Delcam Case Study

The latest release of Delcam's (Windsor, ON) CopyCAD software includes improved methods for generating split lines, providing an efficient process for moving directly from scan data to mold design and so giving major time savings in the product development process. Most reverse engineering software requires the user to create a surface model from the scan data before work can start on the tooling design. In contrast CopyCAD's range of triangle modeling tools allows mold cores and cavities to be generated directly from triangle models. For several releases, CopyCAD has been able to fill holes in the model resulting from missing or sparse data. The software also has tools to smooth and sculpt the model.

A common problem with reverse engineering is the difficulty in creating geometrically perfect forms, for example, perfectly flat surfaces. CopyCAD uses its morphing technology to convert the data into perfect geometry even if the original data includes a degree of error. Another key part of this process is the generation of the horizon lines on the model, which is also improved in the new release. CopyCAD now has the ability to handle nested splits, when split surfaces need to be generated to fill any gaps within the model. Once the split surfaces have been created, the mold cavity can be produced by Boolean subtraction from the block.

The latest CopyCAD release comes at a time when there is a resurgence of interest in reverse engineering, after a period when it was widely believed that the technique would be replaced by computer-based design methods. However, there are still some designers working with very complex shapes who prefer to produce models by hand. Often, it is easier to leave such craftsmen to work with their traditional methods and capture the results with reverse engineering to generate CAD models. Of course, a combination of both techniques can be used to obtain the final CAD model that is needed. For companies that wish to work in this way, Delcam's Total Modeling approach to design allows users to build up CAD models with data from different sources. A similar approach can be taken when developing "new" parts that are, in fact, variations on existing components. It is often quicker to digitize the existing part and limit the CAD work to the desired modifications, instead of completely recreating the whole part with CAD.