SOLIDWORKS® 2016

Surface Modeling

Dassault Systèmes SolidWorks Corporation

175 Wyman Street
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Document Number: PMT1604-ENG
 Contents

Introduction
About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Design Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A Note About Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About the Training Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Training Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions Used in this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Windows® 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Use of Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Graphics and Graphics Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Color Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hide/Show Tree Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
More SOLIDWORKS Training Resources. . . . . . . . . . . . . . . . . . . . . . 6
Local User Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Contents SOLIDWORKS 2016

Lesson 1
Understanding Surfaces
Solids and Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
What is a Solid? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Edges, not Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Behind the Scenes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Introducing: Extruded Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introducing: Planar Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introducing: Trim Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introducing: Untrim Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Working with Surface Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Introducing: Knit Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Checking for a Closed Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introducing: Thicken. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Decomposing a Solid into Surfaces . . . . . . . . . . . . . . . . . . . . . . . 17
Introducing: Delete Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Introducing: Face Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Surface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Why Use Surfaces?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
When Not to Use Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hybrid Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Continuity Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Workflow with Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Working with Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Layout Sketch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Identify Symmetry and Edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Identify Functional Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check your Models Frequently. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Introducing: Verification on Rebuild . . . . . . . . . . . . . . . . . . . . . . 27
Introducing: Check Entity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Folders in the FeatureManager Design Tree. . . . . . . . . . . . . . . . . 28
Clean-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exercise 1: Trimming Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Exercise 2: Trimming and Knitting . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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SOLIDWORKS 2016 Contents

Lesson 2
Introduction to Surfacing
Similarities Between Solid and Surface Modeling . . . . . . . . . . . . . . . 34
Basic Surfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Introducing: Revolved Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Introducing: Swept Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Filleting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cutting the Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Introducing: Radiate Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Introducing: Cut with Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Flattening Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Introducing: Surface Flatten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Exercise 3: Basic Surface Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Introducing: Extend Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Exercise 4: Halyard Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Exercise 5: Finial Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Introducing: Curve Through Reference Points . . . . . . . . . . . . . . . 59
Lesson 3
Solid-Surface Hybrid Modeling
Hybrid Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Using Surfaces to Modify Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Introducing: Replace Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Interchanging Between Solids and Surfaces. . . . . . . . . . . . . . . . . . . . 67
Performance Implications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Surfaces as Construction Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Alternative to Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Introducing: Intersect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Changing a Solid With a Surface . . . . . . . . . . . . . . . . . . . . . . . . . 75
Solid from Imported Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Recreating a Molded Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Making Copies of Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Introducing: Offset Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Repairing Countersunk Hole Problem . . . . . . . . . . . . . . . . . . . . . 80
Exercise 6: Camera Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Exercise 7: Finial Wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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Contents SOLIDWORKS 2016

Lesson 4
Repairing and Editing Imported Geometry
Importing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
What to Import? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Why Do Imports Fail? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Resulting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Repairing Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
FeatureWorks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Repairing and Editing Imported Geometry . . . . . . . . . . . . . . . . . . . . 96
Introducing: Import Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Options for Deleting Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Patching Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Introducing: Filled Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Consistency Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Another Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Editing Imported Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Introducing: Delete Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Exercise 8: Import Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Exercise 9: Using Import Surface and Replace Face . . . . . . . . . . . . 111
Exercise 10: Using Surfaces to Create Solids. . . . . . . . . . . . . . . . . . 114
Lesson 5
Advanced Surface Modeling
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Using Sketch Picture to Capture Design Intent . . . . . . . . . . . . . 121
Ruled Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Introducing: Ruled Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Lofting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Adding a Loft Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
An Alternative Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Modeling the Lower Half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Introducing: Partial Ellipse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Preparation for Using Filled Surface . . . . . . . . . . . . . . . . . . . . . 138
Consistency Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Deviation Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Gap Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Design Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Dynamic Feature Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Introducing: Instant3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Replacing a Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Exercise 11: Mouse Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Exercise 12: Bar of Soap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Exercise 13: Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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SOLIDWORKS 2016 Contents

Lesson 6
Blends and Patches
Complex Blends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Splitting Trim Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
The Cumulative Effect of Tolerances. . . . . . . . . . . . . . . . . . . . . 182
Implications for Mirroring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Hide/Show Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Hiding Individual Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Trimming the Bottom Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Wrap Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Introducing: Isolate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Smoothing Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Three Alternative Approaches . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Boundary Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Introducing: Boundary Surface. . . . . . . . . . . . . . . . . . . . . . . . . . 191
Curvature Combs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Freeform Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Introducing: Freeform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Mesh Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Using the Triad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Moving Control Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Undoing Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Boundary Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Corner Blends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Alternative Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Spline on Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Introducing: Spline on Surface . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Exercise 14: Bicycle Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Exercise 15: Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Exercise 16: Bathtub Fillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Exercise 17: Corner Blend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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Contents SOLIDWORKS 2016

Lesson 7
Master Model Techniques
Introduction to Master Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Transmitting Curve Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Push and Pull type Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Naming Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Specifying the Configuration of the Parent . . . . . . . . . . . . . . . . 237
Split Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Summary of Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . 237
Surface Master Model Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Propagating Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Working with a Solid Master Model. . . . . . . . . . . . . . . . . . . . . . . . . 245
Splitting the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Modeling the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Specialized Features for Plastic Parts . . . . . . . . . . . . . . . . . . . . . . . . 252
Introducing: Fastening Features . . . . . . . . . . . . . . . . . . . . . . . . . 252
Mounting Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Reveal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Introducing: Draft Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Snap Hook and Groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Favorites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Saving the Bodies and Creating an Assembly . . . . . . . . . . . . . . 268
SOLIDWORKS Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Rule #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Exercise 18: Solid Master Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

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