Accurate data conversions

Affordable 3D printers for rapid prototyping (RP) and new methods of direct manufacturing (DM) have exposed yet another gap between design and manufacturing: while the computer-aided design (CAD) vendors have their proprietary geometry file formats, RP and DM equipment need these files as STL files. True, CAD vendors typically have translators to convert their CAD files to STL or some sort of tessellated file format. But, says Jerry Eschbaugh, director at TransMagic, Inc. (transmagic.com), “they don’t typically give you a lot of control over the quality of that file.” TransMagic STL PRO fills that gap. STL PRO is a stand-alone desktop application that lets users open and
view all major native and neutral CAD file formats without needing the authoring CAD software or license.

What’s cool The Auto Repair Wizard in STL PRO has a “traffic-light” display to help users click through various “best practice” options to quickly stitch loose surfaces (faces) together, re-orient surface normals, close gaps in geometry, and otherwise repair geometry. “This ensures that the STL models have the quality needed for applications that require ‘water-tight’ geometry,” says Eschbaugh. Users can view sections, add transparency to parts, and manipulate views of the 3D model within STL PRO. They can then translate the finished CAD files to STL, while controlling tessellation output parameters such as surface deviation and maximum chord length. TransMagic
STL PRO sells for $2,000.

The Auto Repair Wizard is also a feature in TransMagic R8, a 3D data exchange software program. Granted, people can use IGES or STEP files to get 3D solid models from one application into another. But, says Eschbaugh, “this approach typically requires extensive rework to be usable. File translation roadblocks can cause project delays, tie up valuable engineering resources, and increase costs.” Instead, programs like TransMagic R8 export 3D geometry from one proprietary file format directly to another.

What’s cool TransMagic R8 increases productivity and creates smaller file sizes in the data conversion process by including a preprocessing step that identifies multiple instances of the same part in a solids model. The part is translated once. It is then reused as needed within the model.

This release adds binary STL output, which is significantly smaller than ASCII STL files, and it adds OBJ output, which can be used to transfer models to design programs such as Autodesk AliasStudio, Maya, and 3ds Max. Other CAD file formats include Catia V5 R19, Pro/Engineer WildFire 4.0, SolidWorks 2009, Siemens NX 6.0, ACIS R19, Parasolid v20, Autodesk Inventor 2010, and HOOPS 16. TransMagic R8 sells for around $10,000.

3D PDFs for everyone

Not everyone has, uses, or knows how to use a CAD system. In fact, how many people in a collaborative setting really need a CAD system?

What’s cool There’s technology to get around the need for CAD everywhere. For instance, Anark Core 3 from Anark Corp. (anark.com) converts CAD models into 3D PDF documents, which are used for design-review applications such as Adobe Reader and Autodesk Design Review. (It can also output documents in product lifecycle management formats, such as JT, Catia, ACIS, and Parasolid.) The software can produce B-rep (such as Parasolid, IGES, or STEP) and mesh files lightweight enough for emailing and posting to websites. It can also create model-based definition views (such as of 3D tolerance data). As required, designers and engineers can remove sensitive and unnecessary detail from design data, as well as add annotations and preset views. The software also records transformation steps. The resulting “recipes” can then be used to automatically recreate 3D PDF documents when the CAD design changes.

Simple complex-meshing

Object shapes, complex surfaces, complicated joins, and other design elements conspire to make the job of creating complex repetitive shapes—meshes—a non-trivial problem in solids modeling. ParaCloud GEM 2010 R2 from ParaCloud (paracloud.com) transforms flat 2D designs into a 3D mesh—simply and without scripting. Technically, GEM—short for “generative meshes”—converts the polygon faces of a surface into volumetric (3D) containers by creating an offset reference surface. That is, instead of rendering a texture on a design, GEM applies a 3D component over the design. The 3D pattern can be controlled parametrically to match design intent. Up to 10 components can be applied in a GEM session.

What’s cool First, easily creating 3D geometric patterns. Second, “smart” meshing. Users can subdivide and deform polygon surfaces by selecting sets and points of interest. Rules-based tools help in offsetting, deforming, and mapping the geometry according to target, height, and focus points. Rules can be tweaked through an editable ratio graph. Other mesh editing tools can control subdivisions, deformations, welds, and face direction.

ParaCloud Gem works with Google SketchUp (version 7; both free and pro); McNeel’s Rhino3D; Autodesk’s 3DS Max, Maya, and AutoCAD; and any other 3D software that supports OBJ, DXF, and VRML 2.0. The latest release includes a morphing animation system and layer separation output for material rendering and 3D printing. It also supports the Collada file format (mesh and components import, and file export), purging, and the ability to set the number of components per row for an unfolded layout. The unfolded layout tool outputs a file for 3D printing and computer numerical control milling. Use of ParaCloud GEM 2010 is by subscription; a one-year professional license goes for $660.

Easy data transformations

Lattice3D Reporter from Lattice Technology (lattice3d.com) embeds 3D, bill of material (BOM), and related data into Microsoft Excel spreadsheets—from within Excel. XVL Web Master, also from Lattice, transforms 3D data into HTML to post on the Internet or an intranet. Both programs use data within XVL files (eXtensible Virtual world description Language), the company’s proprietary, format-neutral, compressed file format. The programs can also extract 3D data from various sources, including product lifecycle management, enterprise resource planning, BOMs, and 3D models. In short, both programs turn 3D data into usable manufacturing data for the shop floor, suppliers, support, maintenance crew, and other people needing such information.

What’s cool The latest version of Reporter, using predefined templates, can automatically generate a 3D spreadsheet with interrelated parts lists; interactive 3D spreadsheets and BOMs with linked lists and both 3D data and images; print-ready work instruction spreadsheets; and digital work instructions with embedded process animations (assembly/disassembly; with or without exploded parts views). No scripting or animation knowledge required. The latest version of Web Master can extract part descriptions from the 3D model and display them on a webpage, while still relating the part number directly to the 3D part. Web Master can also automatically arrange and display the part numbers of 3D technical illustration and display process instructions on a webpage—without intermediate steps, without having to know HTML.

CAD on an iPhone

The ubiquity and portability of Apple iPhones make CAD an enticing program to have in the palm of one’s hand. Plus there are enticing features that could enhance the use of CAD. For instance, iPhones have a built-in accelerometer (along with GPS, which all cellphones have). This accelerometer can sense X-Y-Z axis movements and otherwise control 3D rotation, zoom and pan, tilt, and other movements in CAD programs that require some sort of mouse click. Sweet, but not yet available.

What’s cool Basic CAD programs are available for the iPhone (and iPod touch). They’re dirt cheap, too. However, consider three caveats: you get what you pay for, these iPhone-based CAD programs are still in their infancy, and it’s not like we’re talking about quad-core, gazillion-hertz processors with gobs of system memory. But for people on the go who want to capture some ideas or show some renderings, these iPhone CAD apps are something to consider for future use.

(There’s one more caveat: iPhone apps have literally created a virtual cottage industry in software development. Caveat emptor regarding tech support. iTunes is generally best for more information about these programs. Moreover, such programs can only be purchased at an Apple store and from iTunes.)

cadTouch by Martin Fabrizio Carianni (cadtouch.com) lets users “draw floorplans or land surfaces (and calculate area and perimeter), mechanical or structural parts (and calculate moments of inertia), diagrams, field notes, and more with precision and right from the palm of your hand.” The latest version (2.2) lets people draw lines, polylines, rectangles, curves, and sketches with fairly good precision using an angle-distance polar coordinates approach on their iPhones. cadTouch has native DXF file support, which makes it compatible with AutoCAD, SketchUp, Illustrator, and Solidworks, to name a few DXF-capable CAD programs. Users can edit the drawings right from the palm of their hand, and then send them back to the office as email attachments. Price: $14.99 (itunes.apple.com/us/applicationcadtouch-r2/id298053937?mt=8).

Another DXF-compatible program, also for $14.99, is Drawvis by DOT Systems (dotsystems.pl/products/Drawvis.html; itunes.apple.com/us/applicationdrawvis/id335573825?mt=8). A free version of Drawvis (itunes.apple.com/us/applicationdrawvis-free/id335586658?mt=8) has the same functionality, but it’ll only store one file.

iTracer by Fabio Policarpo (itunes.apple.com/us/applicationitracer-3d-ray-tracer/id287261575?mt=8) seems to be the most advanced of the bunch. This is a 3D modeling program. Its rendering engine produces high-quality images, which can be saved as PNG or JPG files. Simple gestures and touch movements control view scaling, panning, tilting, rotation, and so on. Scaled objects will snap to an adaptive grid with a simple finger tap. iTracer includes a full material editor with diffuse and specular components, opacity, refraction, reflection, self illumination, even transparent objects. Shadows can be enabled/disabled per light or for an entire scene. Built-in objects include spheres, cylinders, and cones; generic triangle meshes with per-vertex normals are supported. Completed 3D scenes can be exported as 3DS files, including all models, materials, lights, and camera. These files can then be imported into common desktop 3D modeling applications, such as 3D Studio Max and Maya. Price: $2.99.