Introduction
SolidWorks helps designers develop more accurate molds and saves time and money. With SolidWorks software, you can not only define mold geometry, but also access a wide range of automated mold design tools. Therefore, you can verify the key position of the mold design before producing the mold. Plus, you can automatically determine undercuts, complete side draws, verify draft angles, define parting lines, create parting surfaces, and ensure mold durability. With SolidWorks, you can perform all of these functions in the same familiar modeling and facet environment. In addition, you can access formwork and other standard components and integrate with CNC machining applications.
In an increasingly competitive mold manufacturing market, your customers may require shorter lead times, lower prices, or may outsource their operations to cheaper overseas suppliers. It is impossible for mold developers to cut prices and shorten lead times by cutting corners during the design process. Therefore, you must ensure that the parts produced by the mold are fully compliant with the customer's geometric and mechanical properties. Often, if the mold is not put into production for the first time, you must also bear the cost of any changes.
SolidWorks offers a unique and powerful mold-specific design automation and verification tool to help you overcome today's mold manufacturing challenges so you can develop molds faster, more accurately, and cost-effectively. Anyone familiar with SolidWorks software can use these integrated tools without any additional cost and without having to convert files or geometry.
SolidWorks Solution Partners also offer a library of standard formwork and dedicated mold parts that you can drag and drop into mold designs and assemblies. Because SolidWorks is fully associative, changes to components, assemblies, drawings, or bills of materials are automatically applied to all related entities. The combination of mold-specific design automation and verification tools in SolidWorks with integrated partner applications enables you to cost-effectively develop molds and respond quickly to customer design changes.
Most tenders (RFPs) contain a 3D solid model or a series of 2D drawings that illustrate the geometry of the injection molded part. The first step in responding to an RFP is to evaluate the customer's part geometry. SolidWorks can open more different types of CAD files than any other design system. Whether you receive documents in intermediate file formats (such as DXFTM, DWG, IGES, STEP, ACIS®, and Parasolid®), or other systems (such as Inventor® Mechanical Desktop®, Unigraphics®, CADKEY®, AutoCAD®, Pro/) ENGINEER® and Solid Edge® are proprietary formats that SolidWorks give you access to the geometry.
Because data errors can occur when importing geometry from other design systems, SolidWorks provides a comprehensive set of tools for repairing imported files and cleaning up geometry. In the import process, you can automatically create a solid model by simply joining the entities in the intermediate file together into solid geometry. SolidWorks also provides diagnostic tools to help you join entities together. For example, the Check Entities feature allows you to identify geometry problems and determine where the problem is. Using SolidWorks' Input Diagnostics tool, you can identify and repair unclosed boundaries and repair damaged faces to create a 3D model that can be used immediately for machining designs.
After importing part geometry, you can use SolidWorks integrated tools to gather the information you need to estimate the cost of the mold and make a quote. Using these tools, you can estimate whether an acceptable mold can be made based on the original 3D solid of the molded part. You can use the SolidWorks undercut detection feature to determine the side draw required to remove the part from the mold. SolidWorks also includes a Thickness Check, which allows you to detect areas of a part that do not reach the specified thickness. If the thickness is not corrected, problems may occur during manufacturing.
These mold analysis tools allow you to quickly evaluate the manufacturability of your parts in response to RFP. With this feature, you can significantly reduce the cost of designing and testing your molds, because the time or cost of fixing them can be much reduced during the early stages of the design process. Your bids will be more precise, as you can identify areas where problems may occur during the development of the bid and point them to the customer.
Use the SolidWorks eDrawings® collaboration tool to quickly communicate design change recommendations to your customers before finalizing the bid. eDrawings simplifies the tendering process by enhancing communication with customers. You can email eDrawings containing 2D drawings and 3D models to your customers, and customers can quickly view, print, and inspect these drawings and models using the free viewer software. Not only can they zoom in or out, but they can also pan and rotate the model for viewing from all angles; while intuitive annotation tools allow customers to provide complete and comprehensive feedback. eDrawings not only enables your customers to fully understand the process, but also enables your company to stand out from the competition.
With SolidWorks product data management software, an integrated solution that is part of SolidWorks, you can safely archive and organize multiple versions of previous projects to quickly search 2D and 3D designs to find relevant benchmarks for mold assemblies . This tool instantly generates a baseline bill of materials so you can accurately determine the cost.
Mold design
Typically, the first step in mold core and cavity design is to apply a cooling shrinkage factor based on the material of the part. With SolidWorks, you can do this with a single click of the mouse. In addition, SolidWorks can automatically suggest the best parting line based on the draft direction in the part.
With a mouse click, the SolidWorks software identifies all areas of the part that are not adequately drafted. You can also access tools that speed up the draft angle adjustment, such as the parting line draft command, which adjusts the angle of the draft face relative to any adjacent edge.
Often, the next step in mold design is to create a parting surface that defines the split position between the core and the cavity. In addition to automatically creating parting surfaces for simple molds, SolidWorks offers a range of solid modeling and surface tools that make it easy to create parting surfaces even for the most complex molds.
Core functions include advanced solid modeling features such as lofting, variable radius fillets, shelling, and draft angles. Advanced surface modeling features include n-sided surface patches that let you fill surfaces that are tangent to any number of boundaries. You can also draw a network of curves, and you can drag any point on the curve to modify the surface and combine the analysis entities and splines into one feature.
Once the parting surface has been created, you can use the Cut Split command to split the mold into two entities. The next step is to build the core and cavity of the mold on the surface defined in the cutting segmentation. These entities can then be used to create assemblies that are associated with the original multibody part design. SolidWorks provides a side core function that automatically creates all of the side cores and core geometry required to remove the formed part from the mold.
20% to 90% of conventional formwork is made up of purchased parts. With 3D ContentCentral®, you save time, improve accuracy, and easily access 3D CAD models from well-known partners who offer a complete library of formwork and components, including guide posts, guide bushings, and ejection Plates, brackets and gates (Sprue Bushings®). You can browse the product categories to view competitive products, configure supplier parts to meet your needs, and drag and drop the supplier's product model directly into the design.
The SolidWorks Design Library provides a platform for developing company standards that includes features, parts, and assembly models that you can drag and drop into new designs. SolidWorks Toolbox is also part of SolidWorks Professional software, which provides access to models of ANSI, ISO, DIN, and JIS standard parts such as fasteners, bearings, retaining rings, and gears. You can drag and drop models of bolts, nuts, and washers from the SolidWorksToolbox to the appropriate locations on the assembly. Smart component technology automatically adjusts the size and position of the component based on its position and orientation in the assembly.
SolidWorks makes it easy to generate production-level 2D drawings from 3D assembly models. You simply draw a line in SolidWorks to draw a section view of the assembly and automatically generate the drawing. You can add or change dimensions at any time, and the dimensions will be updated instantly to match the design changes. You can quickly create an exploded view that describes how the mold works: first arrange the components in a 3D environment and then select the profile to define a 2D partial engineering view. In addition, the part numbers in the bill of materials can be easily labeled on these views.
Sometimes moldmakers must ensure that their molds are able to adapt to tight duty cycles. You can use SolidWorks Simulation (provided with SolidWorks Premium) to determine the stress, strain, deformation shape, and displacement of mold parts in production to prevent field failures. With this tool, you can quickly identify defects in your original design. The software can generate new digital models quickly and cost-effectively, allowing you to solve problems that are difficult to detect, which might otherwise occur during the test and, even worse, in the customer's factory. By calculating the precise duty cycle of your parts, you can use smaller and lighter parts to reduce the cost and weight of your molds. Design changes SolidWorks allows you to assemble related components together, so if a component changes, the related components change. If the customer changes the design and sends it to you via a new CAD file, you can simply import the CAD file into the original part design and use it to automatically update the mold design.
Using SolidWorks ensures that changes made at any point in the process automatically update all product documentation (including parts, assemblies, and drawings) to avoid costly mistakes. This way, you can use the 2D drawing of the formwork to control the size of all or part of the part. When you change the layout, the ejector plates, guide posts, guide bushings, and other components are automatically changed to the appropriate dimensions.
SolidWorks provides some powerful tools for identifying differences between different versions of the same part. This feature is useful, for example, if a customer sends a new version of a part during mold development. You can synchronize different versions of the view to compare geometry, surfaces, and features, and you can apply one version of the feature parameters and properties to another version. These tools let you understand any impact of design changes on existing designs.
With SolidWorks' animation capabilities, you can create animations that let your customers see virtual molds in action to fully understand your design. SolidWorks animations let you demonstrate how a moving part of a mold moves, exploding or unexploding an assembly to show how the parts fit together. When you're demonstrating an animation, you can fly around the mold, or you can rotate the mold 360 degrees on the turntable to show the appearance of each angle.
Testing and manufacturing
Dassault Systèmes SolidWorks Corp. works with industry-leading computer-aided machining (CAM) software companies to provide a variety of powerful CNC programming solutions for drilling, turning and electrical discharge machining. Because the certified CAM solution reads the original SolidWorks geometry and is fully associative, your design changes can be reflected in the CNC program. The certified CAM product is integrated into the same window of the SolidWorks design, enabling the generation of CNC program paths in a familiar SolidWorks environment. Other SolidWorks Certified Gold Partner products offer additional integrated analytics solutions for verifying mold design, automated mold development, and creating and modifying parts.
The SolidWorks manufacturing network, SupplierSource.com, simplifies the process of finding design and manufacturing service providers that use SolidWorks software. Because you are using the original SolidWorks file, there is no need to convert or recreate the design file. By browsing through different categories (such as drilling, EDM, and reverse engineering) or by keyword search, you can easily find the right supplier on the network.
in conclusion
SolidWorks Premium software can help mold designers increase revenue. It reduces the time required to produce tenders and design molds, and evaluates completed bids and designs, so you can avoid problems that are not easily noticeable before the mold is produced. By providing numerous integration features, the SolidWorks design environment can help you automate many of the design process. In addition, a range of powerful integrated analysis tools allow you to validate mold designs using digital models to ensure design correctness before the mold is put into production. Other integrated solutions enable you to streamline transitions to the manufacturing stage and communicate quickly and efficiently with your customers. SolidWorks provides the tools you need to design molds quickly, accurately, and cost-effectively, making you invincible in an increasingly competitive machining environment.
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