point data is a collection of points, each having an X, Y, Z location. When viewed up close, raw point data is displayed as simple colored points, as shown in Figure 41.  Shading point data enables a better view of the shape. Raw data is unshaded due to its lack of Normal Information.  Data collected using a scanner in LiveScan is automatically contains the Normal Information.

 For best use with Design X, Points can be triangulated and merged to generate a Mesh.

Figure 41 - Raw Point Data

Figure 42 - Shaded Point Data with Normal Information

Mesh Data A Mesh, or polygon, is a group of triangles, formed by triangulating point data to create the appearance of a surface for the data. Mesh data can be generated automatically when the option is selected inside of LiveScan in Design X. When a mesh object is generated the normal faces are colored blue by default, the back face or opposite side of the normal face is colored brown. The back faces of all meshes are the complementary color of the front face. The front and back face are determined by the direction of the normal of the points.

Figure 43 – Default mesh appearance

Figure 44 – Back faces of mesh

Clicking the Display Panel tab and toggling on Edges in the Geometry Display roll-up group will reveal the mesh construct of any mesh object. 2016 3D Systems

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CAD Data CAD data is a collection of faces or bounded surfaces created in Design X, or imported in from other software. Design X uses two different types of CAD bodies. Design X designates if a body is a Solid or Surface body. Solid bodies are grey, and surface bodies are yellow.

Figure 46 Figure 45 Solid Bodies – A collection of connected surface elements resulting in a manifold body.

Surface Bodies – A non-manifold area in 2D or 3D space with defined boundaries.

CAD data is typically the primary result of using Geomagic Wrap Free Activate Geomagic Design X software. It occurs by:  Generating sketches, extrudes, revolves, lofts, etc. inside of Design X.  Importing external CAD files, IGES, STEP or CAD neutral file exchange formats  Directly opening or importing supported native CAD file formats

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Scan Preparation Overview On many occasions, the scan data will require post scanning processing. Design X has the capability to align multiple scans, merge scans into one cohesive mesh, and then edit and enhance the mesh. After a mesh is generated, there are many options for output. A clean mesh can be exported to be 3D Printed, or a CAD body can created and sent for other forms of manufacturing.

Mesh Buildup Wizard The Mesh Buildup Wizard (MBW) is a collection of tools to quickly create a single mesh. The scan data can be aligned and cleaned up in the MBW. ACTIVITY: Mesh Buildup Wizard

Objective Create a single mesh from multiple scans of points.

Highlighted Commands  Mesh Buildup Wizard o

Align Between Scan Data

o

Merge

Training File 03a – Mesh Buildup Wizard.xrl 1.

Open training file 03a – Mesh Buildup Wizard.xrl  Click Open icon in the top left corner.  Use the Open Files dialog to navigate to the folder where the training files reside. Select file 03a – Mesh Buildup Wizard.xrl in the Open Files dialog.  Click Open to open selected file.

 Both scan objects should be visible when the file is opened. If they are not turn them on in the Point Clouds group of the Model Tree.

Figure 47 2.

Begin the Mesh Buildup Wizard, located in the POINTS Tab>Wizard Group>Mesh Buildup Wizard.

 The first stage of the MBW, 1/5 – Data Preparation, is for selecting the data and

options for the wizard. If not listed under Select already, select the target scan data.

 Under Set Scanner Type, choose Unknown.  Using Unknown will display all options in each stage.

 Uncheck any box for Set Data Condition 2016 3D Systems

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 The data is not aligned already and we want to remove unwanted data.

The dialog box should now read 1/5 – Data Preparation indicating all 5 stages are used.

Figure 48  This dialog box has the standard set up used in the software. o

Select entities section

o

Multiple roll-up groups of options

o

Multi-stage command

Figure 49 3.

The Entity Thumbnails dock, below the Model View, allows for an organized way to view and select all the data available at the current stage.  Click the checkmark next to Setup1 in the Entity Thumbnails. The visibility of Setup1 is now off.  Replace the checkmark to turn the visibility back on.  Hover the mouse over the image of Setup1 in the Entity Thumbnails. A small, independent, window will pop up. This view can be rotated separately from the other scans to view scan quality and completeness.

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Figure 50 4.

Go to the Next Stage of the Mesh Buildup Wizard.

5.

Remove any unwanted points in the 2/5 - Data Editing stage.  Set the Max. Poly-Vertices/Faces Count Per Noisy Cluster to 100.  Click on Find Noisy Cluster radio button

 Any groups of points, 100 or less, which are distanced from the main body, will be selected.  Inspect which points are selected, then press the Delete key or icon.

Figure 52

Figure 51 6.

Click the Next Stage button in the Mesh Buildup Wizard dialog.

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7.

Use Stage 3/5 – Data Pre-Aligning to align the two scans.  Change the Method to Local Based on Picked Point.

 The Model View will be divided into 3 view ports. The upper left view port is the Fixed view port and the upper right view port is the Floating view port. The wide frame at the bottom serves as a preview after registering the object in the Floating view port to the object in the Fixed view port.  With proper scanning technique, the Auto Guess method should align the scans.  With Reference highlighted in yellow, choose one of the scans. Notice the scan now appears in the top right box labeled Reference.  Manually select the Moving option and select the other scan.  One scan should be set as Reference, and one scan should be set as Moving.  Setting one scan as Reference will keep it static. Scans that are pre-aligned during LiveScan should be set as Reference.  Orient each scan in the Reference and Moving boxes to have approximately the same positioning.  Click on a point on the Reference scan that also exists on the Moving scan. A red point should appear.  Click on the same point on the Moving scan. The red points should match.  Repeat with at least two more points on each scan.  The order of points is Red, Green, and Blue. At least 3 points are needed to align scans.  Select the Apply check next to the 3/5 – Data Pre-Aligning line.

Figure 53

Figure 54 8.

Go to the Next Stage of the Mesh Buildup Wizard.

9.

Stage 4/5 – Best-Fit Aligning will refine the alignment between the scans.  Use a rectangular selection to highlight both scans for the Moving group.  Sampling Ratio controls the percentage of data being used. Press the Estimate wand to see the amount used when set to Auto.

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 Click the Apply check to complete the fine alignment of the scans.

Figure 56 Figure 57

Figure 55

10. The Best-Fit Aligning can be run multiple times at different Sampling Ratios. When satisfied with the alignment, press the Next Stage button. 11. Stage 5/5 – Data Merging will combine and triangulate the point clouds.  The MBW has two different merging options. Select Mesh Construction.  Place a Check next to Reduce Noise.  Click the Apply check to create a single mesh out of the scan data. 12. Inspect the mesh, then press the overall OK (Apply All and Finish) check to finish the Mesh Buildup Wizard.

Figure 58 End of Activity

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Mesh/Polygon Editing Design X now allows for the mesh to be selected and deleted without entering any edit mode. All of the tools used to edit, optimize, enhance, and heal the mesh are in the POLYGONS tab. ACTIVITY: Clean up mesh data

Objective Create one clean, watertight, closed mesh using a variety of tools.

Highlighted Commands  Decimate  Fill Holes  Rewrap  Enhance  Healing Wizard

Training File Continue from previous or Open 03b – Mesh.xrl

Reduce Polyface Count After the Mesh Buildup Wizard, the resulting mesh may have more polyfaces, or triangles, than needed. The Decimate command can intelligently remove and merge polyfaces to have the lowest amount possible. This will allow for future processing times to be significantly reduced. Saved file sizes will also be smaller. 1.

Select the POLYGONS tab to easily access all of the mesh editing tools.

2.

Click on the Decimate command located in POLYGONS>Optimize>Decimate and progress through the dialog menu from top to bottom.  Select the mesh as the Target Mesh.  Change the Method to Allowable Deviation.

 This method will remove as many polyfaces as possible without allowing the mesh to change at a greater distance than the set value.  Under Options set the value to 0.0254 mm.  Press the OK check to Decimate the scan.  The total triangles now should be under 1,000,000.

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Figure 59

Geomagic Design X 2016

Create Manifold Mesh Downstream applications, such as 3D printing, require a well cleaned mesh. A watertight mesh will produce best results for 3D printing applications. Geomagic Design X has tools that can fill in individual holes, and it can also wrap an entire part to fill in all the holes at once. 1.

Navigate and zoom in to approximately the view shown in Figure 60.

Figure 60

Fill Holes 1.

Select the Fill Holes command located in POLYGONS>Repair Holes/Boss.

Figure 61 – Fill Holes Dialog Layout 2.

Choose the large boundary shown above in Figure 61. Once the command is accepted, this hole will fill in.

3.

Edit the boundary to make a cleaner perimeter. Select Fill Gulf from the Editing Tools rollup group.

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 Left click one time on the top, left-most point of the gap shown below in Figure 62.  Left click again on the opposite side of the gap to immediately fill in a portion of the hole.  Before making the second selection, a preview of the area to be filled will be shown.

Figure 62 – Fill Gulf 4.

Use Remove Peninsula to quickly delete excess, indented data. Edit the boundary to make a cleaner perimeter.  Left click one time on the top, left corner of the area shown in Figure 63.  Left click again on the opposite end to instantly delete this portion of data.

Figure 63 – Remove Peninsula 5.

Select the Remove Island Editing Tool to delete floating areas of data.  Left click on the boundaries of any islands to delete them.

Do not click on any boundary of the main mesh. The entire mesh will delete. To Undo any Editing Tools, click on the left-pointing arrow at the end of the Editing Tools rollup menu.

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Figure 64 – Remove Island 6.

Select Add Bridge to split the boundary into smaller sections.  Left click and hold the mouse button down on one edge of one polyface.

 The polyface edge will highlight when selected.  While holding the LMB, select a triangle on the opposite side of the boundary.  The original selected boundary is now listed as two boundaries.

Figure 65 7.

Adjust the More Options settings to match the previous Figure 66.  Add a check next to Smooth Boundary in the More Options rollup group.

8.

Accept the Fill Holes command by pressing the OK check.

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Rewrap Instead of having to select every boundary in the part, the Rewrap command can extend all boundaries until there are no holes in the scan. 1.

In the dropdown from POLYGONS>Optimize>Global Remesh, select Rewrap.  Under Fitting Options, slide the Geometry Capture Accuracy bar over to Tight. Move the Overall Smoothness bar to Min.

 This will preserve the organic shape of the scan as much as possible.  Place a check next to Extended Boundaries in the More Options group.  Extend Boundaries on will fill in every size hole. If it is deselected, the very large holes will not fill.  Click OK to run the command.

Figure 68

Figure 67

Optimize Mesh For higher quality printing, the scan data should be enhanced and optimized further. For parametric modeling, the following steps are not generally needed. A higher quality mesh will create higher quality surfaces. 1.

In the POLYGONS tab, select the Enhance Shape command in the Optimize group.  Increase the Sharpness to Max.  Decrease Overall Smoothness to Min.  The Enhance Level can be set to the halfway point.

 The Enhance Level can be altered in the second stage.

Figure 69

 Go to the Next Stage by clicking the arrow.

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2.

Adjust the Enhance Level to find optimal result.  Decrease the slide bar to Min.  Check the mesh to see the results.  Increase the slide bar to Max.  View the difference in the mesh.  Adjust the slide bar to the third mark.

Figure 70

Figure 71 – Min Enhance Level

Figure 72 – Max Enhance Level

 Accept the Enhance Shape command with the OK check. 3.

Select the Healing Wizard in POLYGONS>Wizard>Healing Wizard to remove the last erroneous triangles. This command finds these triangles automatically, and after accepting the command, they are removed.

4.

Accept or Cancel the Healing Wizard to exit.

 The Healing Wizard will find any small groups of floating triangles, small polyfaces, or dangling, folded, or crossing poly-faces automatically. The parameters for each of these categories can be modified as needed.

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Figure 73  The Mesh is now ready for 3D printing, surfacing, or other production methods.  Additional mesh editing exercises can be found in the Appendix. Design X also has built in Tutorials.

End of Activity

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Auto Surface A quick, easy, non-parametric way to generate an IGES or STEP file from a cleaned Mesh is the Auto Surface. The mesh is analyzed and surface contours are automatically generated to create extremely accurate surfaces to the scan. ACTIVITY: Generate CAD Body

Objective Create an accurate CAD body to the scan data. The resulting body can be exported as a STP, IGS, x_t file, or other generic file types.

Highlighted Commands  Auto Surface

Training File Continued from previous or Open 03c - AutoSurface.xrl 1.

Open training file 03c - AutoSurface.xrl or continue from previous exercise.

2.

Enter the Auto Surface command located in the SURFACING tab.  Select Organic in the first option for patch structure.

 The Organic method creates a curve network as evenly distributed as possible, and is good for models that have non geometric faces and with few distinct feature shapes. The Mechanical method will create a curve network more uniform and grid like.  Leave the Patch Count in Patch Network Option at Auto Estimate to let the software decide the amount of Geomagic Wrap Free Activate needed for surfacing.  Slide the Geometry Capture Accuracy bar one away from Max.  Change the Tolerance to 0.1285.  Go to the Next Stage in the command.  The first stage of the Auto Surface command sets how the software will construct its NURBS network. The Auto Surface command applies to the entire mesh.

Figure 74 – First Stage

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Figure 75 – Second Stage 3.

The second stage allows for editing of the generated patch network.  Select the Deform option.  Zoom in to the area shown in Figure 76.  Click and drag the center node of multiple patches to manipulate the form of all 5 quadrilaterals.

 If a patch is not in a clear enough four-sided shape, the software might not fit a surface. Occasionally patches need to be edited and reshaped in order to build a better surface body.

Figure 76

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4.

Edit the form of a single edge of a patch with the Deform option.  Click and drag a node on a single spline to adjust the edge of a patch.

 Straightening out a patch edge can help create better quality connections between the patches.

Figure 77 5.

Press the OK checkmark to accept the Auto Surface.

 If the resulting body is a manifold network of surface patches, the body will become a Solid.  Editing the network is generally only needed in the Organic method when patches fail. The Auto Surface can be edited after completion to go correct any failed patches.

Figure 78

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Inspect Accuracy The Auto Surface creates an extremely accurate CAD body in relation to the scan data. Use the Accuracy Analyzer to verify the resulting body. 1.

The Accuracy Analyzer is located in an unpinned dock on the right side. Open the Accuracy Analyzer dock.  Turn on the nord vpn license key - Crack Key For U button for Deviation for Body.

2.

Change the tolerance on the color bar to 0.05mm. The default tolerance is set to 0.1mm.  On the color bar, double click on the green 0.1.  Set the value to 0.05.

3.

Hover the mouse over various areas of the mesh to see the deviations.

Figure 79 End of Activity

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Regions Regions classify areas of the mesh based on curvature and geometry features. An automatic segmentation of the scan data into regions is one of the first steps in the modeling processes for most standard workflows. Regions can assist with many processes, including:  Aligning  Quick Selection  Wizard Tools

ACTIVITY: Understanding Regions

Objective Create and edit regions on a mesh to assist in modeling.

Highlighted Commands  Auto Segmentation  Merge  Split

Training File 04 – Regions.xrl 1.

Open training file 04 – Regions.xrl

 No mesh editing will be necessary for the part.

Figure 80

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2.

In the REGION tab, select the Segment>Auto Segment command.

 Press the F1 key to read more about the Auto Segment  Set the Sensitivity to 5.  Click the OK button.  The sensitivity option classifies a shape as being round or prismatic. To make smoothly connected areas in a single region, move the slider to the left. To make strictly separated regions, move the slider to the right.

Figure 81 Figure 82

Editing Regions 1.

Change the Selection Type to Paint Brush Selection Mode in the Upper-Side Toolbar.

 To resize the paint brush tool, hold down the Alt key while left-clicking and moving the cursor. 2.

Paint across the regions shown below to select many regions with one click.

3.

The REGION>Edit>Merge option will now be active. Select the Merge to combine the painted regions.

 The Paint Brush can quickly select multiple smaller regions to merge together.

Figure 83 4.

Figure 84

Change the Selection Type to the Rectangular Selection Mode.

 The Rectangular Selection will allow for single click selections of entire regions. 5.

The Merge tool can combine regions that are not physicallly touching.  Click on the five top Sphere regions show in Figure 85.  Select the Merge command in the REGION tab.

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Figure 85

Figure 86

 Non-adjacent, single regions can be separated back apart by selecting the region and then choosing the Edit>Separatecommand in the REGION tab. 6.

Select the Edit>Split tool to convert single regions into multiple separated regions.  After selecting Split, the Limit to Region is automatically activated. Select the region shown in Figure 87.  Switch the Selection Type to the Paint Brush again.  Paint across multiple regions, including the previously selected.  Accept the command.

7.

Figure 87

Use the Insert command to manually create a region.  Select the Extend to Similar Selection Mode in the Upper-Side Toolbar.  Click on the marked area to select the entire area in a single click.  With the command now active, select REGION>Edit>Insert to create a region independent of the previously merged regions.

Figure 88

Figure 89 End of Activity

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Align to Coordinate System Scan data should be moved and aligned to a more useful position with the general coordinate system. Geomagic Design X has multiple ways to move ACTIVITY: 3-2-1 Alignment using Regions

Objective Learn the basics of aligning scans to the coordinate system using the regions of a mechanical part.

Highlighted Commands  Interactive Alignment

Training File 05a – Align 321.xrl

Scan Setup 1.

Open training file 05a – Align 321.xrl.

 No mesh editing will be necessary for the part.

Figure 90 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 65.  Click the OK button.

Figure 91

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Interactive Alignment 3.

Start the Interactive Alignment in the Alignment>Scan to Global group.  Click the Next Stage button.

4.

Create a 3-2-1 alignment using three planar regions.  The Plane option will set the Front Plane, and therefore the XY Plane and the Z Axis direction. Choose the large Plane Region on the bottom of the part.

Figure 92

 The Vector will set the Top Plane and the Y Axis direction. Choose the pink long thin Plane Region pointed at in Figure 93.  The Position will set the Right Plane and the location along the X Axis. Select the Plane Region shown in Figure 94.

Figure 93

 Click OK to accept.  The origin will be located at the intersection of the three planes selected above.

Figure 94

Figure 95 End of Activity

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ACTIVITY: 3-2-1 Alignment using Reference Geometry

Objective Learn how to create other types of reference geometry to use for an Interactive Alignment.

Highlighted Commands  Ref. Plane  Interactive Alignment

Training File 05a – Align 321.xrl

Scan Setup 1.

Open training file 05a – Align 321.xrl.

 No mesh editing will be necessary for the part.

Figure 96 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 65.  Click the OK button.

Figure 97

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Reference Planes 3.

Create a Ref. Geometry>Plane down the center of the part two directions.  Select the Lock icon to stay inside the command and make multiple planes.  Change the Average.  Select two long planes shown to find the mid plane between them.  Click the OK button to accept.

Figure 98 Figure 99 4.

Create a symmetry plane going down the center of the part in the other direction.  Change the Method to Draw Line.  Draw a line roughly in the orientation shown in Figure 100 to create a plane.  Click the OK button to accept.  Change the Method to Mirror.  In the Model Tree, hold the Ctrl key and select the Mesh (Align1) and Plane2.  Click OK to accept.

 A plane representing the center of the mesh in the direction of the drawn plane will be found.

Figure 101

Figure 100

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Interactive Alignment 1.

Start the Interactive Alignment in the Alignment>Scan to Global group.  Click the Next Stage button.

2.

Create a 3-2-1 alignment using the generated reference planes and a region plane.  The Plane option will set the Front Plane, and therefore the XY Plane and the Z Axis direction. Choose the large Plane Region on the bottom of the part.  The Vector will set the Top Plane. Choose Plane1 to set the Y Direction normal to the plane.  The Position will set the Right Plane and the location along the X Axis. Select Plane3.  Click OK to accept.

 The origin will now be set to the middle of the part along the bottom face.

Figure 103

Figure 102 End of Activity

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ACTIVITY: XYZ Alignment

Objective Learn how to Geomagic Wrap Free Activate other types of reference geometry to use for an Interactive Alignment.

Highlighted Commands  Ref. Vector  Interactive Alignment

Training File 05b – Align XYZ.xrl

Scan Setup 1.

Open training file 05b – Align XYZ.xrl.

 No mesh editing will be necessary for the unity pro serial number 2020 Figure 104 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 50.  Click the OK button.

Figure 105 2016 3D Systems

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3.

Create a Ref. Geometry>Vector down the center of hub of the fan.  Set the Method to Find Cylinder Axis.  Choose the two large cylinder regions around the central hub.  Finish the Vector by right-clicking and selecting the checkmark from the context menu.

 Design X version 2016 and newer has many new rightclicking capabilities.

Figure 106

Interactive Alignment 1.

Start the Interactive Alignment in the Alignment>Scan to Global group.  Click the Next Stage button.

2.

Create an XYZ alignment using the generated reference planes and a region plane.  The Position will set the location of the Origin. Select the Vector1 and Region Plane representing the top of the middle hub.

 The intersection of a vector and plane represents a point, which can be used for position.  To set the directions of the coordinate system, select Axis Z and choose the Vector1.  Click the Flip Direction arrow to adjust the positive Z in the desired direction.  Axis X and Axis Y do not need to be set. The blue circle can be twisted to manually clock the part to any location.  Click OK to accept.  The origin will now be set to the middle of the hub of the propeller with the Z Axis going through the middle.

Figure 107 End of Activity

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ACTIVITY: Scan to CAD Alignment

Objective Learn how to import a CAD body and align the scan data to the CAD body.

Highlighted Commands  Quick Align  Best Fit Align

Training File 05a – Align 321.xrl 05 – Align CAD.igs

Scan Setup 1.

Open training file 05a – Align 321.xrl.

2.

Import the IGES file, 05 – Align CAD.igs, by selecting HOME>Open/Import>Import.

 Importing a file will place it in the same open file.

Figure 108 3.

Choose the ALIGNMENT>Scan to CAD>Quick Fit command to align the scan data to the CAD data.  Set the Target Body to be the CAD body.  The Align1 scan should be automatically set as the Moving Entities.  Click the OK button to accept.

 The Run Best Fit Alignment should be checked under More Options.

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Figure 109

Geomagic Design X 2016

4.

The Best Fit Alignment will automatically start and have all of the options populated. Press the OK key to accept.

 The Best Fit Alignment will always need to be run after a Quick Fit. This will make a much better registration between the files.

Figure 110 Aligning a scan to an already built CAD file can be used for multiple reasons, including:  Check the accuracy of the scanned part to the CAD.  Add features to a Solid Body that were not in the original file. End of Activity

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Parametric Modeling The strength of Geomagic Design X is in its sketch based modeling. Any model can be created regardless of the scan quality. Design X utilizes sketches and standard CAD operations, such as Extrude, Revolve, Sweep, and Loft, to generate a parametric model. ACTIVITY: Introduction to Sketching

Objective Learn how to set up a Sketch and the basic principles of creating sketches. Creating sketch entities, constraining entities, and dimensioning are all introduced in this lesson.

Highlighted Commands  Setup Sketch  Rectangle  Parallelogram  Fillet

Sketch Entities 1.

Create a New File by selecting the icon on the top-most toolbar.

2.

Click SKETCH>Setup>Sketch to begin a 2D sketch.  Select the Front Plane from the Model View.

 The sketch will start immediately after selecting the base plane.

Figure 111

 If a plane is already selected, choosing Sketch would directly start a sketch on that plane.  The Sketch button has now changed to Exit in order to complete the sketch. 3.

Create a Rectangle using the SKETCH>Draw>Rectangle tool.  Left-click in the top-left corner of the origin, as seen in Figure 113, to begin the Rectangle.  Left-click the bottom-right corner to finish the Rectangle.  Finish the Rectangle by right-clicking in the Model View and selecting the Checkmark from the context menu.

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Figure 113

Figure 112 4.

Drag a Line or a Point of the Rectangle to modify its size until it is roughly centered at the Sketch Origin (red U and green V axis).

 By dragging a Line of the Rectangle you can alter one dimension (Length or Width of the Rectangle) at a time, while dragging a Point would let you alter both dimensions at the same time.

Constraints 5.

Double-click on the top-left Point of the Rectangle. The Constraint and information for that single point is now shown.

 A Coincidence Constraint is applied on the end point of the two lines forming the corner.  To see Constraints of another entity, only single left-click on the entity without leaving the Properties Dialog.

Figure 114 6.

Show and add Common Constraints of multiple sketch entities.  LMB Click on the bottom line of the Rectangle to view the Constraints.

 A Horizontal Constraint should be shown.  Shift+LMB Click on the other horizontal line of the Rectangle (Figure 116).  Both lines will be selected to show the Common Constraint between all selected entities.  Select the Independent Constraint Horizontal and click the button Delete Constraint to remove.  Select Parallel to set the Common Constraint.  Repeat with Vertical lines.

Figure 117

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Figure 115 Geomagic Design X 2016

 Alternatively, a Parallelogram could have been chosen from the beginning by clicking the small triangle next to the “Rectangle” tool in the SKETCH Ribbon and selecting the “Parallelogram” in the tools list to produce the same result.  The Ribbon always remembers the last method of a tool button, for quicker repeatability. 7.

Apply a Perpendicular Constraint to the lower left corner of the Rectangle.  Close the Constraints Dialog Tree with a RMB click check or the dialog checkmark.  LMB click anywhere in the Model View background to deselect all entities.

 After most operations, selections will persist after the dialog is closed.

Figure 118 8.

Create a pivot point for rotating the sketch by constructing two intersecting Centerlines with the SKETCH>Draw>Centerline tool below the Line tool.

 The Line tool could have been used with the option For Construction selected.  Move the cursor over the middle of the left line, and LMB click at the Mid-Point Constraint to start the Centerline (Figure 119).  After clicking to make the point, move the cursor back over the left line to activate the Parallel and Perpendicular assist axes.  LMB click to place the Centerline when the yellow Perpendicular and white Vertical symbol are visible.  Creating the centerline perpendicular to the base will keep it related ta rotatable rectangle.  RMB click to finish the line.  Move the cursor over the middle of the bottom line, and LMB click at the Mid-Point Constraint to start the Centerline.  Finish the line at the end point of the first centerline, Perpendicular to the Mid-Point.

Figure 119

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9.

LMB Click and Hold on the intersection point of the two Centerlines and drag it onto the intersection of the red and green Sketch U/VAxis to place the Coincident Constraint.

 The center point should turn black signifying it is fully defined.  Click and drag a mid-point of the rectangle lines and the rectangle will rotate and resize.

Figure 122

Dimensioning 10. Select the Smart Dimension tool from the SKETCH>Draw ribbon to apply the Linear and Angular dimensions as shown.  LMB Click one line and then select the parallel entity. LMB Click in space to set the linear dimension.  Repeat for the other set of parallel lines.  Select the inferred horizontal horizon line and one of the created Centerlines. LMB Click in space to set the angular dimension.  Sketch entities will turn black when they are fully constrained by dimensions and constraints.  Click OK to accept the command.

Figure 124

Figure 123 11. Edit the Dimensions by double-clicking on each value.  Set the two linear dimensions to size the box.

 Change the angular dimension to rotate the box to a specific angle from the horizon. 12. Click the Exit button to finish the sketch. 2016 3D Systems

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Figure 125  This sketch can be easily controlled and updated for future MathType 7.4.8 Crack + Product Keygen Full Version Free {2021} in CAD. End of Activity

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ACTIVITY: Basic Concept

Objective Learn the basics of sketching and extruding to create and cut solid bodies.

Highlighted Commands  Mesh Sketch  Extrude  Fillet

Training File 07 – Basic Concept.stl

Scan Setup 1.

Import training file 07 – Basic Concept.stl.  Click the Import button on the Quick Access Toolbar.  Or choose MENU>Insert>Import from the dropdown.  Navigate to the file then choose Import Only.

 Design X requires importing files that are not native Design X file types.  No mesh editing will be necessary for the part.

Figure 126 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 50.  Click the OK checkmark to accept.

Figure 127 Figure 128

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Interactive Alignment 1.

Create a Plane through the middle of the part to use for alignment using the MODEL>Ref. Geometry>Plane command.  Change the Method to Mirror.  In the Feature Tree, hold the Ctrl key and select the Right plane and Basic Concept mesh.  Click OK.

 The Mirror method will read the selected mesh and find the symmetry plane of the scan based on the given direction of the selected plane.

Figure 129 Figure 130 2.

Begin the alignment by selecting Interactive Alignment from ALIGNMENT>Scan to Global.  Go to the Next Stage.

3.

Change the Moving option to X-Y-Z.  Set the Position as the region Plane on the bottom of the part and the region Cylinder of the central hole.

 The Origin will now be set to the point where the cylinder axis would intersect the plane.

Figure 131 Figure 132

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 Click on Axis Z, and then select the same region Plane as before to set the Z direction.  Select the Flip button next to Axis Z to point the Z Axis through the part.  Click on Axis X, and then select Plane1. 4.

Click OK to accept the alignment based around the central hole.

Figure 134

Create Main Body 1.

In the SKETCH tab, choose Setup>Mesh Sketch.  Select the Front plane as the Base Plane.  Set the Offset Distance From Base Plane to 5mm.  Click the OK button to begin sketching.

 The Offset Distance From Base Plane is only to set a cross-section distance of the model to be projected back to the originally selected Base Plane. All sketches will still be created on the Base Plane, regardless of the height of the Offset Distance.

Figure 135

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2.

Use the Model Tree to Hide the Mesh.

3.

Select the Draw>Line tool.  Click on the top-most solid pink line. A line will be best fit to the entire segment.  Click the OK button to accept the line.

4.

Select the Draw>CenterPoint Arc command.  Click on the left-most solid pink line. An arc will be best fit to the entire segment.  Click on the Accept Fitting check.  Double click the right-most solid pink line. This will create and accept the arc while still staying inside the command.

5.

Use the Centerpoint Arc to create the lower, segmented arc.  Single click on the five segments to create one best fit arc between the segments.  Double click anywhere in space to accept the fitting.  Click the OK button to accept.

Figure 136 6.

Open the Accuracy Analyzer on the right side toolbar to display all points of an open loop.  Place a checkmark next to the Disjoined Ends box.

 Disjoined Ends will add a green end point to any point of opening in a sketch chain. 7.

Using commands from the Tools group allows for quick ways to close open sketch loops. Select the Tools>Trim command to close endpoints to a sharp corner.  Change the option the Corner Trim.

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 Locate the two open ends shown in the picture below.  Zoom in to one corner. Left click on one line segment surrounding one corner.  Select the other line segment to join the two ends.  This command uses the sketch segments, not end points. The Trim will be directed based which side of the segment is selected.  Repeat on the other corner.  Click the OK button to accept.  If the OK is greyed out, clicking the Cancel button will keep the Trim and exit the command.

Figure 138

Figure 137 8.

Use the Tools>Fillet command to close the other two open points with smooth, tangent arcs.  Left click on one sketch segment near the missing arc segment.  Click and HOLD the LMB on the second segment.  While still holding the LMB, move the mouse around to adjust the size of the fillet.  Release the mouse button when the arc is best fitting the pink polyline.  Repeat to create the second arc.  Click OK to accept.

Figure 139 9.

Figure 140

Figure 141

Double click on a dimension to edit the value.  Using a design intent approach, change each dimension to 88 mm.

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10. Verify there are no openings in the sketch loop, then press the Exit button in the top toolbar.

Figure 142 11. In the MODEL tab, select the Create Solid>Extrude command to generate the body.  Turn on the Mesh and Region visibility by pressing Ctrl+2.  The Base Sketch should automatically be selected as Sketch1 (Mesh).  Change the Method to Up to Region. The Sub Method should automatically set to Trim with Region Fit Surface.  For the Up To option, select the top, Freeform region.  Click the OK to accept.  The Up to Region>Trim with Region Fit Surface method will automatically fit the extrusion to the shape of the region.  Press F1 to see all the different methods of Extruding.

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Figure 143

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Figure 144 12. Turn on Deviation for Body inside of the Accuracy Analyzer dock.  Rotate the body to inspect the accuracy of the model.  The Bottom View will display the area of high deviation. This face shows the solid body is both too small in areas and too large.  Select None to turn the deviations off.

Figure 145 13. To fix the inaccuracies of the model, Edit the base sketch.  RMB on Sketch1(Mesh) in the Feature Tree.  Select Edit from the dropdown menu. 14. Press the Normal To button on the Upper-Side Toolbar, or Ctrl+Shift+A. This will align the sketch back normal to the screen. 15. Select the lower sketch arc and press Delete.

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16. Using the Draw>Line command, reconnect the loop by clicking on one endpoint and then the other.  Click the OK to accept.  A yellow and black concentric circle symbol will appear when selected on the end point. 17. Click and HOLD the LMB on the new line and drag it below the pink polyline.

Figure 146 18. Click the Exit button to exit and accept. 19. Make sure the Regions are still visible, but HIDE the Solid Bodies using the Model Tree, or by pressing Ctrl+5. 20. Create an accurate, form-fitting surface along the back face of the mesh with the MODEL>Wizard>Mesh Fit command.  Select the Revolution region that represents the inaccurate face.  With the Resolution set to By Allowable Deviation, limit the Max. No. of Control Points to 20.  Click OK to accept the Mesh Fit surface.  A Mesh Fit surface will be created accurately to any mesh surface. This surface is not directly editable since it is not based off of a sketch. If changing the Mesh Fit parameters does not create the desired surface, the mesh itself can be optimized and editing to make a better fitting surface.

Figure 147

Figure 148

21. Turn back on the Solid Body visibility.  This surface will be used to cut off the excess solid body. 2016 3D Systems

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22. Select the MODEL>Edit>Cut command to cut a solid body using a surface body.  Select the Mesh Fit1 surface as the Tool Body.  Select the Extrude1 solid as the Target Body.  Click on the Next Stage arrow. Notice the OK check is not available until the next stage is completed.  Click on the main portion of the Solid Body to select as the Target Body. This is the portion that will be kept.  Select the OK check to accept the cut.

Figure 149

Figure 150 23. Turn the Deviation for Body back on in the Accuracy Analyzer dock to see the new resulting body.

Figure 151  It is recommended to turn the deviations back off after viewing. This will speed up processing time for all proceeding steps instead of making the software rerun the analyzer.

Extrude Cut 1.

Turn on and off visbility of entities until only the Mesh and Regions are visible.

2.

Right Click on the Plane region shown below.  Select the Mesh Sketch icon to immediately enter the Mesh Sketch Setup up with the region as the Base Plane.

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Figure 152  Set the Offset Distance From Base Plane to 2 mm, or drag the thin, blue arrow up until the outline of the cutout shown is visible.  Place a Check next to Draft Angle.  Select the Measure Angle button then click on the two planar regions shown in Figure 154.  Set the Draft Angle to 1°.  The total angle will be displayed. This will show if there is any draft from the base plane. The Mesh Sketch Setup can compensate for the draft when projecting the poly-lines back to the base plane.  Click the OK check to begin sketching.  Hiding the Mesh can make it easier to see the underlying polylines.

Figure 153 3.

Figure 154

Sketch the inner cutout using the Line and 3 Point Arc tools.  RMB Click in the Model View. An array of common sketch tools will immediately appear.  Select the Line icon and sketch the two vertical lines by double clicking the LMB on each polyline.  Draw a Line between the bottom end points to close the loop.  RMB Click and select the Check to accept the line command.  RMB Click. Select the 3 Point Arc icon. Click on both end points and then the height of the pink polyline radius.  RMB Click and select the Check to finish the command.

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Figure 155

4.

Figure 158

Figure 157

Figure 156

Edit and adjust the sketch for a better overall model.  Double Click on one of the vertical sketch lines.  A dialog box will appear with the editing and constraint options. Select Vertical from the Constraints box.  Hold Shift and select the other vertical line. Select Parallel from the Common Constraint options.  Double Click on the arc. Hold Shift and select one of the vertical lines. Select Tangent from the Common Constraint options. Repeat the process on the other line to create tangency with the arc.  Adjust the sketch entities until the sketch looks like Figure 160.  RMB Click and select the Exit button.

Figure 160

Figure 159

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5.

RMB Click in space on the Model View and select Solid Extrude.  Turn on the Mesh and Solid Body visibility.  Check Sketch2 (Mesh) is selected as the Base Sketch.  Change the Method to Through All.  Place a Check next to Draft and input the 1° measured earlier.

 Check the direction of the draft is correct. Use the Flip Direction arrow next to the Draft input.  Set the Result Operator options to Cut.  Click the OK check to accept.

Figure 161

 The sketch must still be highlighted, and the RMB click must not be on a plane to give the Extrude options. 6.

Hide the Solid Bodies, then RMB Click on the plane shown and start a Mesh Sketch.  Set the Offset Distance From Base Plane to 2 mm.  Click the OK check to accept.

Figure 162 7.

RMB Click on the Model View and select the Auto Sketch command.  With the option set to Make Selected Only, select only the inner loop sketch.  Click the OK check to accept.  RMB Click and select the Exit button to finish the sketch.

Figure 164

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8.

RMB Click in space on the Model View and select Solid Extrude.  Turn on the Mesh and Solid Body visibility.  Check Sketch3(Mesh) is selected as the Base Sketch.  Change the Method to Through All.  Set the Result Operator options to Cut.  Click the OK check to accept.

Figure 165

Revolve Cut 1.

Create a Vector in the MODEL>Ref. Geometry group.  Select the Right and the Top Planes.  If not done automatically, set the Method to Intersect 2 Planes.  Click the OK to finish.

2.

Right-Click on the Right Plane and select the Mesh Sketch icon to start sketching.  The sketch setup will already be located in the correct location. Click the OK to accept and begin sketching.

Figure 167

Figure 166

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3.

Use the Model Tree to Hide the Mesh and Solid Bodies.

4.

Select the Draw>Line tool.  Use a box select method to create the 3 lines from the polylines.  Draw a vertical line starting from the vector to create a complete sketch.  Right-Click in space to select the Check and accept the command.

5.

Right-Click on the Vector and select Convert Entities.

6.

Select the Draw>Trim command.  Check it is set to Corner Trim.  Click on all of the lines surrounding each open connection to close.  Right-Click in space to select the Check and accept the command.

7.

Set constraints and dimensions then Right-Click in space and Exit the sketch.

Figure 168

Figure 169

 Only half of the figure needs to be sketched for the Revolve command.

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8.

Choose the MODEL>Create Solid>Revolve command to cut out the section.  With the previous sketch populating the Base Sketch and Profiles, chose Axis and select Vector1.  Under Result Operator, select Cut.  Click the OK to cut out the area.

Figure 170

Create Fillets 1.

Choose the Fillet command in the MODEL>Edit group.  Create a Constant Fillet by selecting the edge shown in Figure 171.

 The Tangent Propagation option will select all edges of the solid tangent to the first choice, reducing the need to manually select all edges.  Next to the Radius box, press the Estimate Radius From Mesh magic wand button.  Adjust the value to 1.5mm.  Click the OK to finish.

Figure 171

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2.

Repeat the process on the fillet around the outside of the mesh. Add all edges belonging to the same size fillet.

Figure 173 3.

Right-Click the solid edge of the other cut out in Figure 174, and choose the Fillet icon.  Change the type to Variable Fillet.

 The Profile View will appear below the Model View. This will be used to figure out the varying radius.  Manually select all 3 edges used for the variable fillet then click the Estimate Radii From Mesh Button.  Look at the predicted fillet radius down in the Profile View. 4.

Adjust the end points to match the pink polyline.  Set the R(adius) value to 4mm at each end point.

Figure 174

 Click on the middle section to re-zoom around this segment. Click again to place a new point in the approximate middle of the line.  Drag this point up to tallest peak of the pink polyline.  Click OK to finish.

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Figure 175 Figure 176

Figure 177 5.

Insert any additional fillets to the model.

End of Activity

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ACTIVITY: Mechanical Freeform Surface Modeling

Objective Create a surface body using Modeling Wizard and Model Surface Features, and then combine the surfaces using 3D sketches and surface trimming tools. Analyze modeling result with Accuracy Analyzer™.

Highlighted Commands and Concepts  Surface Fitting  Surface Editing  Surface Loft  3D Sketching

Training File 08-Mech Freeform Surface.xrl

File Open 1.

Open training file 08 – Mech Freeform Surface.xrl.  Navigate to the file from the Open Files dialog and press the Open button.

 The data is already aligned and classified with regions.

Figure 178

Upper Surfaces 1.

Select the Mesh Fit button in the MODEL>Wizard group on the ribbon to create a surface on the large, upper face.  Select the large, upper target Region shown in Figure 179.  Set the Resolution type to By Allowable Deviation, and the Allowable Deviation to 0.1mm.  Rotate the preview plane with a manipulator node until it is parallel to the x-axis.  Click the OK to accept the command.

 The orientation of the preview plane will be the same as the finished surface. Having the surface more square to the part will allow for higher quality surfaces in the end.

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Figure 179 Figure 180 2.

Hide only the Mesh Fit(1) surface body using the Model Tree.

3.

Select the Mesh Fit button in the MODEL>Wizard group on the ribbon to create the adjoining surface on the upper face.  Select the target Region shown in Figure 181.  Click the OK to accept the command using the previous options.

Figure 182 Figure 181

Join Surfaces 1.

Click the 3D Sketch button in the 3D SKETCH > Setup group on the ribbon.

2.

Select the Spline tool in the Draw group.  Draw a Spline from edge to edge of the Mesh Fit(1) surface body, as shown in Figure 183.  Right-Click to end the first spline.

3.

Repeat Step 2 for drawing a Spline on Mesh Fit(2) as close to parallel as possible to the first spline, then Accept the Spline.

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Figure 184 – Mesh Fit(2)

Figure 183 – Mesh Fit(1) 4.

Click the Split button in the 3D SKETCH>Edit group on the ribbon.  Split the first curve by clicking on two points near the edges of the Mesh Fit(2) surface.  Accept the command.

Figure 185 5.

Click the Exit button in the top left corner to finish the 3D Sketch.

6.

Hide Meshes and Mesh Fit(2), and Show Mesh Fit (1).

7.

Select the MODEL>Edit>Trim Surface command to trim the surfaces with the 3D Splines.  Select the first Spline in 3D Sketch(1) as the Tool Entities.  Select Mesh Fit(1) as the Target Entities.  Click the Next Stage button to continue.  Chose the correct larger portion of the surface as the Remaining Bodies.  Click the OK button to accept.

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8.

Repeat Step 7 using the second drawn Spline as the Tool Entities, and the Mesh Fit(2) as the Target Entities.

Figure 188

Figure 189 9.

Figure 190

Turn on visibility for both Trim Surface(1) and Trim Surface(2), and turn off visibility for 3D Sketch(1).

10. Select the MODEL>Create Surface>Loft command to join the surfaces.  Double check the Surface Loft command has been selected.  Select the Edge1 of Trim Surface1, and Edge2 of Trim Surface2 as the Profiles.  Set the Start Constraint and End Constraint to Tangency To Face. This will apply tangency to the lofted surface where it connects to the original surfaces.  Click the OK button to create the lofted surface.

Figure 193 Figure 192 Figure 191

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11. Finish joining all the surfaces into one body with the Sew command, found in the MODEL>Edit group.  Select all three surfaces as the Surface Bodies.  Click the Next Stage button.  Click the OK button to accept the result.

Figure 194  Alternatively, the Sew step can be skipped if the “Merge Tangent Faces” option is selected during the Loft command.

Reasoning for splitting the spline When trimming a surface by a curve, the split points on the curve will create a separate edge along the surface. Therefore, the surface edge length can be adjusted for lofting by editing the split points. If the edge lengths are of similar size when lofting, the resulting surface will be smoother and of higher quality.

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Figure 195 – 3D Sketch with Split

Figure 196 – 3D Sketch without Split

Figure 197 – Loft with Split

Figure 198 – Loft without Split

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Figure 199 – Deviation with Split

Figure 200 – Deviations without Split

Create Side Surfaces 1.

Hide Surface Loft1 to view the Mesh with Regions on.

2.

Choose the Loft Wizard command in the MODEL>Wizard.

3.

In the 1st stage of the Loft Wizard, set the location and orientation of the Loft.  Choose the three regions, shown in Figure 202, as the Regions/Poly Faces.  Change the Section option to By No. Of Sections, and set the value to 5.  Check the options match Figure 201.

Figure 202

Figure 201 4.

Rotate and adjust the manipulator to stretch the preview planes the long way across side body.

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5.

Click the Next Stage button to continue. A preview of the flow of the fitted surface body will be displayed.

Figure 204 6.

Turn on the Deviation for Body in the Accuracy Analyzer™, and use these deviations to add and move sections for a higher quality surface.

 Sections can be moved by clicking and dragging. Sections can be added by holding Ctrl and clicking and dragging the section planes.  These sections cannot be easily added and moved once the Loft Wizard has be completed.

Figure 205 7.

Figure 206

Click the OK button to finish the lofted surface.

Figure 207

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8.

Create the adjacent surface with a Mesh Fit surface. Select MODEL>Wizard>Mesh Fit on the ribbon.  Select the region shown in Figure 208 as the Target Regions/Poly-Faces.  Click the OK button to accept the surface using the previous settings.

Figure 208

Figure 209

Join Side Surfaces 1.

As done previously, enter into a 3D Sketch to create clean trim lines for lofting between surfaces.

2.

Hide Surface Loft1 and Surface Loft2 to only show the new Mesh Fit surface.

3.

Select the Spline tool in the 3D Sketch>Draw group.  Draw a Spline on the Mesh Fit3 surface body (Figure 210).  Hide the Mesh Fit3 surface and Show Surface Loft2.  Draw a second spline on the Surface Loft2 body (Figure 211).

Figure 210 Figure 211

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4.

Select the Split button in the 3D SKETCH>Edit group on the ribbon.  Turn on visibility of the Mesh Fit3 surface to see where the split points should be located.  Click on two points on the second spline to split the line.

5.

Click the Exit button in the top left corner to finish.

6.

Turn on the visibility for Mesh Fit3 and Surface Loft2.

7.

Select the MODEL>Edit>Trim Surface command on the ribbon.

Figure 212

 Select the first spline in 3D Sketch3 as the Tool Entities, and Mesh Fit(3) as the Target Entities.  Click the Next Stage button to continue.  Choose the correct Remaining Bodies.  Click the OK button.

Figure 214 Figure 213 8.

Repeat Step 7 using the second spline as the Tool Entity and Surface Loft2 as the Target Entity to Trim the lofted surface.

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Figure 216 Figure 215 9.

Hide 3D Sketch3, and Show Trim Surface3 and Trim Surface4.

10. Create a Surface Loft with the MODEL>Create Surface>Loft command to join the surfaces.  Select the Edge1 of Trim Surface3, and Edge2 of Trim Surface4 as the Profiles.  Set the Start Constraint and End Constraint to Tangency To Face. This will apply tangency to the lofted surface where it connects to the original surfaces.  Place a check next to Merge Tangent Faces in the Options rollup.  Click the OK button to create the lofted surface.

Figure 218 Figure 217

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Finish Side Surfaces 1.

Create the next with a Mesh Fit surface. Select MODEL>Wizard>Mesh Fit on the ribbon.  Select the region shown in Figure 219 as the Target Regions/Poly-Faces.  Click the OK button to accept the surface using the previous settings.

Figure 219

Figure 220

2.

Enter into a 3D Sketch to create clean trim lines for lofting between surfaces.

3.

Hide all surfaces except the new Mesh Fit surface.

4.

Select the Spline tool in the 3D Sketch>Draw group.  Draw a Spline on the Mesh Fit4 surface body (Figure 221).  Hide the Mesh Fit4 surface and Show Trimmed Surface3.  Draw a second spline on the Trimmed Surface3 body (Figure 222).

Figure 221 5.

Figure 222

Select the Split button in the 3D SKETCH>Edit group on the ribbon.  Click on two points on the second drawn, and longer, spline at approximately the length of the first spline.  Click OK to accept the Split.

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6.

Exit 3D Sketch with the button in the top left corner.

7.

Turn on the visibility for necessary surfaces.

8.

Select the MODEL>Edit>Trim Surface command on the ribbon.  Select the split spline in 3D Sketch4 as the Tool Entities, and Trim3 as the Target Entities.  Click the Next Stage button to continue.  Choose the correct Remaining Bodies.  Click the OK button.

Figure 224

Figure 225 9.

Figure 226

Select the MODEL>Edit>Trim Surface command on the ribbon.  Select the other spline in 3D Sketch4 as the Tool Entities, and Mesh Fit4 as the Target Entities.  Click the Next Stage button to continue.  Choose the correct Remaining Bodies.  Click the OK button.

Figure 227

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Figure 229

Figure 228 10. Hide 3D Sketch4 and show all the side surfaces.

11. Create a Surface Loft with the MODEL>Create Surface>Loft command to join the surfaces.  Select the Edge1 of Trim Surface5, and Edge2 of Trim Surface6 as the Profiles.  Set the Start Constraint and End Constraint to Tangency To Face. This will apply tangency to the lofted surface where it connects to the original surfaces.  Place a check next to Merge Tangent Faces in the Options rollup.  Click the OK button to create the lofted surface.

Figure 230

Figure 231

12. Click the Sew button in the MODEL > Edit group on the ribbon.  Select all the side surface bodies as the target Surface Bodies.  Click the Next Stage button to continue.  Check the previewed result and then click the OK button.  This step is only necessary if there are multiple side surfaces.

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Figure 232

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13. Click the Environment Mapping button in the Accuracy Analyzer™. Check continuity of the surface bodies.

Figure 233

Combine Upper and Side bodies 1.

Turn on the visibility of the upper and side surfaces (Surface Loft1 and Surface Loft4).

2.

Select the MODEL>Edit>Trim Surface command on the ribbon.  Select the Loft1 and Loft4 as the Tool Entities.  Deselect the Target checkbox.

Figure 234

Figure 235

 Click the Next Stage button to continue.  Choose the correct Remaining Bodies, as shown in the image below.  Click the OK button.

Figure 237

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Add Fillet 1.

Add a rounded, fillet edge to the connection of the two surfaces. Click the Fillet button in the MODEL > Edit group on the ribbon.  Change the method to Variable Fillet.  Select the edges between the two surfaces for the Entities, as shown in the image below.

Figure 239 Figure 238  Set R to 10-11mm for each edge.  These values can be directly edited by clicking them in the Profile view or in the graphic window.  Click the OK button.

Figure 241

Figure 240

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Finishing Features 1.

Begin a 3D Sketch by Right-Clicking in space in the Model View, and select the 3D Sketch icon.

2.

Draw a spline along either side of the fillet with the Draw>Spline tool.  Draw the first spline at the edge of the Fillet1 surface body to the first seam. (Figure 242).  Draw a second spline below the crooked fillet (Figure 243).

Figure 242 3.

Figure 243

Click the Split button in the 3D SKETCH > Edit group on the ribbon.  Select a point on the top spline near where the side surface ends.  Click the OK button to accept the command.

Figure 244 4.

Right-Click and select the Exit button to finish the 3D Sketch.

5.

Hide the Mesh. Show the Surface Body and 3D Sketch 5 only.

6.

Click the Split Face button in the MODEL>Body/Face group on the ribbon.  Select the split spline as the Tool Entities.  Select the upper surface face as the Target Entities, as shown in the image below.  Click OK button to accept the command.

7.

Repeat Step 6 using the lower spline and the side surface face. (Figure 246).

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Figure 246

Figure 245 8.

Remove the newly split area with the Delete Face command found in the MODEL>Body/Face group on the ribbon.  Select the Faces, as shown in Figure 247.  Click the OK button to remove the area between the splines. (Figure 248)

Figure 247 9.

Figure 248

Hide 3D Sketch5.

10. Create a Surface Loft with the MODEL>Create Surface>Loft.  Select Edge 1 and Edge 2 as the Profiles.  Apply the Start and End Constraint as Tangency To Face.  Select the small Edge 3 as the Guide Curve to create better connections with the surrounding surfaces.  Click the OK button and a lofted surface will be created.

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Figure 251 Figure 249

Figure 250

11. Repeat all of the previous steps on the other side where the fillet becomes unsmooth.

 3D Sketch on either side of the fillet with a spline to connect  Split Face of the surface using the 3D Sketch  Delete Face  Surface Loft

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Figure 252 – 3D Sketch

Figure 253 – 3 Splines with Split Point

Figure 254 – Split Face

Figure 255 – Split Face

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Figure 256 – Delete Face

Figure 257 – Removed Face

Figure 258 – Surface Loft

Figure 259 – Finished Surface

12. Sew the remaining surfaces together with the MODEL>Edit>Sew command.  Select all the surface bodies as the target Surface Bodies.  Click the Next Stage button to continue.  Check the previewed result and then click the OK button to accept.

 The model has more surfaces created and joined the same way the lesson demonstrated.  Continue creating surfaces or move to the Advanced Modeling section.

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Figure 260 13. Click the Deviation for Body and the Environment Mapping buttons in the Accuracy Analyzer™.

Figure 261

Figure 262 End of Activity

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Advanced Modeling ACTIVITY: Hybrid modeling

Objective Create a model by combination of automatic and parametric modeling. Hybrid modeling allows for quickly creating a model which has accuracy and parametric features. The resulting model is helpful for checking assembly and analyzing.

Highlighted Commands  Global Remesh  Enhance Shape  Optimize Mesh  Auto Surface  Sketch  Extrude - Cut

Training File 09-Knuckle.stl

Scan Setup 1.

Import training file 09-Knuckle.stl.  Click the Import button or select Import from Menu>Insert.  Use the Import Dialog to navigate to the training files folder. Choose Knuckle.stl from the Import dialog.  Click Import only. The file is loaded and displayed in the Model View.

Figure 263 2016 3D Systems

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1.

Select the Auto Segment command located in REGION tab.

 The Auto Segment command can be activated by RMB context menu after selecting the mesh with a double click.  Set the Sensitivity to 10.

Figure 264  Press the OK button to finish the Auto Segment.

Figure 265 2.

Click the Knuckle from Feature Tree and select Copy from MENU>Edit (Ctrl+C).  Click the OK button to copy the selected mesh data.

 After editing a mesh to create a better Auto Surface, the original mesh will still be needed to show where cuts and features belong.

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Figure 266  Select Paste from MENU>Edit (Ctrl+V) and paste the Copied Mesh in Feature Tree.

Figure 267

Edit and Optimize Mesh 1.

Select Knuckle in Feature Tree to edit.

 For a higher quality Auto Surface, details can be removed from the mesh and smoothed over. The Copied Mesh can still be used to track these features and shapes to use for sketch based modeling.  When there are multiple meshes, a mesh needs to be selected before editing with the POLYGONS tab. 2.

Select Offset command located in POLYGONS>Edit group on the ribbon.

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Select ~8 regions while holding the Shift key (Figure 268).

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Figure 268  Change the Distance to 1mm.

Figure 269  Press the OK to finish the Offset.

Figure 270 3.

Select Global Remesh command located in POLYGONS tab.

 Recalculate the entire mesh to make watertight, and improve the mesh quality.  Verify the mesh is still selected in the Tree if the command is not available.  Change the Target Average Edge Length to 0.5mm.  Place a check next to Make Clean And Manifold Solid Mesh. 2016 3D Systems

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Figure 271  Press the OK check button and finish Global Remesh.

Figure 272  It is easier to see the mesh quality without Regions. Ctrl+2 will toggle Regions on and off.  Select Shaded With Edges (F8) from MENU>View>Mesh Display Mode to show the mesh edges. 4.

Select Enhance Shape command in POLYGONS>Optimize group on the ribbon.

 Improve the quality of the mesh by sharpening corners and smoothing flat or rounded areas.  Change the options like the figure below.

Figure 273  Press the OK check button and finish Enhance Shape.

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5.

Select Optimize Mesh command located in POLYGONS>Optimize>Global Remesh dropdown.

 Optimizes a mesh based on its feature shapes and improves the quality of the mesh. This command also offers advanced options to control the size of poly-faces and the effects of smoothing a model.  Change the Method to High Quality Mesh Conversion.

Figure 274  Press the OK check to finish Optimize Mesh.

Figure 275

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Create Solid Body 1.

Select the Auto Surface command located in SURFACING tab.  Select Knuckle for Mesh and click Organic button.

Figure 276  Press the OK check button and finish Optimize Mesh.

Figure 277

Create Cutting Planes Create reference planes which are used as base sketch. These planes should be located at original mesh not on offset mesh. 1.

Click Copied Mesh in Feature Tree.

 Hide the visibility of the Mesh Knuckle.  Select the Auto Segment command located in REGION tab.  Use the previous settings.  Press the OK check button and finish Auto Segment.

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Figure 278 2.

Select the Plane command located in MODEL>Ref. Geometry tab and group.  Select the Don’t Quit Command With OK Lock button to remain in the command after accepting.  Select both the regions like the figure below.  Verify the Method is set to Average.  Press the OK check button.

Figure 280

Figure 279 3.

Immediately create a new Plane.  Select the region as shown Figure 281 below.  Press the OK check button.

Figure 281 2016 3D Systems

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4.

Select the region shown in Figure 283.  Press the OK check button.

Figure 284

Figure 283 5.

Select the region like Figure 285.  Click the OK check button.

Figure 286

Figure 285 6.

Select the region like Figure 287.  Click the OK check button.

Figure 288

Figure 287

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7.

Select the region like Figure 289.  Click the OK check button to create the sixth plane.

Figure 290

Figure 289  Press the Cancel button and finish the Plane command.

Create Sketches 1.

Create sketches to cut off redundant parts from solid model for machining.  Click Knuckle in Feature Tree.

2.

Select Mesh Sketch command in Setup group located in SKETCH tab.  Select Plane1 for Base Plane and press the OK check button.  Draw a sketch similar to Figure 291.  Press the EXIT button and finish the Mesh Sketch.

Figure 291 3.

Click Knuckle in Feature Tree and select Mesh Sketch in the SKETCH>Setup tab.  Select Plane2 for Base Plane and press the OK check button.

4.

Draw circular sketch line like the figure.  Press the Exit button and finish Mesh Sketch.

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5.

Click Knuckle in download rapid php 2018 - Free Activators Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane3 for Base Plane and press the OK check button.  Draw sketch similar to shown in Figure 293.

Figure 293  Press the EXIT button and finish Mesh Sketch. 6.

Click Knuckle in the Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane4 for Base Plane and press the OK check button.  Draw sketch line like the figure.

Figure 294  Press the EXIT button and finish Mesh Sketch.

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7.

Click Knuckle in the Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane5 for Base Plane and press the OK check button.  Draw sketch line like the figure.  Press the EXIT button and finish Mesh Sketch.

Figure 295 8.

Click Knuckle in the Feature Tree then select Mesh Sketch command in SKETCH>Setup group.  Select Plane6 for Base Plane and press the OK check button.  Draw sketch line like the figure.  Press the EXIT button and finish Mesh Sketch.

Figure 296 9.

Show only Solid Bodies and Sketches in the Model View.

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Cut Solid Body by Extruding Sketches 1.

Extrude each sketch with the MODEL>Create Solid>Extrude command to cut the Solid Body.  Select Sketch1 (Mesh) for Base Sketch.  Set the Method to Blind with a Length of 20 mm.  Place a check in the Cut box in Result Operator.

Figure 298  Press the OK check button and finish Extrude.

Figure 299

Figure 300

 Repeat operation to cut the body. 2.

Select the Extrude command.

 Use Ctrl+Space bar to execute previous command.  Select Sketch2 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button. 2016 3D Systems

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Figure 301 3.

Figure 302

Select the Extrude command.  Select Sketch3 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 304

Figure 303 4.

Select Sketch4 (Mesh) in the Feature Tree, then Right-Click in space and select the Extrude (Solid) icon.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 306

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5.

Select the Extrude command with any method.  Select Sketch5 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 308

Figure 307 6.

Select the Extrude command with any method.  Select Sketch6 (Mesh) for Base Sketch.  Place a check in the Cut box in Result Operator.  Press the OK check button.

Figure 310

Figure 309

Make a Hole for Assembly 1.

Select the Vector command located in MODEL>Ref. Geometry tab.

 Create the axis of the Cylinder.  Select Top plane and Right plane for Entities and create a vector which will intersect both Planes.

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Figure 311  Press the OK check button and finish Vector. 2.

Click Copied Mesh in Feature Tree.

3.

Right-Click in space, then select the Mesh Sketch icon.  Select Right plane for Base Plane.  Click the Apply check button.  Draw sketch line as shown in Figure 312.

Figure 312  Press the EXIT button and finish Mesh Sketch. 4.

Select the Revolve command from Create Solid group located in MODEL tab.  Select Sketch7 (Mesh) for Base Sketch,  Select Vector1 for Axis.  Select the Cut check box in Result Operator.

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Figure 313  Press the OK check button and finish Revolve.

Figure 314

End of Activity

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ACTIVITY: Impeller Workflow

Objective Create an impeller using surfacing and solid tools.

Highlighted Commands  Revolving Silhouette Mesh Sketch Setup  Loft Wizard

Training File 10-Impeller.stl

Scan Preparation 1.

Import training file 10-Impeller.stl.  Click the Import button or select Import from Menu>Insert.  Use the Import Dialog to navigate to the training files folder. Choose Impeller.stl from the Import dialog.  Click Import only. The file is loaded and displayed in the Model View.

Figure 315 2.

In the POLYGON tab, use the Fill Holes and Smart Brush command to clean and smooth a single vane of the impeller.

 Assuming all blades Geomagic Wrap Free Activate the same, only one will need to be edited for the modeling. The single modeled vane can be patterned.  With the Repair Holes/Boss>Fill Holes command, select all the holes on one vane to fill in with Curvature.  Use the Wizard>Smart Brush command and the Smooth option to paint the specific areas that are rough. 2016 3D Systems

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Figure 316 3.

Figure 317

In the Tree dock, change the tab to Viewpoint.  Orient the part to focus on the edited vane.  Select the Add Viewpoint button to save the view.  Toggle back to the Tree dock.

Figure 318

 The Viewpoint can be saved for later use to be able to quickly move back to the edited vane. 4.

After editing the mesh, use the Optimize>Decimate command to reduce the triangle count.  Select the Allowable Deviation method with a value of 0.01 mm in the Options.  Accept the command to see the new triangle count.

Figure 319 Figure 320

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5.

Select the Auto Segment command located in REGION tab.  Set the Sensitivity to 5 then accept.

6.

Use the Edit>Merge command to merge the the regions on either side of the cleaned vane.  Hold Shift and select the multiple regions on a single face.  The Merge button is now active. Select.  Repeat process on other side face of vane.

Figure 321

Align To Coordinate System 1.

Create Ref. Geometry>Vector to more accurately align the scan.  Select the Revolving Axis method.  Select all regions where the central axis would be the same as the center of the impeller.  Preview and then Accept the Vector.

Figure 322 2.

Align the scan to the coordinate system using ALIGNMENT>Scan to Global>Interactive Alignment.  Verify the mesh is selected then go to the Next Stage.  Change the Method to XYZ.  For Position, select the Vector1 and a Plane Region on the bottom of the scan.  Set Axis Z to Vector1. If needed, Flip Direction of the positive axis.  Use the Blue Circle of the Manipulator to clock the part about the Z Axis. Rotate until the X Axis (Right Plane) is passing through the edited vane.  Check the alignment is in position on the right half of the screen then Accept.

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Figure 324

Figure 323

Main Body 1.

Create a Mesh Sketch on the Right Plane.  Change the method to Rotational Method.  Use the Offset Angle From Base Plane or the Green Circle to rotate the base plane to find the best sketch angle for the main body of the impeller.  Accept the sketch setup.

Figure 325 2.

Sketch the inner profile shown in Figure 326.  Use Arc and Line tools to create a sketch of the inside profile of the impeller.  Exit the sketch when finished.

 The bottom post is not rotational and does not need to be sketched.

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Figure 326 3.

Create the body with Create Solid>Revolve.  Set the previous sketch as the Base Sketch and Profile.  Select the Centerline of the Sketch as the Axis.  Accept the command.

Figure 327

Figure 328

Vane 1.

Create a surface on either side of the cleaned vane with a Loft Wizard or Mesh Fit command.

Option 1  RMB on the region of one side of the cleaned vane scan and choose the Loft Wizard icon.  In Section, select By No. Of Sections, then set the No. Of Sections to 7, and increase the smoothness.  In Profile Types, select Ref. Planes and Mesh Sketches. 2016 3D Systems

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 Adjust the size of the bounding box of the surface with the red, green, and blue dots to be much larger than the mesh, then go to the Next Stage.  Turn on the Deviation From Body.  LMB and hold on the planes to readjust the position of the planes.  Ctrl+LMB on a plane will add a new plane. Readjust the planes to reach the desired accuracy then accept the command.

Figure 329

Figure 330

Option 2  RMB on the region of one side of the cleaned vane scan and choose the Mesh Fit icon.  Make any desired adjustments to the settings, or press the OK button to accept the command.

Figure 331

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Figure 332

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2.

Repeat either option on the other side of the vane.

3.

Edit any sketches created by the Loft Wizard to smooth and better the surface.  RMB on Sketch 5(Mesh), or any other sketch created by the loft wizard, and choose Edit.  Select the generated spline.  In the Rebuild Spline>No. Of Interp. Pts box, enter 20 then press Enter.  Look at the spline, then edit the value again but to 10.

Figure 333

Figure 334

 Exit the sketch to see how much smoother the surface is in one spot. 4.

Repeat Step 3 on the other sketches as desired.

 Reducing the spline points is one way to edit the loft wizard to change the resulting surface.  Other ways could be to completely remove the spline and remake the sketch using lines and arcs.

Figure 336- Edited Surface

Figure 335- Original Surface 5.

Create a Mesh Sketch on the Right Plane to capture the outer profile of the vane.  Change the option to Rotational Method for the sketch setup.  Pull the Green Arrow or change the Silhouette Range to encompass the entire cleaned vane, then accept the command.

 The Rotational Silhouette Range will create a wedge to contain the desired area, and then project by rotating about an axis.  The Offset Angle can also be adjusted for a better cross section.  Create the sketch of the outside vane profile using Line and Arc tools.  Use Figure 338 to create the sketch then Exit. 2016 3D Systems

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 An open profile sketch can be used only for surfaces. Close the sketch to create a solid revolve.

Figure 337 6.

Figure 338

Use the Create Surface>Revolve to revolve the surface the necessary amout to enclose the surfaced vane.

 The Sihlouette command will place the sketch near the vane or on the opposite side of the impeller.  A small rotation in both directions could be needed, or a large rotation to encompass the entire vane.

Figure 339 7.

Create an Edit>Surface Offset of the original rotated body to completely enclose an impeller vane.  Select all faces along the top of the solid.  Change the Offset Distance to 0 mm then accept.

 An offset at 0 is duplicating and creating a surface on the solid face to use in more commands.

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Figure 340 Figure 341– Enclosed Vane 8.

Select MENU>Insert>Surface>Solidify to create a solid from the selected surfaces.  Select the four surface bodies needed to enclose a vane and accept the command.

 If an error occurs or a surface does not extend fully through the other surfaces, use the Extend Surface tool to lengthen the surface before repeating the Solidify command.  Check the Visibility of the Solid Bodies is on to view the main body and single vane. 9.

Use the MODEL>Edit>Fillet command to place a small fillet on the top edges of the vane.

Figure 342

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Figure 343

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10. Select Pattern>Circular Pattern to create the remaining vanes.  Choose the Vane as the Bodies.  Select Vector1 as the Rotation Axis.  Set the No. Of Instances to 16.

Figure 344

Edits and Shaft 1.

Merge all solid bodies to one body with the Edit>Boolean command.  Set the Operation Method to Merge.  Select all 17 solid bodies as the Tool Bodies then accept to have a single solid body remaining.

2.

Create the lower shaft using a Mesh Sketch on the Front Plane or any plane normal to the shaft.  Offset the Offset Distance From Base Plane to cross through the triangular shaft and accept the set up.  Use Arc and Fillet tools to create the sketch then Exit when completed.

Figure 345 2016 3D Systems

Figure 346

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3.

Create Solid>Extrude the sketch to create and merge the shaft.  Use the Up to Region method with the Max Position sub method.  Select the lower region of the scan shaft.  Check the Merge option is selected under Result Operator, then Accept.

Figure 347 4.

Create a Mesh Sketch on the top face of the shaft to cut out the top hole.  Select the top solid face as the Base Plane.  Offset the sketch profile down slightly to see the inside circle then accept the Mesh Sketch Setup.  Sketch the inside Circle then Exit the sketch to cut out the hole.

Figure 348

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Figure 349

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5.

Cut out the hole with the Create Solid>Extrude command.  Set the Method to Blind and cut down about 25 mm in to the mesh.  Set the Result Operator to Cut.  Accept the command.

Figure 350 6.

Repeat process for lower hole in shaft.

Figure 351 7.

Add Fillets where needed on the model.

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Exact Surfacing Exact Surfacing is a workflow designated to create a very accurate surface on a complex scan. The new SURFACING toolbar walks through the steps needed to create a good patch network to generate the surfaces. The Create/Edit Patch Network group in the SURFACING tab has all the tools needed to create the surface. Step 1: Extract Contour Curves –Detect and automatically extract 3D contour curves for the area of high curvature on a mesh. These curves can be edited and adjusted manually to create a better Patch Layout.

Figure 354

Step 2: Construct Patch Network – Automatically construct the patch network within the patch layout.

Figure 355

Step 3: Shuffle Patch Groups – Reorient the patches within the panels in a 3D patch network for better continuity.

Figure 356

Step 4: Fit Surface Patches- Create NURBS surfaces inside each patch of the 3D patch network. An accurate freeform surface body will be created.

Figure 357

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ACTIVITY: Exact surface

Objective Learn about exact surfacing. This exercise converts a polygon object to an exact surfaces object and activities the remainder of the exact surfaces tab. This workflow generates surfaces match the object exactly as it is constructed.

Highlighted Commands  Extract Contour curves  3D curves  Construct Patch Network  Shuffle Patch Groups  Fit Surface Patches

Training File 12-Exact Surface.xrl

Import file 1.

Open training file 11-Exact Surface.xrl  Click the Open button or select Open from Menu>File>Open.  Use the Open Dialog to navigate to the training files folder. Choose 11-Exact Surface.xrl from the Open dialog.  Click Open. The file is loaded and displayed in the Model View.

Figure 358

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Extract counter network 1.

Go to the SURFACING tab to begin the Exact Surfacing workflow. the Extract Contour Curves and set the curvature Sensitivity Potion to 60 and then click to next stage  Select the Extract Contour Curves command in the Create/Edit Patch Network group.  Set the Curvature Sensitivity Position to 60 then select the Next Stage button.

 The Extract Contour Curves command automatically places red separators between regions of relative flatness. The Next Stage allows adjustment of those region separators and then places 3D contour lines inside the regions.

Figure 359

Figure 360 2.

In the Next Stage, click the Enable Real Time Preview option to have live feedback of the editing of the separators.  Use the Paint Brush Selection Mode to add, remove, and clean regions.

 Best practice will be to extend all separator regions to a scan boundary, similar to Figure 457.  Edit the Contour Curves regions as shown in Figure 362.  Hold Ctrl when selecting to remove separator regions.  Other selection modes, such as the Line, Rectangle, and Circle can be used to edit separators.

Figure 361 - Before Editing

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Figure 362 - After Editing

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Figure 363 – Edited Separators

Edit Contour Curves on a Mesh 1.

The generated contour curves are now a 3D Sketch. Go to the 3D SKETCH tab to edit.  Select all of the Contour Curves by pressing Ctrl+A or box selecting the part.  In the ribbon, find the Rebuild Toolbar. Change the value of No. of Interp. Pts to 10 then click the OK button.

 Each curve will now have 10 points; therefore, the contour curves are more easily controlled.

Figure 365

Figure 364 2.

Select a junction point on the contour curves and swing the point back and forth so that the connected curves are smoothed.

3.

Adjust all contour curves to be continuous and four sided. The Edit>Trim tool can remove extra segments.

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Figure 367 - After Editing

Figure 366 - Before Editing 4.

Select all of the Contour Curves and Rebuild them again.  In the ribbon, find the Rebuild Toolbar. Change the value of No. of Interp. Pts to 20 then click the OK button.

5.

Verify all lines are straight and the patches seem continous.

 Each of these four sided figures is a panel. The panels will dictate the layout of the patch network.

Figure 368

Constructing a 3D Patch Network 1.

Allow the software to automatically construct a patch network from the panels created previously with the Construct Patch Network step. This is found in the Create/Edit Patch Network group.

 Note that Construct Patch Network command can be found in the 3D SKETCHING and the SURFACING tabs. In both of these tabs, the command is located within the same group.

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Figure 370

Edit 3D Patch Network 1.

In the 3D SKETCH or SURFACING tab, choose the Create/Edit Patch Network>Shuffle Patch Groups command.  Click on a panel as shown in the Figure 371.

2.

Select Add/Del 2 Paths in the Action roll up, and select the Auto Fill Neighboring Panels option in the More Option roll up.

 The Auto Fill will match the number of paths in the adjacent panel when paths are added or removed.  Select a point along the lower side of the panel to increase the number of paths along the edge until the edges match.  To decrease the number of paths in a panel, hold Ctrl when clicking on the panel edge.

Figure 372

Figure 371 3.

Click the Deselect Current Planel next to Action in the top roll up to clear the previous selection and make choose a new panel to edit.  In the More Option roll up, click the Next arrows to navigate through patch panels and find the ones needing rearranging.

4.

Select a panel that needs to be shuffled and repeat steps 2 and 3 until all panels have equal patch sides.

 While the define option is selected in Action, check the vertices of each panel is properly placed in each corner of the panel. If not, click the vertex to redefine and Accept.

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Figure 373

Create a NURBS Surface 1.

In the SURFACING tab, choose the Fit Surface>Fit Surface Patches command.  Select the 3D Sketch1(Mesh) as the Mesh Curves base.  Select the Adaptive option as Fitting Method.

Figure 374

 Adjust the slider of the Geometry Capture Accuracy option to one notch away from Max to improve the accuracy of the fitting surface patches.

Figure 375

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Figure 376 End of Activity

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ACTIVITY: Self Exercise

Objective Create a propeller using the skills learned throughout the training course.

Highlighted Commands  Interactive Alignment  Mesh Sketch – Silhouette  Loft Wizard/Mesh Fit  Revolve

Training File 12-SelfExercise.stl

Figure 377

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Appendix I – Mouse and Keyboard Control Mouse Control The default Right-Hand Mouse is shown.  Selection Button o Change tabs in ribbon o Activate commands o Select and activate entities

LMB

o Make individual or box selections

 Scroll Wheel o Zoom in and out of center of screen. Roll the mouse up and away to increase magnification; roll the mouse down to decrease magnification.  Toggle Button

MMB

o Activate second level of mouse buttons. Most buttons will rotate the part.

 Rotate Button o Hold to rotate the view of the part about the center of the screen.  Context Menu

RMB

o Activate common commands based on the entity selected. o Accept and Exit Commands

 Pan o Move the part laterally on the screen.

LMB and RMB

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Shortcut Keys Listed in the table are the commonly used default Shortcut Keys. These shortcut keys will allow quicker access to certain functions quickly without selecting the function from the Tool Bar.

Command

Shortcut Key

Menu New Open Save Select All Select Inverse Undo Redo Repeat Last Command

Ctrl+N Ctrl+O Ctrl+S Ctrl+A, Shift+A Shift+I Ctrl+Z Ctrl+Y Ctrl+Space

Zoom Fit Meshes Visibility Regions Visibility Point Cloud Visibility Surface Bodies Visibility Solid Bodies Visibility Sketches Visibility 3D Sketches Visibility Ref. Points Visibility Ref. Vectors Visibility Ref. Planes Visibility Normal To

Ctrl+F Ctrl+1 Ctrl+2 Ctrl+3 Ctrl+4 Ctrl+5 Ctrl+6 Ctrl+7 Ctrl+8 Ctrl+9 Ctrl+0 Ctrl+Shift+A

View

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Appendix II - Mesh Editing ACTIVITY: Mirroring scans

Objective This training course is designed to show how to mirror half a scan and edit the mesh of a bottle scan to prepare it for either 3D printing or modeling.

Highlighted Commands  Mirror  Thicken

Training File Bottle.stl

Import Scan Data 1. Import the Scan Data found at:

(~/Appendix/Bottle.stl)

Figure 379

Add a Reference Plane 1. Hold down the Ctrl button and click-drag the Right plane to the neck of the bottle by 105mm.

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2. Click the Visibility icon next to the Top Plane and Right Plane entities in the Model View to hide them, leaving on the Front Plane and Plane1 visible.

Figure 381

Figure 382

Splitting the Mesh 1. Click the POLYGONS>Edit>Split button in the ribbon.  Select the By Entity method.  Choose Plane1 as the Tool Entity.  Do not use the Cap Section Ends option and toggle the Don’t Quit Command With OK button to turn it off.

Figure 383 2. Click the Next Stage button. 3. Select the region to remain and click the OK button.  Make sure to select the larger section of the bottle and de-select the smaller section.

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Figure 384

Figure 385

Mirror and Thicken 1. Click the Mirror button in the MENU>Tools>Mesh Tools>Mirror option.  Select the Front base plane as the Position.  Enable the Trim & Merge with the Remesh Poly-Faces Around Mirror Plane option enabled.

Figure 386

Figure 387

2. Click the OK button. The mesh will be identically mirrored across the Front base plane.

Figure 388

Figure 389

3. Click the POLYGONS >Edit>Thicken button on the ribbon. This command creates a constant thickness along the walls of the model.  Choose the Surface method, set the Thickness to 2mm and choose the Direction2 option.

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Figure 390

Figure 391

4. Click the OK button and the mesh will now have a thickness of 2mm.

Figure 392

Figure 393

5. The mesh of the bottle is now complete and thickened and ready for the modeling process.

Figure 394 End of Activity

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ACTIVITY: Global Mesh Enhancing

Objective This training course is designed to show how to optimize and enhance messy scan data.

Highlighted Commands  Optimize Group  Decimate  Enhance Shape

Training File Grasshopper.stl

Import 1. Import the Scan Data found at: (~/Appendix/Grasshopper.stl)

Figure 395

Hide Reference Planes 1. In this training the Ref. Planes will not be utilized, so they can be hidden from the Model View by pressing the Ctrl + 0 keyboard shortcut or by clicking the visibility icon next to the Ref. Planes entity in the Model Tree.

Figure 396

Change Mesh Color 1. Click the Right Mouse Button (RMB) on the Grasshopper entity in the Model Tree and select Properties from the pop-up menu if it is not already visibile on the right side toolbar.

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 

Click the Material option in the Appearance options. Change the color to the green material.

Figure 398 3. Click the OK button. The color of the mesh material for the model will change to green.

Figure 399  Changing the color of the mesh is used to help in recognizing the mesh in the application. It does not change the color information of the mesh file.

Global Remesh 1. Click the Global Remesh button in the POLYGONS>Optimize group.  Set the Edge Length Multiplier to 1 to create similar edge lengths for the entire model.  Enable the Make Clean And Manifold Mesh option to generate a clean and closed mesh.

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 Click the OK button.  The mesh will now be globally remeshed by regenerating mesh structures and removing defects from the curvature flow of the mesh. All poly-faces will be remeshed to have the same edge length, resulting in a more uniform mesh.

Figure 401 – Before Remesh

Figure 402 – After Remesh

Decimating the Mesh Show Edge 1. Enable the Edge option under the Mesh section in the Display tab, or press the F8 key on the keyboard.

Figure 403

Decimate 1. Click the Decimate button in the POLYGONS>Optimize group.  Click the Don’t Quit Command With OK button to continuously use the comm and without exiting it.  Set the Reduction Ratio to 70%.  Click the OK button to apply the command without exiting it.

Figure 404

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2. Apply the command again by clicking the OK button, then click the Cancel button.  The mesh will be reduced by 70% again to further reduce the poly-face count.

Figure 405

Figure 406

Optimize Mesh 1. Click the Optimize Mesh button in the POLYGONS>Optimize>Global Remesh dropdown group.  Select the High Quality Mesh Conversion Method.  Set the Min Edge Length Multiplier to 0.5 and the Max Edge Length Multiplier to 8.

Figure 407  This method creates regular sized triangles from the original mesh by generating more triangles in high curvature regions and fewer triangles in low curvature regions. 2. Click the OK button. The mesh will now be optimized.

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Enhance Shape 1. Click the Enhance Shape button in the POLYGONS>Optimize group.  Change the Overall Smoothness to Mid and the Enhance Level setting to Max.

Figure 410 2. Click the OK button. Areas of high curvature will become sharper than the original shape. Apply this command again with the same options to emphasis sharper areas even more.

Smooth 1. Click the Smooth button in the POLYGONS>Optimize group.  Change the Smoothness Level to Max.

Figure 411 2. Click the OK button. The mesh will be smoother globally.

magic Design X ning

Figure 412

Figure 413

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ACTIVITY: Mesh Editing

Objective This training course is designed to show how to edit the mesh of a phone scan to prepare it for the modeling process.

Highlighted Commands  Defeature  Fill Holes  Edit Boundaries  Healing Wizard

Training File Phone.stl

Import Scan Data 1. Import the Scan Data found at:

(~/Appendix/Phone.stl)

Figure 414

Defeature 1. Click the Defeature button in the POLYGONS>Repair Holes/Boss group.  Click-drag and release around an area near the top of the phone as shown in the image below.

Figure 415  The defeature command is useful for models where small irregular features exist that may hinder the modeling process. 2016 3D Systems

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2. Click the OK button. The feature will be removed.

Figure 416

Fill Holes 1. Click the Fill Holes button in the POLYGONS>Repair Holes/Boss group.  Toggle on the Don’t Quit Command With OK button to continuously use the command without exiting it.  Select the microphone hole boundary on the bottom of the phone (Figure 417) using the default settings.  Click the OK button.

Figure 417

Figure 418

Add Bridge 1. Click the Add Bridge button in the Editing Tools.  Click on hold the LMB on the edge of one triangle on one side of the gap seen below.  Drag the mouse to the other side and release one an edge is highlighted.

Figure 419  Adding bridges is useful for filling in complicated holes or boundary areas that are irregular in shape.

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2. Click the Boundaries button and  Select the boundary created by the bridge shown in Figure 420.  Toggle off the Don’t Quit Command With OK button to disable it and then click the OK button to complete the command.

Figure 420

Figure 421

Edit Boundaries 1. Click the Edit Boundaries button in the POLYGONS>Edit group. This command enhances boundary shapes on a mesh.  Toggle on the Don’t Quit Command With OK button.  Select the Fit method and change the Fit Option to Circle.  Select the largest circular boundary in the middle of the model shown in Figure 423.

Figure 422 

Figure 423

Figure 424

Click the OK button. The boundary will be changed to a circle.

2. Change the Method to Smooth and select the outer boundary of the mesh. Set the Select N-Depth Boundary to 3.

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Figure 425 

Click the OK button. The boundary will be smoothed by 3 poly-faces from the original boundary. 3. Click the Cancel to exit.

Figure 426

Figure 427

Healing Wizard The wizard will remove unwanted and irregular poly-faces using an automated wizard process.

Remove Dangling Poly-Faces 1. To remove any remaining dangling poly-faces on the mesh boundary, click the Healing Wizard button in the POLYGONS>Wizard group.  De-select all options except for the Dangling Poly-Faces option.

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Figure 429 2. Click the OK button. The dangling poly faces on the mesh will be removed.

Figure 430

 Dangling Poly-Faces are edges that are not connected to neighboring poly-faces.

2 Sides Open

3 Sides Open

End of Activity

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Appendix III – Additional Models ACTIVITY: Iterative modeling

Objective Reinforce common skills, such as importing scan data, region segmentation and editing, and 2D sketching and basic modeling concepts to create a parametric model. Reverse model a casting and iterate the model to the desired result by modifying the parametric features.

Highlighted Commands and Concepts  Mesh Sketch Setup (Advanced)  Convert Entities  Iterative Modeling

Training File A1-Iterative Model.stl

Scan Setup 1.

Import training file A1-Iterative Model.stl.

 The model is not a complete scan, but all the information required to model is available.

Figure 431 2.

In the REGION tab, select the Auto Segment command.  Set the Sensitivity to 65.  Click the OK checkmark to accept.

3.

Switch to the Geometry Type Display Mode from the Upper-Side Toolbar.

 Each specific geometry will have a specific assigned color. For example, all Planes will be blue.

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Method 1: Extracting Geometry 1.

While still in the REGION tab, Hold Ctrl and select all three regions of the curved top face.  Select the Edit>Merge command to merge the regions.

 Certain commands in the extracting geometry workflow require the selection of a single region.

Figure 433 2.

Use the Extrusion Wizard to quickly create a base body.  RMB click on the recently merged region and select Insert/Merge.  Click the Select None next to Sides then Top.

3.

The automatically selected regions were not appropriate for the desired outcome.  For Top, select the Freeform, merged region on the mesh, and for the Bottom select the Ref. Plane Front plane.  For Sides, select the three Plane walls.  Set the Custom Extrusion Direction to the Ref. Plane Front to be able to select Fix Sketch Plane With Selection.

 The extracted 2D Sketch for the upcoming Extrusion will be placed on the Front Plane.  Uncheck the Draft Angle option.

Figure 435 Figure 434

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4.

Select the Next Stage arrow to view and edit the generated sketch and extrusion.  Slide the Resolution slide bar all the way to Min to avoid the noise of the scan data in the final sketch. It should appear as a rectangle.  Set the Geometry Capture Accuracy all the way to Loose to allow for constraint (Perpendicular, Tangent, etc.) entities to be assigned to the sketch.  Accept the Extrusion Wizard Geomagic Wrap Free Activate long as the created body is previewed.

Figure 436 5.

RMB click on the Sketch1(Mesh) that has been created in the Feature Tree, and select Edit.

 Wizard parameterscannot be edited after acceptance because editable, parametric features are created in the Feature Tree.  Select the Front Viewpoint from the Upper-Side Toolbar.  Adjust the right-most line to better fit the model.  Exit the sketch to re-extrude the base.

Figure 438

Figure 437

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6.

Inspect the quality of the surface by checking different Surface Analyzing Modes.  From the Upper-Side Toolbar, or Accuracy Analyzer dock, select Deviation For Body. The majority of the surface is green so within our desired tolerance.  Change the option to Iso Line. This will show the curvature of the freeform surface.

 Although this is a quick way of extracting the actual situation of the scan data, it is not always the desired method. The top, freeform surface is not editable in CAD. The surface is not easily reusable because its flow cannot be controlled by the user.

Figure 439

Figure 440

Method 2: Creating Geometry  Looking and investigating the nature of the top surface, it is a surface that consists of two differently tilted areas that are blended between. Do not delete or undo the previous body. It can still be utilized in the next method. 1.

Create a Mesh Sketch on each of the side faces of the solid body.  Select the actual face of the side wall shown in the Figure as the Base Plane.  Set the Offset Distance From Base Plane to 1 mm inward on the part.  Click OK to begin sketching.

 Tilted surfaces should ideally get a zero offset, but some cases require a slight offset to capture better data.

Figure 441

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2.

Set the left and right edges of the base by converting the extracted base.

 Turn the visibility of the Solid Bodies ON and the visibility of the Meshes OFF.  RMB click on the left-most vertical edge and select Convert Entities.  Repeat on the right-most vertical edge. 3.

These lines have a Converted Constraint. Change the lines to Construction Lines.  RMB click on each line and select the Make As Construction Line symbol.

 Hide the Solid Bodies to avoid selecting when finishing the sketch.

Figure 444 Figure 443 4.

Finish the sketch with the Line and Corner Trim tools.  With the Line tool, double click on the long diagonal pink profile line.  Use the Corner Trim command to connect the diagonal to the vertical lines.

5.

Add Dimensions using the Smart Dimensions command.  Select the end point of the diagonal top line, vertically down to the U Axis to define the height.  Repeat on the other vertical line.  Turn on the Deviation from the Upper-Side Toolbar to adjust the best assumed heights.

 In the Accuracy Analyzer dock, increase the Vector Multiplier to view the deviation easier.  Change the dimensions to the best fit height, or adjust to match Figure 445.  Exit the sketch.

Figure 445

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6.

Repeat the same process for the opposite face.

 Mesh Sketch on the solid face, offset 1mm inward.  Convert the vertical edges and make as construction.  Dimension to match Figure 446.

Figure 446 7.

The other two sides needs to be created using Mesh Sketches and the previous sketches.  Set up the Mesh Sketch on a remaining face, offset inward 1 mm.  Create a Line on a straight stretch of the pink profile line by using the rectangular selection method of drawing a line (Figure 447).  Double-click on the end point then Shift+LMB on the grey line of the previous sketch.  Select the Pierce Constraint from the Common Constraints List.  Repeat on the other side of pink profile lines.

Figure 447

Figure 449

Figure 448

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8.

Use a Spline tool and only two points to connect the open entities.  Add Tangent constraints to the connection of the spline and each line. This will allow the spline to bend and better fit the polylines.  Use Smart Dimensions to define the sketch as shown in Figure 450.

Figure 450 9.

Repeat this process on the other side.

 Mesh Sketch on the face with the profile offset 1mm inward.  Create two lines and Pierce them to the previous sketches.  Use a spline to connect the two lines.  Constrain and Dimension.

Figure 451 10. Create the top surface using the MODEL>Create Surface>Loft command.  For the Profiles, select both sketch chains with the splines.  The Surface Normal depends on the order the profiles are selected. Choosing the profiles from right bottom to left bottom, or left top to right top, will create a surface normal pointed in the desired direction.

Figure 453

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11. Use the MODEL>Body/Face>Replace Face command to use the newly lofted surface.  For Target Faces, choose the extracted, curved top face of the solid body.  For Tool Entity, select Loft1 from the Model Tree.  Accept the command to finish the solid.

Figure 454

12. Check the changes in the different deviations between the Extracted geometry and the geometry created with sketches and dimensions.

Figure 455 – Extracted Deviation

Figure 456 – Extracted Iso-Line

Figure 457 – Extracted Design Quality

Figure 458 – Created Deviation

Figure 459 – Created Iso-Line

Figure 460 – Created Design Quality

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Casting Body Features 1.

Find the position and orientation of the rib feature.  Method 1: Create Ref. Geometry>Vector, and select the Cylinder region shown and the Front plane.  Change the Method to Projection then accept the command.

 This method is most accurate to the scan data, but unable to change parameters of the vector. The created vector will not be used.

Figure 461

 Method 2: Create a Ref. Geometry>Polyline, and select the top fillet regions of the rib feature.  Change the Method to Fillet then accept the command.  Polylines can be inserted into Mesh Sketches and sketch entities will snap to the lines to give full control of the shape and form. 2.

Figure 462

Create a Mesh Sketch on the Front Plane with 0 offset.  Bring the Ref. Polyline into this sketch using MENU>Tools>Sketch Tools>Insert Polyline.  Sketch a Line on the inserted polyline.  Convert the intersecting edges of the solid base and Make as Construction Geometry.  Use the Edit>Extend tool to extend the sketched line to the converted edges.  Dimension the endpoints and angle of the line to the vertical V Axis.

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3.

Create a Ref. Geometry>Plane on the sketch line.  Choose the Right Plane and Sketch (Curve 1) as the Entities.  Change the Method to Projection and accept.

 A plane, orthogonal to the Front Plane, will now be set on the sketch line to use to create the rib. 4.

Create a Mesh Sketch with the new plane, Plane 1, as the Base Plane.  To capture the maximum height and profile of the rib, set the Silhouette Range to be wider than the rib, about 38 mm and accept the sketch setup.

 The Geomagic Wrap Free Activate and lower boundaries of a volume around the section plane will be projected to the base plane.

Figure 465 5.

Sketch the profile of the rib as shown in Figure 466.  Use the Auto Sketch tool to quickly extract sketch entities from the poly-lines.  Adjust the Resolution slide bar to find the appropriate poly-line segments.  With Make Selected Only, choose the top profile of the rib and accept the dialog.

Figure 466 6.

Use Convert Entities to bring in the lower line of the rib sketch profile.  Select the line from the previous sketch.

7.

Trim the profile to close the sketch loop.

8.

Smart Dimension the sketch to define the rib, then Exit the sketch.

 A 4.5° draft between the vertical and side lines of the sketch were added for manufacturing purposes.

Figure 467

 For better maintainability, sharp corners were created. Dimensions on the corner points, rather than the arc centers, will allow for easier radii changes. 2016 3D Systems

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9.

Select Create Solid>Extrude from the previous sketch to generate a solid model.  Select all three closed sketch loops for the Profiles.  Set the Method to Mid Plane. Drag the arrow until it snaps to the upper boundary of the planar side region.  Change the Length value to a round number.  Remove all checks under Result Operator, and then Accept the Extrude.

 A draft is still needed for the extruded sides, but it will be added at a later step.

Figure 468

Figure 469

10. In the MODEL tab, select Edit>Fillet.  In Constant Fillet, select the corner edge of the extruded rib.  Use the small Measure Radius button next to the Radius input field.  Click on the larger radius sketch entity.  Verify the Radius is now set to 75 mm.  Accept the command.

Figure 470 11. Apply the Edit>Draft command on the rib.  Set the method to Parting Line Draft.  Select the planar, top face of the rib as the Pull Direction.  For Parting Lines, select 4 planar and 2 round edges along either side of the top rib face, with their respective arrows pointed down, in to the part.  Adjust the draft Angle to 4° with this arrow pointing up and away from the part.  Accept the Draft.

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Figure 471 12. Apply a Fillet to the smaller edge of the rib, the same was as in Step 9.  In Constant Fillet, select the corner edge of the extruded rib.  Use the small Measure Radius button next to the Radius input field.  Click on the larger radius sketch entity.  Verify the Radius is set to 20 mm then Accept the command.

Figure 472

13. Press the Ctrl+Space keyboard keys to repeat the previous command of Fillet.  Change the type to Full Face Fillet to round the entire rib face.  Select one of the large side faces as the Left, and the other large face as Right.  Select the top rib face as the Center and Accept.

Figure 473

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Adjustments and Deviation Checking 1.

Turn on the Deviation for Body to see how the solid model matches the scan. Make adjustments as needed.  The four sketches (Sketch2-5(Mesh)) guiding the lofted face can be edited to minimize deviation of the top freeform loft face.  To edit the Spline Tangent Lengths, double-click on the Spline inside of the Sketch to enter the Properties Dialog Tree. Click, hold, and drag the Tangent Arrow around to create a smoother tangent transition. (Figure 475)  Edit the Extrusion width to fit the scan width better.  Adjust the position and angles of the rib with Sketch6(Mesh) and Sketch7(Mesh).

Figure 474

Figure 475

Figure 476 - Extracted

Figure 477 - Extracted

Figure 478 - Extracted

Figure 479 - Created

Figure 480 - Created

Figure 481 - Created

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Cone Features 1.

Generate an editable axis for one of the cone features by creating a Mesh Sketch.  Select the Right Plane as the Base Plane.  Offset the Section Poly-line until it is in the cone region (Figure 482), about 60 mm.

2.

Use the Draw>Circle tool to find a center point of the central cone axis.  Double click on the pink arc line to create the circle.  Use Smart Dimension to fully define the center point.

 The Cone could be quickly and easily made with the RMB Insert/Merge command to extract from the scan data. Accurate to the scan geometry would be generated, but it would not be easily editable.

Figure 483

Figure 482 3.

Create a Ref. Geometry>Vector for the central axis of the cone.  Select the Sketch Circle Center and the Right Plane.  Change, if not done automatically, the Method to Pick Point and Line.

4.

Quickly generate the cone body with the Revolution Wizard.  RMB click on the Cone Region and select the Insert/Merge icon.  Add the fillet region and the planar face region to the Target.  Place a Check next to Get Partial Shape then go to the Next Stage.

5.

The second stage allows for slight editing of the revolution and base sketch.  Modify the angle of revolution with the green and grey arrows.  Lower the Resolution slide for clean faces of the cone and no fillet in the sketch.

Figure 485

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6.

After accepting the wizard, investigate the revolved shape by looking from the Front Viewpoint. A gap between the cone and the rib is revealed.  RMB click on Sketch9(Mesh) in the Feature Tree and select Edit.  Click and drag the right edge further in to the rib section, then Exit the sketch.

Figure 486 7.

Figure 487

Figure 488

The previous cone was perpendicular to the ref. coordinate system. Create the axis of the second cone by again using a Mesh Sketch.  Use the Front Plane as the Base Plane, and offset the section until it crosses through the entire conical face. They polylines will look like Figure 489.  Accept the sketch setup and create the dimensioned sketch shown in Figure 490.  Start with the Parabola tool found under Draw>Ellipse. Four points are needed to create the parabola.  Use best judgement to choose the center point of the parabola. It should be near the apex. Use Figure 489 to help place the other points of the parabola.

 Just try to get the parabola close to the pink poly-lines. Dimensions and constraints will edit and move the entity.  Use the Centerline tool to draw a line between the center point and the apex point of the parabola. This line will be used to set angles and begin other dimensioning.  Use the Smart Dimension to manipulate and find the central axis of the parabola.

Figure 490

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8.

Create a Ref. Geometry>Plane with this center line.  Select the Top Plane and the Center Line of parabola as the Entities.  Change the Method to Projection if it does not change automatically.

Figure 491 9.

RMB click and select Insert/Merge on the Cone Region.  Change the view to the Bottom Viewpoint.  Notice the extracted axis generated by the Revolution Wizard is at about the same height as Vector 1.

 This assumption can be used when manually generating this axis. The Revolution Wizard can show how the cone should be made, but it will be difficult to edit.  Cancel the wizard command. 10. Create a new Mesh Sketch on the new Plane 2.  RMB click on Vector 1 and select Convert Entities.  The center line is constrained to the first cone. Edits to this axis will change the axis of this cone.  To edit the center line independently, delete the Converted constraint and add a dimension and horizontal constraint.

Figure 492 11. Create a Ref. Geometry>Vector on the center line from the previous sketch using the Extract Method.

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12. Right-Click on the Cone Region and select the Insert/Merge icon.  Check the Revolution Wizard has automatically found Plane 2 and the Vector 2 to use for the sketch and the revolution.  Adjust the Auto Sketch Options to find the best fitting Cone.  Increase the degrees of revolution by pulling on the arrows.  Accept the wizard command.

Figure 493

Figure 494

13. Right-Click on Sketch12 (Mesh) and select Edit.  Adjust the length of the sketches to ensure it is long enough and extends in to the rib.  Dimension the part to constrain the sketch and make it easier to edit in the future.

Figure 495 - Example of dimensioning 14. If needed, adjust any sketch or center lines of the first cone axis or parabola to fit better deviations.  Turn on Deviation for Body to check how each edit can affect the overall part.  If entities are converted or tied to a previous entity, one edit could change multiple parts.

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Figure 497

Figure 496

Figure 498

Pin Feature 1.

Investigate the final pin feature.  This feature has the least amount of information available from the scan.  From the Right Viewpoint, the two different angles of the pin are visible.

2.

Create a Mesh Sketch on the Front Plane.  Offset the section to about 62.5 mm; above the fillet in an area with the most possible amount of data.  Create a sketch on the slot cross section. Draw the Center Line of the slot.  Exit the sketch.

 The information of the slot cross section can allow for the assumption that it is perpendicular to the Top plane.

Figure 499

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3.

Select the Ref. Geometry>Plane tool to create the sketch plane for the side of the pin.  Select the Center Line of the slot sketch, and the Right Plane.  Change Method to Projection if necessary.  Accept the command.

4.

Create a Mesh Sketch on this new Plane 3 and begin sketching.  Since the left and right sides of the sketch have different draft angles, the best approach would be to create half the sketch and then mirror it about a center line.  Create half of the sketch with the Line tool, and fully constrain with the Smart Dimension.  Use the Center Line command and find the center of the feature.

 This sketch will control the position of the pin, the tilt of the top and side faces, and the draft of the side faces.

Figure 501 5.

Create the sketching plane for the top shape of the pin by generating a new Ref. Geometry>Plane.  Turn on the Visibility of Sketch 14(Mesh).  Select the Front Plane and the top Line of the last sketch.  Change the Method to Projection.

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6.

Create a Sketch on the new Plane 4.  Use the Circle command to create a circle from the center point of the line from the last sketch to the end point of the sketch.  Use the Pierce and Converted commands to constrain the sketch and pull in points needed for constraining.  Use the Center Line and Offset commands to create split points for the circle.

 The two arcs should be separate so different extrusions can be made to account for different draft angles.  Accept the sketch when it looks similar to Figure 503.

Figure 503 7.

Insert a Create Surface>Extrude to generate one side face of the pin at a time.  Sketch 15 will be the Base Sketch, but only have one Sketch Chain as the Profile at a time.  Select Custom Direction and choose the angled centerline from Sketch 14(Mesh).  Place a check next to Draft and set the angle to 4.5°, as calculated in the sketch, so the extrusion will match up with the solid line.  Set the Method to Up To Vertex and select the end point of the line used for Custom Direction.  Accept the Extrude.

8.

Repeat Step 7 to the other profile from Sketch 15.

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Figure 505

Figure 504 9.

To join the two open surfaces, use the Create Surface>Loft command.  The two facing edges will be the Profiles.  Apply a Curvature To Face, Start and End Constraint.  Add a Check to Add Side Curve Influence.  Accept the Loft.

Figure 506 10. Use the Edit>Fill Face command to close the top and bottom faces of the pin and create a solid body.  Select the four edges of the circular opening for Edges.  Apply a check next to both options in More Options to create a closed entity.  Accept the command. 11. Repeat Step 10 to the slot shaped opening of the pin.

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Fillets 1.

Use the Edit>Boolean command to create a single solid body.  Set the Operation Method to Merge.  Select all solid bodies as Tool Bodies then accept the command.

 In the Model Tree, only one Solid Body should remain. 2.

Turn on the Deviation for Body to see where all the Fillets are needed.

Figure 508 3.

Choose the MODEL>Edit>Fillet command to generate the rounded edges.  Use a Constant Fillet on each of the fillets around the cones.  Select an edge of the Solid Body, then press the Magic Wand button to Estimate the Radius from the Mesh. This found value can be adjusted to the nearest round number.  Press the Add Radius plus sign button to insert a different size fillet in the same command.  Select a different edge and press the Magic Wand button again to read this fillet.  Repeat on the other cone fillets then accept the Fillet command.

4.

Create a new Fillet for the fillet where the casting body meets the freeform face.  Select an edge then press the Magic Wand to find the value.

 Since this fillet was done after the cone edge fillets, all the edges should be tangent making only a single click to select the edges necessary. Check all needed edges are selected.

Figure 510

Figure 509

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5.

Create one more Fillet around the edges of the pin.

Figure 511 6.

Use a Fillet>Face Fillet to define the top edge of the pin feature.

 A width of the fillet segment would change with the angles of the faces of the pin in a constant fillet. The Face Fillet would keep a constant width even with changes to the face angles.  For the first set of Faces, choose only the top face of the pin.  Select the green based Faces set and click on the side faces of the pin.  Turn the Deviation for Body on to see what Radius would be best.  Change the Radius to 5 mm and accept the Fillet.

Figure 512 7.

Check the different Deviations of the finished solid model.

Figure 514

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Figure 515

Figure 516

End of Activity

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