Software Speeds Organic Design Prep for Production

When you consider things like complex, organically shaped products—items that are often molded or cast, toys, patient-specific dental implants, jewelry, and the like—it is clear that getting the designs prepped for manufacturing is (a) not easy and (b) consequently time-consuming.

Enter FreeForm v. 11 from SensAble Technologies (sensable.com), a 3D modeling program with features that speed everything from concept design and modeling through preparing models for tooling production.

Listen to Nick Whitmore, a digital sculptor with designworks group (designworksgroup.net), which used the software to develop things like the “Doctor Who” character (the 11th Doctor) from the BBC TV show of that name (shown in the accompanying image; bbc.co.uk/doctorwho/dw): “Version 11’s enhanced tools for prepping our models for manufacturing are so fast that we’ve reduced the time involved in fixing undercuts by 75%. We simply design in FreeForm, then send digital files directly to the manufacturers for tooling and molding for incredible efficiency.”

FreeForm users use a haptic stylus for their design work: as they move the stylus, there is actually force feedback generated during the digital design process. Among the speed-enhancing features of the new software package:
•    A parasolid editing feature. The “sculpt and refit” process eliminates the need for surfacing, cutting, trimming, or stitching the original solid-based model.
•    Lattice Deform tool. Provides a way to restrict deformations to specific areas of the model. Allows multiple pieces to be deformed as a single unit. This means designers can simultaneously re-proportion multiple 3D shapes.
•    Faster volumetric shape definition. Using a simple curve network, volumetric shapes can be defined, then with a single click, a solid model generated.
•    Fill to Plane model. Simplifies the creation of the core for the main tooling used in creating vacuum-formed packaging.
•    Import/Export via XML. Facilitates mold design layouts through the positioning of low-resolution copies of model pieces on the family mold, then importing them into the high-resolution model, where they are automatically positioned.
•    Ring Patch tool. Creates transitional surfaces from a perimeter parting line to the main parting surface of a mold.
•    Parting line analysis function. Pinpoints part-to-curve gaps so problems can be addressed.
•    Analyze Fit and Analyze Thickness tools. The former displays color layers so users can assess and adjust the relations of two pieces of a model. The latter, through color mapping, helps minimize excess material costs, design for part strength, and accommodate injection molding requirements.

Bottom line: design and review time is collapsed in a way that those who aren’t Time Lords (bbc.co.uk/doctorwho/classic/guide.shtml) can appreciate.