Practical SolidWorks II: Design for Manufacturing

Training course outline

Course Summary
Course will teach practical methods to design
plastic and metal parts with moderate to
complex shapes. Real life industry examples will
be used and discussed to detail out the
application of the theory and to demonstrate
how to apply software commands, tools and
techniques to perform engineering design in
different applications.
Duration
45 hours (15 sessions) of training courses plus
extra time for each design team to discuss and
provide technical support on existing running
design projects.
Who should attend?
Existing users who want to take advantage of
SolidWorks' advanced functionality. Users who
are designing for manufacturing in their job
roles.

Practical SolidWorks II course is

for users who want to take full
advantage of SolidWorks' part
and assembly modeling
capabilities and become more
productive on designing different
types of mechanical parts using
the application.
Course will include practical
examples to design plastic and
metal parts from moderate to
complex shapes. Real life
industry examples will be
covered that detail out the
application of the theory to
demonstrate how to apply
software commands, tools and
techniques for specific job tasks.

Pre-requisites
Delegates should have:
Basic knowledge to create 3D parts and
assemblies and build parametric models, as
taught in SolidWorks I.
Method of delivery
Training is designed for the busy professional,
being short and intensive and combining lecture
and demonstration. Practical exercises carried
out under guidance help delegates to learn the
techniques taught.
Delegates have ample opportunity to discuss
specific requirements with the trainer.
Courseware
Delegates receive SolidWorks training
courseware including practical design examples,
documents and files.
General information
Whilst attending training, delegates have the
use of a computer running licensed SolidWorks
software on which to practice the techniques
taught.

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Course syllabus
Please note: Course topics may be modified by the instructor based upon the knowledge and skill level of
the course participants.

Introduction to Complex
Part Design

Design technique for complex parts

Multibody Solids

Shelling and Ribs for Plastic or Casting parts

Thin Features

Design for Multibody

solids (Complex Plastic
parts, Casting Parts,
Welded Parts)

Parts with Complex

Geometry

Multibody techniques
Feature scope
Patterning bodies
Using Tool body
Combining bodies Introducing: Combine, Split
Indent feature
Modelling negative space Using cut to create multi-bodies
Saving solid bodies as parts and assemblies Splitting part into
multi-bodies
Creating an assembly
Using split part with legacy data

Sweeping

Case study: raised panel door Sweep with guide curves

Case study: Bottle Sweep options
Advanced sweeping
Orientation and twist control Align with end faces Sweeping
along model edges Sweeping a tool body
Sweep with guide curves and Selection Manager

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Working with curves

Case study: Modelling a spring Sweeping along a 3D path

3D sketching
Helix and spiral, Projected curve, Composite curve, Fit spline
Applying the label to the Parts
Modelling threads
Creating a curve through a set of points
Equation Driven curves

Lofting and sweeping: Whats the difference? How lofting

works
Basic lofting
Using derived and copied sketches Copying a sketch
Derived sketches Centerline lofting
Cleaning up models, deleting faces, deviation analysis
Advanced lofting Layout sketches Boundary feature

Other advanced tools

Advanced fillets
Analyzing geometry - Display curvature, Intersection curve,
Zebra stripes, Wrap feature Deform feature, knit surface
Moving and deleting face Performance considerations

Choosing the Right

Manufacturing Process

Eg. Process based on quantities? Accuracy? Size?

Repeatability?
Eg. What factors go into selecting mfg process
Other??

Choosing the right

Material

Key factors to consider?

Application
Fatigue
Flex
Friction
Price/Cost

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Design for Injection Molded

Parts

Part design for injection mold process using SOLIDWORKS:

Introduction to the injection molding process

Designing the Nominal Wall

Designing Three Dimensional Shapes

Designing Projections off the Nominal Wall

Designing Depressions in the Nominal Wall

Designing Hollow Bosses

Designing Molded Threads

Insert Molding

Overmolding

Metal Injection Molding overview

The Injection Molding Design cycle (Part Design iteration, Tool

Design iteration, Being Steel Safe, Part Design Tuning, Tool
Design Tuning)

Introduction to Machining processes (Turning, Planning and

Shaping, Milling, etc)
Tool direction and access, Tool and part setup, Machining jigs
Cost Effective Design for machining process
Design for Machined Metals
Design for Machined Plastics
Examples for complex machine parts

What is EDM Process

Advantages for EDM
Design requirement for EDM process

Dimensioning and Tolerancing

Type of Dimensions, Tolerances, Fits
Datum Features and Symbols
Baylis drawing reading and practices

Design for Machining

Design for EDM process

Introduction to Geometric
Dimensioning and
Tolerancing (GD&T)

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Tolerance Analysis

Testing

Dimensional Part
Inspection/Dimensional
Validation

Overview
How to approach a tol stack
How to know which stackups to put in a tolerance stackup
Thinking of the tolerance stackup all the time when designing
mechanical features
Statistical Tolerance Stackup
Baylis examples
Detailed Mechanical FMEA
o systematic approach to identifying failure modes
Identifying all Part functions and FMs for those
functions
o Assigning Risk
o Top Down/Bottom Up
Deriving test criterias from the detailed R&D DFMEA
How to know you need to test (based on risk of feature failure
in the FMEA)
Make-or-Break Testing: Not being afraid of failure
What to test
When to stop testing how do you know youre done?
Baylis examples
Other??

How to design for inspection

How to know whether to inspect a feature or not (based on
risk of dimension in the Tolerance Stackup)
How it relates to drawing creation and GD&T & design intent
When do you need to perform validation of parts (eg. IM part
OQ/PQ)
Other??

Introduction to Part
Mechanical Analysis

Introduction to Finite Element Analysis

Main things FEA can be used for
Stress and Deformation Contours
Factor of Safety
Watch-outs

Part Analysis
(Finite Element Analysis)

Basic Part Analysis using SimulationXpress

Linear static analysis of part
Loads and boundary conditions, meshing options, postprocessing, graphs and plots, reporting.

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Top-down Design (Design

in Context of Assembly)

Working with Assemblies

Introduction to Top Down Design Method

Top-down assembly modelling Stages in the process
Building virtual parts Building parts in an assembly Incontext features
Propagating changes
Saving virtual parts as External references
Breaking and removing external references

Advanced mates
Adding mate references
Designing library parts
Capturing mate references
Smart components
Advanced and mechanical mate types Inserting and
mating components
Multiple mate mode
Using copy with mates

Design and Process

Configurations

Design Configurations
Introduction to Configurations
Terminology
Size, Shape and Position Configurations
Configuration Manager
Defining the Configuration
Changing Configurations
Design Tables

Part Appearance

Display states
Appearances, materials and scenes
Creating Realistic Images

Assembly editing

Assembly Editing activities

Replacing and modifying components
Troubleshooting an assembly
Replacing components using Save As components
Hole alignment

Layout-based assembly
design using Master
Model/Layout

Layout-based assembly
Design Blocks
Inserting blocks
Creating a part from a block
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Managing Files, Large

assemblies, CPU/Memory

Managing Large assemblies

Lightweight components/Assemblies
Using configurations with large assemblies
Modifying the structure of an assembly
Assembly visualization
Design review Mode
Tips for Faster Assemblies Drawing

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