Delcam - PowerSHAPE 2010 Training Course en - 2009

Important Notice
This document is supplied as part of a Delcam Training Course. It is not intended to be

distance learning material: rather as an aid for Tutors when presenting material to course
delegates and as a subsequent aid memoir to those delegates.
Delcam does not accept responsibility for any personal belongings / valuables whilst on the
premises. Delegates are advised to keep their belongings on their person at all times.
Delcam plc. has no control over the use of the software described in this document and cannot
accept any responsibility for any loss or damage howsoever caused as a result of using the
software. Users are advised that all results from the software are checked by a competent
person in accordance with good quality control procedures.
The software described in this document is furnished under a license agreement and may be
used only in accordance with the terms of such license.
Copyright  2009 – Delcam plc. All rights reserved
Training Centre Customer Support

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PowerSHAPE Contents
PowerSHAPE Contents
Chapters Page Number
Monday
1. Introduction 1.1 - 1.12
2. Wireframe modelling 2.1 - 2.20
3. Workplanes 3.1 - 3.12
4. Surfaces and Solids 4.1 - 4.20
5. Primitive Surfaces 5.1 - 5.22
Tuesday
6. Automatic Surfacing Wizard 6.1 - 6.26
7. Limit Selection 7.1 - 7.6
8. Advanced Surfaces 8.1 - 8.40
Wednesday
9. Editing Power Surfaces 9.1 - 9.8
10. Trim Region Editing 10.1 - 10.14
11. Levels 11.1 - 11.4
12. Shading & Model Analysis 12.1 - 12.20
Thursday
13. Model Fixing 13.1 - 13.16
14. Basic Solid Modelling 14.1 - 14.54
15. Delcam Drafting 15.1 - 15.6
16 Mold Die Wizard 16.1 - 16.8
Friday
17. Further Solid Modelling 17.1 - 17.14
18. Plotting 18.1 - 18.6
19. Exercises 19.1 - 19.4
20. Parasolid Fixing 20.1 - 20.30
21. Assembly Modelling 21.1 - 21.18
Issue PSHAPE 2010 1

Contents PowerSHAPE
2 Issue PSHAPE 2010

PowerSHAPE 1. Introduction
1. Introduction
PowerSHAPE Introduction.
PowerSHAPE is a CAD Modelling package, which comprises of a Core module and several
specialised modules. These are Draft (generating detailed drawings), Toolmaker (mould
design), Electrode (Electrode solid model wizard), Assembly (Assemblies of solid models)
and Crispin (Shoe design). Note:- Some of the specialised modules are cost options.
• To open PowerSHAPE, double click on the desktop icon.
Once loaded, the screen looks as shown.
Pulldown Menus Main Toolbar
Viewing an
Shading
Toolbar
Command Options Graphics Area
PowerSHAPE automatically starts a New Model

for the user to work in. The Model name is displayed at the top left hand corner. Note that a
New Model is not stored externally to disc.
Issue PSHAPE 2010 1.1

1. Introduction PowerSHAPE
The model can be Saved permanently with a more appropriate name and stored to an external
directory. One or more previously stored models can be opened within the same
PowerSHAPE session.
At the top of the screen there are a series of pull down menus.
• Select the File menu, using the Left mouse button.
This menu contains a comprehensive list of

operations available.
Sub menus accessed by clicking on symbol.
Beneath the pull down menus are the Main Toolbar icons which when clicked either open
up a form alter the choice of command icons located to the left of the graphics area.
If the mouse is held over an icon for a few seconds, a box containing a description of the
command (tooltips) will appear.
To the bottom left of the graphics area is the Levels menu to which entities can be assigned
for long term, group selections.
At the bottom of the screen is the Workplane Selector, Principal Plane selector, the grid
definition, the cursor position, the tolerance and the XYZ position input area.
To the top right of the Main toolbar are several icons providing access to Workplane, Line,
Arc, Curve, Annotation, Surface, Solid, Feature, Assembly, and Wizard options.
1.2 Issue PSHAPE 2010

When one of the above icons is selected a context sensitive menu appears in the toolbar to the
left of the graphics area. The shared toolbar will contain all of the main options for creating
the chosen entity.
• Select the menu for line creation.
The top 2 icons are fixed and comprise Selection and Model -
Editing/Fixing/Analysis/Mesh Fixing and editing
The remaining icons from 3 downwards change depending on the option selected
from the Main toolbar.
This part of the toolbar is currently shown with the line creation options.
Toolbars
All of the toolbars, can also be switched on and off
from the View pull down menu and selecting
Toolbars and left clicking on the Toolbar name to
switch the tick on or off.

PowerSHAPE Options
The Tools Options page allows the user to configure PowerSHAPE to be different from
the factory, default settings.
The options are stored within several

main categories, accessible by clicking on
the adjacent plus symbol.
It is possible to make changes to the

factory default options and store them as
the new default settings to be active with
subsequent PowerSHAPE sessions.
• In File – Model (if not already set) tick the box Always save and open
from outside the database.
• Select Cancel.

Help Contents and Index

PowerSHAPE has an extensive Help index that can be accessed by either selecting Help
from the top menu or by simply pressing F1 on the keyboard.
• Press F1 on the keyboard followed by Getting Started – What is

PowerSHAPE? in the display window.
Topics are listed down the left hand window and the specific help for a selected item is
displayed in the right hand window.
The Hide button can be pressed to hide the topics. The button then turns to say SHOW which
if pressed the topic list re-appears.
If help is no longer required the window can be closed by selecting the ‘x’ located to the top
right of the browser area.
• Close the help window using the X button at the top right hand corner.

Mouse buttons
Each of the three mouse buttons performs a different operation in PowerSHAPE. By using
the ALT, Ctrl or Shift key, these operations can be extended as the following details explain.
Left Mouse button 1: Picking and selecting
This button is used for selecting items off the main pull down
menus, inputting data, and selecting parts of the model.
Middle Mouse button or wheel: Dynamics

Zooming: - Hold down the CTRL key and button/wheel and
move the mouse up and down to zoom in and out of the view.
Hold down the CTRL, Shift Key and button/wheel to select a
framed area to zoom into.
Panning: - Hold down the SHIFT key with the button/wheel
moving the mouse, to move the view across the component.
Rotating: Hold down the middle button/wheel and move the
mouse. A tracker ball appears at the centre of rotation, as does
the view orientation axis in the bottom left corner of the screen.
If View Spinning is switched on (Tools - Options - Views) the
view will spin around until the user executes a further mouse
click.
If available, the middle mouse wheel can be used to scroll text.
Mouse button 3: Special Menus
When this button is held down a menu is opened dependant

on what entity the mouse is over. If for example, the cursor is
on a line, then the Line menu appears. If the cursor is in the
graphics area, the View menu appears.

Exercise 1: Dynamic mouse controls.

In this exercise the user will Import an existing stored model and change the views using the
dynamic mouse options.
• From the main menu select File – Import to open the following form:-
• Import the model:-

D:\ users\training\PowerSHAPE_Data\psmodels_n_dgk\golf-fin.dgk
When a model is loaded into a new PowerSHAPE

session the default view is down the Z-axis.
The view toolbar, on the right hand side of the

PowerSHAPE window, can be broken down into 3
main areas, standard views, dynamics and
shading.
• Select the view Iso 1.
The model is now displayed using the first of 4

isometric views. Surface or Solid entities of
the model can be displayed as shaded if
required.

• From the views toolbar select Shaded view pull out menu.
• From the available options pick Shaded View.
The surfaces have been shaded to show

the full extent of the surface area. The
wireframe from which it is constructed
can also shown if required. The model
can be rotated dynamically so that the
user can view the underside detail.
• Hold down the middle mouse button and move the mouse to rotate the
view to display the underside.
• Hold down Shift and Middle mouse button and move the mouse to
position the view centrally over the model.
The underside can now be seen clearly.

There are many different options for
viewing the model that you can select.
There are also a variety of keyboard
shortcuts that you can use.
• Select Views Single [about selection].
The keyboard shortcut for the views are listed, i.e. Alt + 1 for Iso 1.
By switching Num Lock on the keyboard, the number pad can be
used with the Alt key to change the views.
There is also an enhanced shading option that displays the model in

a Perspective view with the lines running to a vanishing point as if
on the horizon.

• Select Back [+Y].
Another view is displayed. The

PowerSHAPE model needs to be
closed. In this case it does not need
to be saved, as the model has not
been altered.
Selecting and Blanking PowerSHAPE Entities

To be able to perform edits or reposition individual entities it must first be possible to
separate and identify them as selected items.
If an entity is selected with the left mouse button it will be displayed with a yellow colour. If
a box is dragged across a group of entities they will all be selected (The default setting does
not require an entity to be completely boxed).
To select more than one item within a group, the Shift key is held down while selecting
individual entities to add to the selection. To toggle a selected item on or off the Ctrl key is
depressed while using the left mouse key to pick the entities.
There are options in the Selection toolbar to enable the user to globally select all items of a
particular type such as Wireframes, Surfaces, Solids, Surfaces & Solids or Meshes.
There is also a general selection filter where the user can discriminate entities using a
more specific combination of search criteria, such as the type of wireframe, colour, line style,
etc.

If one or more entities are selected they can be temporarily removed from the graphics area
by selecting Blank from the local menu. If it is required to temporarily remove the selected
entities from the graphics area and retain the rest then Blank Except is applied. To return all
entities back to the graphics area then Unblank is applied from the screen menu (The
returned items will be selected (yellow). Most users prefer to use shortcut keys for this
process:- Ctrl J = Blank Ctrl K = Blank Except Ctrl L = Unblank
• In the Selection toolbar select the option Quick select all

wireframes.
• Select Delete to permanently remove all selected wireframe entities from
the model.
• Select the upper surface of the golf club head and it’s wireframe will
change to a yellow colour.
• Select Ctrl J to temporarily remove the upper surface from the graphics
area (as shown above right).
• Select Ctrl L to return the blanked surface back as the selected item.
• Select Ctrl K to keep the upper surface in the graphics area and
temporarily remove all other entities (as shown above right).
• Select File Close.
A message box appears asking if it is required to save

the changes. In this case no changes have been made
to the model.
• Select No.
The current model is now closed.

• Select File Exit.
A message box appears asking if it is okay to exit PowerSHAPE.
• Select Yes.
PowerSHAPE has now been closed.
• Open PowerSHAPE.
A new model is automatically opened.
PowerSHAPE models
PowerSHAPE models consist of any combination of different types of entity the main ones
being workplanes, wireframes, surfaces, solids and meshes.
Wireframe in PowerSHAPE
Wireframe items include lines, arcs, curves, points, text, dimensions etc. These can be 2D
or 3D and are essential for use in Drafting as the framework for generating most types of
Surfaces or Solids.
Surfaces in PowerSHAPE
Surfaces are created from wireframe, as standard primitive shapes, or by conversion from a
solid model. A surface is a best described as a skin stretched across one or more 4 sided,
elements of a wireframe network. A 3D model created as surfaces behaves as a hollow
form.
Solids in PowerSHAPE
Solids are created from wireframe, as standard primitive shapes, or by conversion from one
or more selected surfaces. A 3D model created as a Solid behaves as an enclosed mass.
PowerMILL 2010 creates Parasolids by default, but if required these can be converted to
and from the older version 8 solids,
Note; unlike other solid modellers, PowerSHAPE will support skin based or Open Solid
forms if Version 8 solids are used. These cannot be created directly, but can be created by
conversion from existing planer or open surface models.
Issue PSHAPE 2010

1.11

PowerSHAPE 2.Wireframe Modelling
2. Wireframe modelling
Introduction
PowerSHAPE can generate Points, Lines, Arcs, and Curves both in 2D and 3D space.
These are collectively known as wireframes and have several functions, which include being
the basic framework for several types of Surfaces and Solids, and as the drawing entities in
PS-Draft or PS-Estimator. Wireframes can be Exported in a variety of file formats, for use
in other software products such as PowerMILL.
Wireframe Line and Arc Options
The wireframe Line and Arc options are accessed from the main toolbar.
Single Line
Continuous lines Full Circle
Rectangle Arc Through Three pts.
Polygon Swept Arc About Centre

3D box around selected items Trimmed Fillet
Shortest line between 2 objects Untrimmed Fillet
Trimmed Chamfer
Untrimmed Chamfer
• From the top pulldown menus select File – New, or alternatively click on
the Open New Model icon from the main toolbar.
A new model will be opened in the current PowerSHAPE session.

2. Wireframe Modelling PowerSHAPE
Wireframe Lines and Arcs Exercise

The following tutorial will show the basic operation of the Wireframe modeller by
recreating the 2D profile shown below.
Line Creation
A single line will be generated from 0 to Y40 to coincide with the R 15 arc centre.
• From the Line menu select Single Lines.

• Enter the start co-ordinate of 0 and press Return.
• Input the values 0 40 in the Command input box (lower
right of graphics area) and press Return.
The next part will be generated using continuous lines.
• From the Line menu, select Continuous Lines option.

• Snap to the start of the first line (or enter 0 in the command input box).
• Input the value 60 in the Command input box followed by Return.
• Input the value 40 40 in the Command input box followed by Return.

The Intelligent Cursor

The Intelligent Cursor displays preview information and locks onto key points and major
directional axes during dynamic wireframe creation.
With the continuous line mode still active, a construction line to locate the R30 centre will
be dragged dynamically while being monitored by the Intelligent Cursor.
Note:- If the Intelligent Cursor functionality does not appear, right click within the graphics
area to open the local view menu and check that the option Intelligent Cursor is ticked.
• By moving the mouse, dynamically drag the end of a new line away from
the current position (as shown below) and observe the effect of the
Intelligent cursor (do not click the left mouse key yet).
In the diagram the end of new line has

currently been dragged to a relative,
preview position at an angle of 25
degrees with a length of 60.
Note:- The X direction is 0 degrees

and the Y direction is 90 degrees
anticlockwise.
• By moving the mouse further, dynamically drag the end of a new line to a
position tangential to the previous line and observe the effect of the
In the diagram the end of new line has

currently, locked onto the tangency of the
previous line and has been dynamically
dragged away with a preview length of 38.
• By moving the mouse further, dynamically drag the end of a new line
position to a position along the Y direction and observe the effect of the
In the diagram the end of new line has locked

onto the Y direction and has been
dynamically dragged away with a preview
length of 27.

By moving the mouse further, dynamically drag the end of a new line to a
distance of 30 along the normal (90 degrees) direction and this time click the
left mouse key at accept the line.
The intelligent cursor has locked onto the normal

(90 degrees) direction from the end of last line.
The cursor has been dragged along this normal
until a length of 30 is displayed.
The end position is accepted by applying a left
mouse click.
• Press Escape to exit line creation.
Arc Creation
The remainder of the wireframe is to be created using various arc options.
• From the Arc Menu select Full Arc .

• Input the value r 15 in the Command input box and press Return.
(This input will redefine the default radius).
• Move the cursor over the open end of the vertical line until the text End is
displayed then click the left mouse key to snap the circle centre position.
• Press Select.
If it is required to modify the Circle, quickly

double click it with the left mouse key and the
relevant Arc editor Form will appear.
• From the Arc Menu select Arc through centre, radius and span.
• Snap on the open end of the construction line, for the centre point.
• Move the cursor to the other end of the line and click with the left
mouse button.

The position is now set for the start of the arc.
• Release all mouse buttons and drag the arc around anti-clockwise.
The intelligent cursor displays the current span angle.
When the left mouse button is clicked, the arc is created.
• Click the left mouse button when the arc reaches about 250 degrees.
The blend radius (R 60) will now be

generated using Create an arc
through three points.
The 1st and 2nd points will be

snapped as tangencies to the existing
full circle and arc with the 3rd point
being input as the specified blend
radius value (60).
• From the Arc Menu select the Arc through three points
option.

• Use the intelligent cursor to locate, and Click on Tangent points on the
arc and circle (Do not locate a Key, End or Mid point as these are fixed
positions).
• Drag the radius point to the required shape and to a value as close as
possible to 60 before left clicking for initial acceptance.
• If necessary, In the Arc Confirm form Modify the radius value to 60 and
toggle through Next Solution until the correct shape is achieved, before
pressing OK.
The new arc has been trimmed

back both to the adjacent arc and
circle.
The Arc through three points

option will also be used to create
the R 10 fillet between the line
running along Y and the
remaining full circle.
• Select the Arc through Three points option.

• Use the Arc through three points option to create the radius of 10
between the full circle and the vertical line.

The Curves toolbar
After creating geometry consisting of Lines and Arcs it is often necessary (or just good
practice) to combine these into single entities as wireframe Curves. Also, it is not uncommon
to require wireframe that is defined directly as complex Curves. The most commonly used
Curve definitions are Bezier (free form curves) and Composite (Defined along existing
wireframe and/or model edges).
Bezier Curve and Derivatives.
Composite Curve.
Ellipse, Spiral, Helix.
Fillets and Blends.

Draft Curve.
Oblique Curve.
Model Intersection.
Curve Projection.
Curve Wrapping
Curve Unwrapping

Composite Curves
In many applications it is necessary for the required wireframe to be a single entity. This is
achieved by creating the wireframe as a composite curve.
Note:- A composite curve can only by driven along existing model entities.
The basic wireframe shape now is

complete but is currently made up of
several separate lines and arcs.
The extent of a composite curve can be limited between selected key points along the
potential route (Define start point and Define end point).
• From the Curve Menu, select Composite curve.
The composite curve toolbar

appears.
• Select the Start Point option in the toolbar and left click the lower left
corner on the wireframe model.

• Left click on the bottom line.
The Composite Curve is

generated along the route
until it hits a branch point
where optional directions
will be arrowed and change
colour for the user to
manually select the required
route.
Note: The asterisk at the

start point indicates that
the composite curve is
currently open.
• Left click along the R60 arc.
The Composite curve

has now continued
around the wireframe
back to the defined
Start Point.
Note: a circle at the

Start Point indicates
that the composite
curve is a closed
form.
• On the toolbar select Save to accept the composite curve.
• Select Eject to remove the toolbar.

• Select the construction line with the left mouse button.

• From the right mouse button - menu, select Delete.
The wireframe is now complete and will be Saved as a permanent model.
• Select File Save As.

• In the form Save the Model As:-
D:\users\training\COURSEWORK\PowerSHAPE-Models\cam-example
Wireframe Arcs Example

The next example demonstrates the use of Arcs to create the lever design shown below.

• Select the Arc Menu.
• Select the Full Arc option from the menu.
When this command is selected, the centre position of the circle is required first. This can be
input as a value or by snapping using the Intelligent Cursor.
• In the Command Input box enter 0 for the circle centre

and press return.
A preview of a circle has been generated with a radius input

from the default value. The radius can be altered by dragging
one of the displayed arrow to the required unit value.
To accept the circle, press the escape key.
• With the circle selected, click and hold the handles (arrows) and
dynamically move the mouse to drag a new radius of 35.
The circle now has the required radius. This method can be used to
create the second circle at the same centre position, using the
Intelligent Cursor. Alternatively the user can right click on the arc
and select Modify from the local menu.
• Select the Circle command.

• Position the cursor over the centre of the first circle so the word Centre
appears.
• Click the Left mouse button to accept the centre of the new circle.
This new circle is exactly the same initial radius as the first
Centre circle. To change the default, creation radius a new value is
entered into the Command Input window i.e. R 25.
• Drag the second circle to a radius of 20mm.

The two basic circles are completed. Further circles are

required for this model.
Hint: Use the command input box to enter the circle centre if it
cannot be snapped.
• Create a circle at centre 100 –20 with a radius of 50mm.

• Create a circle at centre 100 –20 with a radius to 35mm.
• Create a circle at centre 200 -40 with a radius of 20mm.
• Create a circle at centre 200 -40 with a radius of 10mm.
• Press Escape.
The default option when creating tangent arcs is to trim back the associated geometry. In this
case it is not required to do this, so the flag (Trim Tangent Items) is switched off. This is
found in the Options form under Tools at the top of the screen.
• Select Tools Options, select Object then Arcs.

• Untick Trim Tangent items.

• Press OK.
For the tangent arcs, the fitted arc option is the most suitable as it provides full dynamic
control through all possible combinations.
• From the Arcs menu select the Three point arc option.
• Move the cursor over the outer left circle until the word Tangent
appears and press the Left mouse button.
• Move the cursor over the middle outer circle so the word Tangent
appears and press the left mouse button.
• Move the cursor over up and down to get the tangent arc in the correct
place and press the Left mouse button.
The Arc Confirm form appears. This can be used to enter an

exact radius.
• Enter a value of 75 and press OK.

The tangent arc is drawn.
The command automatically repeats

until exited by pressing escape or the
selector.
• Move the cursor over the middle outer circle until the word Tangent
appears and press the Left mouse button.
• Move the cursor over the right outer circle so the word Tangent
appears and press the left mouse button.
• Drag a radius of 225 and press OK.
The second radius has been

generated. The further two can be
generated in the same manner.
• Create a three point arc between the left outer circle and the middle
outer circle with a radius of 225mm.
• Create a three point arc between the right outer circle and the middle
outer circle with a radius of 75mm.
The model is complete. The

option needs to be switched off
and the wireframe copied to a
new level.
• Select File Save As.

• In the form Save the Model As:-
D:\users\training\COURSEWORK\PowerSHAPE_Models\lever-example

General Edits
At the top of the left hand toolbar are 2 fixed icons, the second of which includes
access to the General Edits toolbar (default).
A few applications relating to wireframe data will be illustrated in this section.
Note: The General Edits options are also frequently used on other entities
including Surfaces and Solids. Further General Edit options will be
illustrated, as appropriate later on during the course.
• Close the existing Saved model.

• Open a New model.
• Select File - Import and load in the wireframe model:
D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\
GeneralEdit_Wireframe.dgk
The imported wireframe (shown above left) will be modified using the general edits options
initially to produce the 4 finished wireframes (shown above right).

• Select the Point limit option and move the cursor to the end of the
line to be extended and hold down the left mouse key (The cursor will take
the form of a magnet).
• Drag the end of the line tangentially (along the preview line) until the word
Intersection is displayed at which point release the left mouse key,
• Select the Interactively limit wireframes option and left click the
mid-span of any sections of the wireframe network that are to be trimmed
away (as illustrated below).
• Create a Composite Curve from the network of lines and arc wireframes
(Hint: For a ‘shortcut’ method hold down the Alt key and left click
anywhere along the wireframe network).

• With the Composite Curve selected, open the general edit - Move form.
• While the form is open, enter the coordinate values 25 25 in the Command
Input box located at the bottom right of the graphics area.
The Composite Curve is shifted by 25mm along both X and Y.
• Select Y as the operational axis by selecting the Icon located below the
graphics area towards the left hand side.
• With the Curve selected, open the general edit - Rotate form.
• In the Rotate form select the keep original option , enter No of

Copies:- 1, and Angle:- 180 followed by Return.
A copy of the composite curve has been rotated by 180 degrees about the active Y axis.
Note:- In this case the same result would have been obtained if the curve had been mirrored
about the YZ plane.

• Reinstate Z as the operational axis by selecting the Icon located below the
graphics area towards the left hand side.
• With both Curves selected, open the general edit – Mirror form.
• In the Mirror form select the keep original option and select the
icon labelled ZX followed by Return.
Copies of the 2 composite curves are mirrored about the active ZX plane.
Further General Edit options
Offset
• Select the composite curve located in the -X -Y quadrant
and in the General Edits form select the Offset options.
• Select the Round discontinuities option and input Distance 10 to

create an offset copy as shown above (The arrow denotes the offset
direction for a +ve Distance value).

Scale
• Select the composite curve located in the X Y quadrant and in the
General Edits form select the Scale option.
• Enter a Scale factor of 0.5 to reduce the size of the composite curve by
50% of the original size (as shown below).
Create Pattern of objects

• With the scaled down composite curve still selected, click the Create
Pattern of objects option.
The current settings are immediately previewed.
• Input 3 rows along both Y and X with a Y pitch of 50 and X pitch of 75.
• Select OK to accept.

Rectangular is one of 4 main functions in the Pattern Edits form. The other 3 include
Honeycomb, Circular, and along Wireframe. Note: Within each specific Pattern Edit form
further advanced options are available.
Honeycomb
Circular
Wireframe
The General Edits options will be applied as required, later during the course on other
PowerSHAPE entities such as Surfaces and Solids.

PowerSHAPE 3. Workplanes
3. Workplanes
Workplanes
Workplanes are user, defined datums, positioned and aligned as required to simplify model
creation. A model can contain several Workplanes, but only one can be Active at any time.
When a Workplane is Active it becomes the XYZ datum, visually larger in size, and
changes colour from grey to red. Model entities can be copied or cut from the currently
Active Workplane and then pasted back in a different position, relative to a new Active
workplane.
The main Workplane icon is located in the main toolbar which when selected will
provide the following icons in the left hand toolbar:
Single Workplanes.
Multiple Workplanes.
Single Workplane aligned to geometry.
Single Workplane at Top/Centre/Bottom of selection.
Workplane from three points.
Create Points.
In the next example the user will be required to apply wireframe Lines to construct a box
with an angled top. This in turn will be used as the model to demonstrate some basic
applications of Workplanes.
Box Example
• Open a New Model.
The wireframe for the dimensioned form (as

shown right) will now be created.

3. Workplanes PowerSHAPE
• Open the Single Workplane option and enter 0 into the Command
Input window to position it at the World Datum.
• Select the view Iso1.
• From the Line menu select Rectangle.

• Enter 0 in the Command input box and press Return.
• Enter 100 75 in the Command input box and press Return.
Note:- The rectangle is not a single

entity but consists of 4 separate,
wireframe lines.
• From the Line menu select Continuous Lines.

• Snap the start of the line onto the Workplane.
• Enter 0 0 100 in the Command input box and press Return.
• Enter abs 0 75 150 in the Command input box and press Return.
• Snap (left mouse click) the end of the current line to the top left corner of
the rectangle (Marked as End by the Intelligent Cursor below).
• Select the last 3 lines created.

• Open the General Edits - Move option.

• Select the option Make a Copy and enter 100 in the command input box
before pressing Return.
The final 2 Single lines are input by snapping to appropriate key points on the wireframe
model.
• Select Single Lines.

• Press Escape.
The main wireframe model is now complete.
An additional wireframe model based on a

hexagonal Polygon of lines will now be created
to a new Workplane coordinate system at X -100
away from the main model. A copy of this
separate model will later be placed onto the
angled, top face of main model.

• Open the Single Workplane option and snap a new Workplane to

the top End of the line running up Z from the original Workplane.
• Zoom into the new (Active) Workplane and then use the left mouse key to
select it.
When a Workplane is selected a square appears on

the XY plane. The corners and mid points of the
square, along with the Z axis arrowhead are thicker
and darker in colour.
If the left mouse key is held down on one of the
dark bands then the Workplane can be dynamically
rotated about the Z axis.
If the left mouse is held down one of the lighter
coloured bands then the Workplane can be
dynamically rotated about the corresponding,
parallel X axis or Y axis.
Note: If one of the Workplane arrowheads is

selected (instead of a coloured band) during
dynamic re-orientation then all Workplane axes
will rotate simultaneously.

• Select the light band on the +Y side and parallel with the X axis and with
the left mouse key depressed drag and drop on to the upper left corner of
the model (arrowed above).
• Select the 4 lines (Use Shift - left mouse for multi-selection) enclosing the
angled top face of the model and select the Workplane option - single
workplane at centre of selection.
As soon as the icon is clicked a new Workplane

is created, central to the 4 selected lines.
This Workplane will both be Active and
selected.

• From the main toolbar select the Arc options and create a 40 radius - Full
Arc about the currently Active workplane.
The R40 Circle has been created on the XY plane of the

Active workplane central to the angled top face of the
wireframe model.
• Right click on the Active Workplane to open it’s local menu and untick
Activate. As no Workplane is now Active all measurements will now be
controlled by the original World coordinates.
• Open the Single Workplane option and enter -100 into the
Command Input window to position it (along -X) away from the main
model (The new Workplane will become Active by default).
• Create the following network of wireframe lines central to the new
Workplane.
Hint:-
• Use Lines – Polygon.
• In the Command Input box, Input (and return) 0
(Centre point) followed by 0 15 (corner point).
This wireframe will be copied from the

Workplane local to the geometry, to the
Workplane central to the angled face on
the main model.

• With the above workplane Active, select all the new locally created
wireframe and with the cursor on one of the lines, right click to open the
local Selection menu.
• Select Copy in the menu.
The selected wireframe is

effectively, copied via the mouse!
• Activate the workplane positioned central to the angled, top face on the
main wireframe model.
• Right mouse click in the graphics area away from the model and select
Paste from the local menu.
The wireframe created away

from the main model has been
copied relative to the workplane
central to the top angle face of the
main wireframe model.
Note: Data relative to an Active

workplane in one PowerSHAPE
model can be copied and pasted
relative to an Active workplane in
a different PowerSHAPE model
• From the main pulldown menus select File – Save As, and store the
psmodel as:-
D:\users\training\COURSEWORK\PowerSHAPE-Models\Workplane-
Box

Workplane alignment of moulding component

Often when a component design is imported it will not be in a suitable orientation for such
tasks as creating a tool around it, or for maximum accessibility to a 3 Axis machining
operation. In these cases Workplanes are easily applied to achieve a more suitable location
and oriention for the model. To maintain dimensional accountability to the original
component, it is essential to move workplanes around the model as opposed to physically
moving the model relative to the world datum
• Select File - Import and locate the Surface model:-

D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\Interior-
Trim.dgk
The imported model of a plastic

moulding is not in a suitable
orientation from which to create
a mould tool. As a result a
suitably positioned workplane
will be created to provide an
appropriate tooling datum.
The most obvious choice for a
tooling alignment is normal to
the base of the pocket.
• Use the middle mouse key to dynamically rotate the view to display the
underside of the component.
• Select Single workplane aligned to geometry and left mouse

click on the surface defining underside face of the pocket.

• Select the surface defining the underside face of the pocket again
and select the Single workplane at top of selection option.
The latest workplane will be

positioned, exactly central to
the selected surface.
• Select and Delete the original workplane used to create the alignment
with the base of the pocket.
• View the model in all directions to check that a suitable tooling alignment
has been achieved.
It is possible that the model may need to be rotated 180 Degrees about the X Axis at some
stage. This can be performed using the workplane editing form.
• Right mouse click on the workplane and in the local menu select Modify.
• Select the Twist X icon and enter 180 in the Calculator form before
selecting OK, and then OK again in the Workplane form.

The model is now viewed the other way up, relative to the new orientation of the
Workplane.
Workplane toolbar
Below the graphics area in the bottom left hand corner is the Workplane toolbar, which
includes an icon for creating Temporary Workplanes as well as a table as an alternative
means to control the naming and activation of Workplanes.
• Select the down arrow to select another workplane.
If Workplane 1 is selected in the form it becomes active. A Workplane

can be renamed by clicking on the current name and typing over it with
the new name, followed by the return key.
• Click on the Temporary Workplane icon.
• Snap to some existing geometry (or anywhere in the graphics area).
The red and black Temporary Workplane appears. This

Workplane cannot be aligned dynamically nor does it have access
to a local editing form, but can it be modified using the General
Edits toolbar options. It is automatically called Temporary and can
be deleted from using the local menu or by re-selecting the
Temporary Workplane icon.
• Click on the Temporary Workplane icon.
The Temporary Workplane is removed from the model.

Master Workplane
In a PowerSHAPE model one of the Workplanes can be designated as the Master, which
will be displayed with thicker lines to distinguish it from the others.
If another active Workplane is deactivated, instead of PowerSHAPE reverting to the World
co-ordinate system, it activates the Master Workplane.
Example
• Open the model golf_fin.
There are two Workplanes in this model Named 1 and 2. These are listed
above the World co-ordinate system in the workplane selection form.
• Select Workplane 1 and click over it with the right

mouse button to bring up the local menu.
• Select the option Master (this becomes ticked).
• Deselect the Workplane.
The Master Workplane appears below World in the

workplane selector form.
• Activate Workplane 2 and then deactivate it.
The Master Workplane becomes the active datum, instead of the

World origin. This is especially useful for users handling imported data
in the car industry where traditionally every component part has a
common datum (Car Line). This World datum could be metres away
from the component as well as being in an unsuitable orientation for
tooling purposes. It is advisable that this datum is retained in case it is
required to check dimensions relative to the Car Line coordinates.


PowerSHAPE 4. Surfaces and Solids
4. Surfaces and Solids

What is a Surface?
A Surface is best described as a skin of negligible thickness stretched across a defined 2D or
3D area.
There are 3 main types of surface supported by PowerSHAPE which include:-
Primitives, NURBS and Power Surfaces. The constructional attributes and editing
capability of these are very different.
Primitive surfaces
A Primitive Surface is based on simple, standard shapes, and wireframe extrusions or
rotated forms. A Primitive Surface is defined or edited by entering set parameters into a
specialist form (The actual input criteria depends on the type of Primitive Surface).
A major restriction of a Primitive surface is that it is only possible to modify the existing
defined parameters such as length, radius, orientation and where applicable, the original
wireframe. Primitive surfaces also have an inherent workplane like datum, which the user
can manipulate to perform modifications dynamically.
PowerSHAPE - Primitive surface options include:-

Primitive - Plane, Block, Sphere, Cylinder, Cone, Torus. Helix.
Extruded surfaces (From pre-defined wireframe).
Surfaces of revolution (From pre-defined wireframe).
The Primitive Cone Surface is shown selected with the local Cone editing form open.
Note:- The Surface Cone is a skin with the top and base open.
Issue PSHAPE 2010 4. 1

4. Surfaces and Solids PowerSHAPE
NURBS surfaces (Non-Uniform Rational B-Spline)

It is common for a surface model created using a different CAD system to be imported into
PowerSHAPE. For this to be possible, PowerSHAPE supports other types of Surface
definitions such as NURBS surfaces. PowerSHAPE will also create NURBS surfaces
during certain applications or if dictated by the user in the PowerSHAPE - Surface Options.
The control points on a NURBS surface can be dynamically moved around in space, but not
to any degree of dimensional accuracy.
Any such changes are tricky to apply and depend on the users visual acceptance of the new
form.
Conversion of Primitives and NURBS to Power Surfaces

If it is required to perform more complex modifications to the shape of a Primitive or
NURBS surface, it must first, be converted to a Power Surface. With a Power Surface the
user has access to a full range of editing options via a comprehensive surface/curve editing
toolbar or dynamic operations.
Note:- It is not possible to convert a Power surface back to a Primitive or NURBS type.
In the Main pulldown menu option:-

Tools – Options – Objects – Surfaces ensure that in the section labelled Primitives that
Create as NURBS is unticked if direct conversion from Primitives to Power Surfaces is
required (Otherwise when Convert Surface is applied to a Primitive it becomes a NURBS
which in turn will have to be converted to a Power Surface).
Note:- Several of the Surface creation options directly create a Power Surface.

Power surfaces
A Power surface is based on a network of 4 sided wireframe elements appearing as curves
along (longitudinals) and across (laterals) the surface area.
A Power Surface can generate complex forms while retaining full editing capability
including the direction and magnitude through surface curve intersections.
To define holes within the surface area or an outside profile not compliant with a 4 sided
wireframe structure, specialist trim curves called Boundaries are applied.
The area of surface between adjacent pairs of laterals and longitudinals is called a patch.
The curves on a POWER Surface are called longitudinals (along the surface) and laterals
(across the surface). In some cases another (optional) curve exists called a spine. This
generally runs along the longitudinal direction, often in free space controlling the orientation
of the laterals.
Laterals
This surface contains the minimum,
two laterals.
Longitudinals
This surface contains a total of 7
longitudinals flowing from
corresponding points from the first
to the second lateral
Spine (Drive Curve)

The spine (shown dotted) is used to
control the orientation of the
laterals. A spine is not mandatory
and can be created or deleted as
required without changing the
surface shape. It occurs
automatically such as during the
creation of Fillet surfaces or as part
of the controlled geometry of a
Drive Curve surface.
The Cato mark identifies the start point for Laterals and Longitudinals on a POWER surface.
It is positioned a short distance from point 1 along lateral 1 with a short line pointing from it
representing the Longitudinal direction.

What is a Solid?
A Solid is best described as a solid mass. Unlike Surface modelling, there are no options in
Solid modelling that directly create entities that are of negligible thickness (eg Primitive
Plane, or a Split Surface). There are obvious differences in both the options and methods
used as opposed to working with Surfaces. The main advantage of working with Solids is the
inherent History Tree. Actions performed earlier can be retrospectively modified within the
History Tree and the whole Solid will update to fully accommodate the alterations. This
means any amendments to a design can be very quickly implemented in the model.
Solid modelling has been an essential feature of PowerSHAPE for many years but
PowerSHAPE 2010 is the first version to fully support Parasolids as the standard as opposed
to the earlier V8 Solids. V8 Solids are a type of solid that is unique to Delcam whereas
Parasolids are the standard used by other dedicated Solid modelling packages.
An essential reason to use Parasolids is that actions performed on them are generally more
accurate, stable, and reliable. In PowerSHAPE 2010, Parasolids are default, and to the
existing user the options and forms used are little changed from those used with V8 Solids.
Note:- The Solid Cone is fully enclosed mass that includes the top and bottom face.
Summary
From the above explanations it is obvious that Solid Modelling is the best method to use for
creating a CAD model. There are however certain applications that are impossible or more
difficult to create using solids. These include Split Surfaces, Draft surfaces, and Solid
Doctor repair, operations where faces need to be extracted and modified as surfaces patches
before being inserted back into the Solid.

Surfaces Versus Solids

The following simple component will be created using both Surface and Solid modelling to
demonstrate the general differences. This example will also demonstrate the advantages of
using Solid Modelling.
The Holes are Dia 20, the Fillets are Rad 5, and the Draft Angle is 5 Degrees.
Surface Modelling Method
• From the Main pull down menus select File - Save As :-
D:\users\training\COURSEWORK\PowerSHAPE-Models\GettingStarted
• From the Main toolbar select Workplanes

to access the Workplane options toolbar
on the left of the graphics area.
• Create a single Workplane at 0.
Note: The Workplane will automatically become the Active datum on creation.

• From the Main toolbar select Surfaces to access the Surface options
toolbar on the left of the graphics area.
• From the Surfacing options select Block Primitive.

• Left mouse click on the workplane to locate the new Block Primitive on
to it.
• Right mouse click on the Block Primitive and select Modify from the
local editing options.
• Fill the Block form in exactly as shown above before selecting OK.
Fillets
Surface Fillets can only be created along the intersections between 2 or more separate
Surfaces. The Block Surface must first be made into 4 separate Surfaces for it to be
possible to create the Fillets. Before the Surface can be split up, it must first be Converted
from a Primitive to a Power Surface.
• Right mouse click on the Surface and the description at the top of the
local menu includes Surface Block.
• From the local menu select Convert Surface.

• Right mouse click on the Surface and the description at the top of the
local menu should include Power Surface (If it is Nurbs select Convert
Surface again).
• Double Left mouse click on the Surface to both make it selected (Yellow
wireframe) and to open the Surface edits toolbar.
• With the Shift key depressed, use the Left mouse key to select all 4
linear curves running from the base to the top.
• Select the option Break Surface to create 4 separate Power Surfaces.

• Select all 4 Surfaces and from the Surface options toolbar select Fillet
surface.
Use a Fillet Radius of 5
Set Convex (fillet from inside (Red) faces of

Surfaces).
Set Fillet all routes (Automatically creates fillet

surfaces along all available routes).
• Fill in the Fillet Surface form in exactly as shown above before selecting
OK.
Fillet Surfaces are created up the 4

corners of the Block.
One issue with a Fillet Surface running between adjacent Draft Surfaces is illustrated in the
following (exaggerated) diagram.
The cross section of a Fillet Surface is always perpendicular to

the drive curve (Spine) created between adjacent Surfaces.
A Surface Fillet will not proceed beyond the physical edge of the
adjacent Surfaces.
As a consequence of the above rules neither the top or bottom

section of the Fillet Surface are flush with the top or base levels.

Trimming the Fillets

• From the lower left corner of the PowerSHAPE window the select
Create/Remove temporary workplane and in the Command input
box enter 0 0 50.
• Select all 4 sidewall Surfaces and press the keys (Ctrl J) to Blank them
from the view.
• Click on the Show general edits options followed by Limit selection.
• Select the Active temporary workplane to be the Cutting object and then
drag a box across all 4 Fillet Surfaces to trim them back to be level with
the temporary workplane.

• Press the keys (Ctrl L) to return all items back into view (Unblank).
Create a Fill-In Surface

• From the lower left corner of the PowerSHAPE window the select
Create/Remove temporary workplane to remove the current one.
• With the Alt key depressed, left mouse click anywhere on the top edge of
the surface model to create a Composite Curve all around the top edge.
• With the Composite Curve selected, open the Surface Options toolbar
and then click on the Automatic Surfacing option.

• Select Apply to create a Fill-In Surface inside the selected Composite

curve.
• Select and Delete the Composite Curve.
Creating the Holes

• From below left of the graphics area select Y as the operational direction.
• Activate the Workplane.central to the base of the model.

• From the Surfacing options select Cylinder Primitive.
• Enter the values 0 -60 25 in the Command Input box to position the new
Cylinder Primitive.
• Right mouse click on the Cylinder Primitive and select Modify from the
local editing options menu.

• In the above form, input Radius 10 and Length 120 before clicking on OK.
• From below left of the graphics area select Z as the operational direction.
• Select the new Cylinder Primitive and open the general edits toolbar.
• In the general edits toolbar select Rotate items to open the

following form.
• Select the Keep original option, input Copies 1, and Angle 90, before
pressing the Return key.
The 2 Cylinder Primitives must now be trimmed back to each other as well as to the outer
wall Surfaces.

Trimming the Holes

• Select the 2 Cylinder Primitives and apply Blank Except (Ctrl K).
The 2 Cylinder Primitives

need to be trimmed back to each
other.
To ensure this is fully successful
the general tolerance will first
be increased to 0.02.
• In the General tolerance input box (located below the graphics area),
modify the current value to 0.02.
• Select one of the Cylinder Primitives and from the general edits options
select Limit Selection.
Note the green tick shows that the selected Cylinder

Primitive is registered as the Cutter selection.
• With the Limit selection form open, select the other Cylinder Primitive to
produce one of several possible trim results (2 shown below).

• To obtain the correct trim keep selecting Next solution until the correct
one is displayed (as shown below).
Note that the limit selection process will automatically cause the Cylinder Primitives to be
converted to Power Surfaces.
• Close the Limit selection options.

• Select and Blank (Ctrl J) the 4 fillets and top Surface.
• Use Limit Selection to trim back each cylinder to their relevant sidewall
surfaces (Hint: Select a sidewall surface as the Cutter selection and
when applying the trim, click the part of the cylinder protruding outside the
wall).
• Once both cylinder Surfaces have been trimmed to all of the sidewall
Surfaces apply Unblank (Ctrl L) to return all entities to the view.

Note: The visible side of the Cylinder Surfaces are shaded Red (Inside face) as opposed to
the other surfaces which are shaded Blue (Outside face). It is good practice to reverse any
surfaces that are currently shaded red.
• Select the 2 cylinder Surfaces (Shaded Red) and right click over one of
them to open the local menu.
• Select Reverse in the local menu to turn the 2 cylinder Surfaces inside
out.
• Select File – Save to update the externally stored Model file.
• Do not close the model as it will be continued to create the same
component design but this time using Solid modelling.
The Surface Model is now finished, but should any future design changes occur it will be a
laborious process to implement them. If it is required to change such features as the fillet
Radii, Hole Diameters, or general dimensions, other related parts of the Surface Model will
not automatically update, All affected surfaces will need to have the current trimming
deleted and then individually be re-trimmed to comply with the updated design.
Solid Modelling Method

The same component will be created but this time using Solids at a distance of X150 from the
Surface model

• Create a single Workplane at X 150.
Note: The new Workplane will automatically become the Active datum on creation.

• From the Main toolbar select Solids to access the Solid options toolbar
• From the Solid options select Block Primitive.

• Left mouse click on the new workplane to locate the new Block
Primitive on to it.
• Right mouse click on the Block Primitive and select Modify from the
local editing options.
The new Solid will automatically be Active on

creation.
• Fill the Block form in exactly as shown above before selecting OK.
• Double left mouse click on the Solid to

open the History Tree window to the left
of the graphics area (If it is not already
open).
The Solid Block is currently the only item registered

in the History Tree.

Fillets
Solid Fillets are created on the Active Solid along selected non-tangential edges between the
faces.
• From the Main toolbar select Feature to access the Solid Feature
options toolbar on the left of the graphics area.
• Select Create solid fillet from the Solid Feature options toolbar.
• With the Solid Fillet form open, input a Radius 5 and with the shift key
depressed, select the 4 edges running up from the base of the Active
Solid.
• Select Apply to process the Fillets.
Note: Unlike the Surface Modelling example the ends of the Fillets are created to be exactly
level with the original top and base of the Block Solid.
On Clicking the next to the solid registered in the History Tree

the folder will open to display all actions performed and entities
used in the Solid.
The last operation performed is always placed at the top of the

History Tree.

Holes
• From the Solid options select Create solid cylinder.
• In the Command input box enter the coordinates 0 -60 25 to define the
location for the Solid cylinder.
• Double left mouse click on the Solid cylinder to open the Cylinder
editing form.
• Insert Radius 10 and Length 120 before selecting OK to accept the

changes.
The newly created Solid Cylinder will be registered in the History Tree as a separate item to
the existing Active Solid.
The Original Solid is identified with a Red flag to show that it is

the Active Solid.
The Cylinder Solid is identified with a Grey flag to show that it

is not the Active Solid.
Note: A Solid is made Active (or not) by toggling the flag using a left mouse click.

Boolean operation
A Boolean operation will either Add, Remove, or Intersect the selected Solid(s) within the
Active Solid.
• With the original Solid Active (Red wireframe and Red Flag in History
Tree) select the Solid Cylinder using the left mouse.
• From the Main toolbar select Feature to access the Solid Feature
• Select Boolean ’Remove’ from the Solid Feature options toolbar.
The mass of the Cylinder Solid is

removed from the Active Solid.
The Solid Cylinder is now part of the Active Solid and is registered at the top of the History
Tree.

Solid Editing
The previous Boolean Removal operation can be copied and rotated to create the other Hole
by using options from within the Solid HistoryTree.
• Left mouse click the Boolean Removal action located directly above the
Solid Cylinder in the History Tree.
A square box is displayed around the item name on selection.
• Select the General Editing options and switch to Edit selected sub-items
mode.
• Select the Rotate items option and in the resultant form set Keep
original with Copies 1 and Angle 90 before pressing the Return key.
Keep Original
Rotated Copy of the

original Hole
Original Hole
The second Solid Model of the component is now completed. In addition to the overall
process being easier than Surface modelling, design changes can be implemented almost
instantaneously from with the Solid History Tree.

PowerSHAPE 5. Primitive surfaces
5. Primitive Surfaces
Primitive Surfaces
PowerSHAPE can quickly create a range of simple surfaces defined by a few basic
parameters. These are Primitives, which include 6 Standard Shapes, Extruded Surfaces
and Surfaces of Revolution. On Primitive surfaces only the basic dimensional parameters
can be modified with the original defined shape being fixed. Other types of Surfaces used in
PowerSHAPE include Nurbs Surfaces (Frequently obtained from imported data) and
Power Surfaces. Nurbs Surfaces also have limited editing capability and along with
Primitive Surfaces must be Converted to Power Surfaces for a more powerful, a complete
editing capability. Note: The conversion process is not reversible.
Standard Primitive Surfaces

There are 6 standard Primitive Surfaces options in PowerSHAPE, a Plane, a Box, a
Sphere, a Cylinder, a Cone and a Torus. Primitive Surfaces are generated with minimal
data input and can be an ideal starting point for many applications. Primitives are coloured
gold in the pull down menu to distinguish them from other surface creation options.
Each Primitive, when created is given a size proportional to the zoom of the screen and are
then, subsequently modified as required. A Primitive can be moved, copied, rotated,
intersected and filleted. However if it is required to alter the defined shape by actions such
as moving surface points or adding extra sections, a Primitive must first be converted to a
Power Surface.
All Primitives are created in the direction of the active Principal Axis (By default this is
along the Z-Axis).
Basic Primitive Example
• Select Create New Model.

• Select the Surface menu icon from the Main Toolbar.
• Move the mouse over the Surface Primitives fly-out commands.
This menu allows the user to create a range of surface primitives. They are, from left to right,
Plane, Block, Cylinder, Cone, Sphere and Torus, and Spring Primitive.
• Select Plane Primitive.

5. Primitive surfaces PowerSHAPE
A moveable Primitive Surface - Plane is attached to the cursor, with the centre of the Plane
being it’s local origin. This can be positioned by locking onto an item using the intelligent
cursor or by typing in X Y Z co-ordinate value in the Command Input window.
The selected Plane is shown is positioned with an

inherent workplane attached to it. The orientation
of the Primitive Plane can be changed
dynamically by selecting and dragging on
workplane attributes.
The sides of the actual Plane can be dynamically

dragged to a different size.
• Select the blue edge at the top of the square and dynamically pull it out
wards until a value of 280 is displayed and release the mouse button.
The width can also be modified at this point

using the same method.
• Select the blue edge at the side of the square and dynamically pull it
outwards to 100.
• Double click on the Plane to open the editing form.
This form has two tabs and allows the user to

rename or reverse the surface, input different
values for width and length, re-orientate directly
along a major Axis, or by applying a twist about
a major Axis to change the angle.

• Change the Length (Y) to 100.

• Select the Workspace tab and change the define Z position to 40 before
selecting OK.
• Press Select to exit Primitive Plane creation mode.
Do not close the model the above Plane will be used as part of the next example.
Simple Gear Shift design using Primitives

In the following example each of the six Primitive Surface options will be applied to the
construction of a basic Gear Shift design.
• Click the Workplane icon and the option Single Workplane.

• Enter 0 in the Command Input box and press Return.
This Workplane will provide a visual marker for the dimensional datum.
• From the Surface fly-out menu , select Block Primitive.

• Drag or Edit the Block dimensions to X 100, Y 100 and Z 40.

• From the Surface fly-out menu , select Cone Primitive.

• Enter 0 0 40 in the Command Input box and press Return.
• Drag or Edit the Top Radius to 5, Base Radius to 27.5 and the Length to
be 50.
• From the Surface fly-out menu , select Cylinder Primitive.

• Drag or Edit the Radius to 5 and the Length to 60.
• From the Surface fly-out menu , select Sphere Primitive.

• Drag or Edit the Radius to 15.
• From the Surface fly-out menu , select Torus Primitive.

• Drag or Edit the Minor Radius to 1.5 and the Major Radius to 5
• Press Select to exit Primitive Plane creation mode.

• In File - Save the model as D:\users\training\Coursework\GearStick and
select File - Close.
Extrusion Surfaces
This type of Surface is formed as an extrusion of a wireframe entity normal to the
wireframe’s planer base (default). If required, it is possible to change the settings in Tools –
Options – Objects -Surfaces for the extrusion surface to generate along the active X,Y, or
Z Axis. If several items are selected for extrusion then a series of separate surface will be
generated.
As with standard Primitives an Extrusion Surface can only have basic parameters
modified unless irreversibly converted to a Power surface.
By default the wireframe used to create the extrusion surface will be deleted. To retain the
wireframe tick the pulldown menu, setting:-
Tools Options - Object - Surfaces - Keep wireframe (extrusions and revolutions).

Extruded Polygon example

This example demonstrates the option to create a wireframe, polygon which in turn will be
used to generate an octagonal extrusion surface with a side length of 50 and a height of 100.
• Select Open New Model.
• Open the Line menu.
• From the menu select Polygon.
The Polygon creation form is displayed. This allows the

user to specify the Number of sides in the Polygon as
defined by one of three available options.
The option to Create composite curve provides the user

with the option to create a Polygon as a single entity. If
this option is switched off (default) the sides of the
Polygon will consist of single lines.
• Set the Number of sides to 8.

• Select Edge points and tick - Create composite curve.
Start and end points of the first span need to be defined before dismissing the form.

• OK the Polygon creation form.
The wirefame is completed and is already a single closed

composite curve.
This will be used as the shape of the Extrusion Surface.
• Select the composite curve.

• Select the Surface menu and select Extrusion.
This produces an extrusion surface from

the selected composite curve up the Z-axis
by a default value.
The extrusion has two sets of Double

Arrows which are used to dynamically
change the length up or down the Z axis and
if required to create a negative extrusion
(lower set).
• With the Left mouse button select the upper set of double arrows.
• Drag the extrusion upwards to a length of 50.
• Double-click on the surface edge.
The Primitive Extrusion editing form will open

providing the options to input settings and
dimensional values. The Extrusion can be given
a positive or negative draft angle.
The extrusion can be repositioned by entering

new origin coordinates, and aligned to, or
rotated about an Axis.
• Enter a length of 100 and press OK.

• De-select the surface by clicking away from the surface.
The Extrusion Surface is completed.

PowerSHAPE can also simultaneously extrude several, separate selected geometry items to
make individual surfaces.
• Select the extruded Surface.

• From the Right Mouse button menu, select Delete (or the keyboard
Delete key).
The Surface has now been deleted and the original composite curve does not exist either.
This was deleted earlier by default when the extrusion was created. To automatically retain
future curves tick the box accessed from the pull down menu Tools - Options – Objects –
Surfaces - Keep wireframe (extrusions and revolutions).
Extrusion Example 2
• Select the Workplane menu.

• From the Workplane menu select Single Workplane.
• Generate the following 8 lines around the new Workplane.
Each of the selected wireframe entities will create a separate Extrusion Surface.
• Box select all the wireframe.
• Select the Surface icon and select Extrusion.

For multiple wireframe selection a different form

appears which requires a common input for
Length, Draft Angle, and Negative Length for
of all the Extrusion Surfaces being generated.
• Enter a length of 70 and press OK.

• De-select the surfaces.
• From the Shading menu, select Shaded Wire View.
PowerSHAPE has created 3 separate

surfaces.
Note: once created the Extrusion

Surfaces can be edited individually.
• Select all of the surfaces and select Delete.
A 3D wireframe can be used to create an Extrusion Surface.
• Import the Model:-

D:\users\training\PowerSHAPE_Data\models\psmodels_n_dgk\3D_Wirefr
ame.dgk
An Extrusion Surface will be created from the

imported 3D composite curve.
• From the Surface menu and the option Extrusion.

• Edit the length of the Extrusion Surface to 50mm.

It can be seen that the surface has been extruded along the
normal to the average, planar base to the wireframe.
• Select Undo to get back to the stage prior to creating the Extrusion
Surface.
• Select Tools Options - Objects -Surfaces.
The section Primitives controls the

standard behaviour as they are
generated.
The default option is for Create extrusions normal to planar base to be ticked.
• Untick - Create extrusions normal to planar base and press Accept.
• Select the Z Axis and select the composite curve.
• From the Surface menu and the option Extrusion.
The Extrusion Surface will now be generated

along the active Principle Axis Z.
• Select File Close but do not Save the model.

Pump Project Example

In this example an IGES file containing wireframe data is Imported into PowerSHAPE
and the Surface Model will be created in stages to provide a practical application of the
content from the remaining chapters. Many different types of data formats can be imported
into PowerSHAPE depending on the customer having purchased the relevant translators.
One off, data translations can also be licensed through the internet on a ‘pay as you go’ basis
through the Delcam Technical Support department.
• Select Import Data File.
The Select a file to Import form

appears to enable the user to
browse for the required file.
• From D:\Users\Training\PowerSHAPE_data\iges select pump.igs and

press Open.
The multi-coloured wireframe appears.
• Select all of the wireframe that defines the base.

• Select the Z- axis.

• Drag the extrusion length to 40.
• Press Select.
The extrusion surface is complete. The

model must now be Saved ready for the
next stage.
• Select File Save As and enter the name pump-project2 and press
Save (Work will continue on this model during later chapters).
Surfaces of Revolution Example

A surface of revolution is creating by revolving single geometry or a composite curve around
a specified principal plane.
• Create a Workplane at 0 and create the

bottle section geometry.
This shape will be connected together with a composite

curve.
This curve will be revolved by 360 degrees around the

workplane generating a surface. The correct axis for
rotation around must be pre selected.

• Select the Y-Axis.

• Create a composite curve of the section geometry.
• Select the wireframe and select the Surface menu.
• Select Surface of Revolution.
The selected composite curve is spun around

the active axis (Y) producing the surface of
revolution producing the bottle shape. A lid can
be created by generating a curve around the
end profile, and applying the Fill-In surface
option.
• Select the Curve menu and select Create a Composite Curve.

• Click on the top part of the bottle.
A composite curve can be used to trace

all around the curves of a surface.
• Trace around the top of the bottle until closed.
• Select Save and Eject on the composite curve menu.

• Select the Composite Curve.
A fill-in surface is generated from a composite curves or a series of wireframe entities. It

is especially useful for filling in gaps in models.

• From the Surface menu select the Automatic-Surfacing Wizard.
• Use the pull down to select Fill In (if not already picked).
This wizard will be used later on

in the course.
• Press Apply and then OK.
The surface has been generated. The inside skin area of the
surface is displayed with a red colour. This is the inside colour
which cannot be changed by the user. It can however be
transferred to the other side of the surface skin by reversing the
surface.
• Select the surface with the Left mouse button.

• From the Right mouse menu select Reverse.
The surface has been reversed, showing the user defined,

coloured side, which is known as the outside.
• Select File Save As and save the file as:-

D:\users\training\COURSEWORK\PowerSHAPE-Models\my-
parameters .
When a PowerSHAPE model is saved the undo/redo facility is reset. Only work carried out
after the Save will be eligible to be undone or redone.

Wheel Example
Create the following wheel shape. This will then be altered using various commands.
• Select the view from top.

• Select and Delete the two surfaces.
• Generate the basic wireframe shape.
• Select all the wireframe.
• Select the view Iso1 and select the Y plane.
• From the Surface menu
select Surface of Revolution.
The surface of revolution is generated. The only

option available to edit this surface by
parameter is to change the number of degrees it
spins around from the default of 360 degrees.

• Double click the surface with the left

mouse button.
The primitive revolution form appears, showing the

workplane options as well as the Angle.
• Change the Angle to 180 and press OK.
The surface had been generated through an angle of

180 degrees.
To alter the physical shape of the surface of

revolution the original wireframe has to be altered.
One way to alter the wireframe is to use the stretch

command from the Edit toolbar.
• Click on Undo twice to return back to the original wireframe.
• Select Edit toolbar and open the Move/Copy menu.
• Select stretch object.

• Select the top half of the shape, by dragging a box over it as shown.
• Enter 0 50 which will only move the selected parts 50mm in the Y,
stretching the back and inner wall.

The top half is dragged upwards and the

connecting geometry is stretched.
A new surface of revolution can be made

of only the inner feature by limiting the
initial composite curve using the start and
stop feature when tracing.
• Select the Curve menu and select Composite Curve.

• Select start point from the toolbar.
The cursor changes into two vertical bars like the Define start point icon. A circle will mark
the selected start point.
• Snap this to the bottom right corner end of the wireframe.
• Select end point.
The cursor changes into two vertical bars, like the Define End point icon.
A circle will marks the selected end point.
• Snap this to the top right corner end of the model for the end point of the
composite curve as shown.
There are two options for the composite curve to be. To select the path, one of the wireframe
lines is selected.

• Select the inner vertical line.
There are two options to create a composite curve in this shape. By

selecting the inner geometry a composite curve is traced between
the two circles.
• Select Save and Eject on the composite curve toolbar.

• Select the Composite Curve.
• From the Surface menu select Surface of Revolution.
The outer surface is produced. This surface can be changed

by using the Edit facility from the primitive revolution form.
• Double click the surface to bring up the primitive revolution form.

• From the Sketch tab, select Edit Sketch.
• From the Surface/Curve editing toolbar, select Edit curve using
active dimensions. (pull down from edit curve in 3D)
PowerSHAPE undraws
the surface and creates
dimensions for the
wireframe. These
dimensions can be double
clicked and changed.

• Double Click on the text 15 dimension.
The dimension value form appears.
• Modify the value to be 35 and press OK.

• Double click the dimension value, 100 input a new value of value of 80,
and click OK.
• Select the Finish button and OK the form.
The surface is modified to suit the wireframe changes.
• Select File Save and then File Close.
Bottle Exercise
Using arcs, generate a bottle shape starting with the base.

• Select the Z-axis and Create a Workplane at 0.
• Generate two circles of radius 15 at 50 0 and -50 0.

• Generate two circles of radius 25 at 0 20 and 0 -20.

Tangent lines will join and trim these circles

together.
• Select the Line option and select the

single line mode.
• Move the mouse over each circle until it says 'Tangent' and click to form
the tangent lines.
The base of the bottle is complete and can now

be extruded.
Note: If the arc trimming does not appear in the correct place as shown.
Select the arc and grab hold of an end circle and drag it around to the end of
the line.
• Select all of the wireframe.

• Modify the length to 200mm.
The sidewalls of this bottle have now been generated.
The next stage is the creation of fill-in surfaces across the top and
base of the bottle form.

A quick way to generate composite curves that are flat on a plane is to hold down the Alt key
and click the geometry with the left mouse button.
• Hold down Alt and left mouse click on the top edge.
• Hold down Alt and left mouse click on the bottom edge.
• Select the top composite curve.
• From the Surface menu select the Surface Wizard.

• Create a Fill in Surface as before.
• Repeat for the bottom edge of the bottle.
The top and bottom surface have been created. To make

the wireframe for the bottle top easier to create, a new
workplane is generated.
• Select the top surface and select Create Workplane at top.
• Select the Y plane.
• Select a view down the Y Axis.

• Select all of the surfaces and select Blank (Ctrl + J).
• Create a continuous line from 10 to 0 0 15 and then to 10.
An arc will be created from the end of the line around an arc of 90
degrees to form the bottle top.
• From the Arc Menu select Arc through Centre.

• Enter a position of 0 0 15 and snap onto the start position.
Arcs can be modified dynamically by moving the ends

around the centre with the left mouse key.

• Drag a span of 90 degrees.

• Select all of the wireframe and select the Z plane.
• From the Surface menu select Surface of Revolution.
The bottle top surface is generated. The blanked items can be

displayed by using unblank.
• Select Ctrl + L (unblank).
• Select File Save As:-

D:\users\training\COURSEWORK\PowerSHAPE-Models\my-bottle


PowerSHAPE 6. Automatic Surfacing Wizard
6. Automatic Surfacing Wizard

Introduction
Several of the PowerSHAPE surface creation options have been included into an easy to
apply, Automatic Surfacing Wizard. If the user selects wireframe before opening the
wizard then the most likely surfacing method is selected ready to be previewed and/or
applied. If an alternative, valid surfacing method is required then the user can toggle to it by
opening the list of options and clicking on the downward pointing chevron.
Automatic Surfacing options covered as training examples in order of appearance include:-
Fill-In
From-Network
Drive-Curve
From Separate
Two Rails

6. Automatic Surfacing Wizard PowerSHAPE
Fill-In Surface
A Fill-in surface is usually created from one or more enclosed wireframes. It can also be
created from open ended, wireframes as well as Point data.
Example
• Create a wireframe, Rectangle of lines from the 0 datum with sides of
X50 and Y75.
• Create R 15 fillets at both of the top corners.
• Select all the wireframe entities.

• From the main toolbar select the Surface icon.
• In the left hand toolbar select the Automatic Surfacing option.
The most obvious option for the selected

wireframes, Fill-in will appear in the form.
• Check that Fill-In is the selected surface creation option and Apply.
A Fill-In surface will is patched inside the enclosed

wireframe.
• Select and Delete the Fill-in Surface.

• From the Main toolbar select the Workplane options.
• From the workplane toolbar select the Create a point option.

• In the command input box enter the following 5 co-ordinate
positions pressing the Return key after each one to accept:-

25 37.5 0
15 15 5
15 60 5
35 60 5
35 15 5
• Select all of the wireframe including the 5 points.

• From the main toolbar select the Surface icon.
• In the left hand toolbar select the Automatic Surfacing option.
The most obvious option for the selected

wireframes, Fill-in will appear in the form.
• Check that Fill-In is the selected surface creation option and Apply.
The Fill-in surface has blended through the selected

point data as well as the outside wireframe.
Die Example
A Fill in surface can also be made up from several wireframes. When a Fill-in surface is
generated, the composite curve is used to create the visible trimmed area within a surface.
• Close the existing model.

• Select File - Import and locate the wireframe model:-
D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\Fill-in_Die.dgk
A new Fill-in surface will be generated inside

the imported, rectangular wireframe and from
composite curves traced around the top edges
of the surface forms.

• With the Alt key held down, left mouse click the upper edge of each
surface form to create a new composite curve for each one.
• Select all the composite curves and right mouse click on one to open the
local menu.
• In the local menu select Delete dependencies (This will remove any
tangencies inherited from surface edges along which composite curves
have been traced).
• With all the composite curves selected, open the Automatic Surfacing
form.
• Select Fill-in as the surfacing Method before selecting Apply.

The trimmed upper surface

appears as shown left.
• From the main pulldown menus select File - Save As, and store the
psmodel as:-
D:\users\training\COURSEWORK\PowerSHAPE-Models\Fill_in_example2
• From the main pulldown menus select File Close.
3D Fill-in Surface Example

A composite curve does not have to be created in advance as it can be generated within the
Fill-in surface form.

• Start a single line at 50 0 0 and input an end point incrementally using
the coordinates -20 0 20.
• Select the Z plane.
• Select the line. Select the wireframe view.
• From the surface menu select Surface of Revolution.
A conical surface has been created.

• Open the Surface Wizard.
• Select the CompCurve Creator option and trace a composite curve

around the top edge of the surface.
• Press Save and Eject.
Once the Composite Curve is completed the Wizard recognises that the curve is suitable for
producing a Fill-In Surface. The surface creation form is updated and a preview of the
surface is displayed. In this case the surface produced is flat but in many cases the user
requires a new surface that is tangential to the surrounding surfaces.
• Switch Tangent to Surface(s) on (ticked).

The surface previewed is tangential to the

surrounding surface.
• Apply and OK the form.

• Select OK to the fill in surface form.
• Select the Shaded view.
The domed Fill_in surface appears as

shown left.

• Select No in response to Do you wish to save the changes….
Pump Project Example….continued.

Using the pump example a Fill in Surface will be used as a flat base for the extruded side.
• Open the model pump-project2.

• Generate a composite curve around the base of the extrusion.
• Make a Fill-in surface from the selected composite curve.
• Select File
Save and then File Close.

Drive-Curve Surface
spine
A Drive Curve surface consists of a spine curve along

which section curves, are aligned perpendicular relative
section to the spine points. The illustration left shows a Drive
Curve Surface using a single section curve running
along the whole length of the Drive Curve.
Minimum requirement is one sectional wireframe
positioned anywhere along the single Drive Curve.
sections
The illustration right shows a closed
Drive Curve Surface with 2 different
shaped section curves strategically
attached to the spine points.
spine
Racket Example
The first step is to create the wireframe for the drive curve of the tennis racket.
• Create a workplane at 0 and then construct the following wireframe.
This shape will form the single drive

curve along which the surface will be
generated.
Wireframe sections will be defined,

in this case, perpendicular to and at
strategic positions along the drive
curve.
Upper Section

• Create a workplane and position it at the midpoint at the top of the racket.
• Zoom into the area around the new workplane.

• Select the X principle plane.
• Generate three circles, circle 1, radius 8 at Z 0, circles 2 and 3, radius 4
at 0 0 10 and 0 0 –10.
These will be joined by using 4 fillet arcs of radius 25. During this process
it will be advised to split the existing circle of radius 8 into 2 separate arcs,
if the default automatic trimming is active.
• Fillet the circles with an arc of radius 25.
This will be the main centre section of the racket.
The other sections are circles and they can be placed directly at the grip end,
without the need for another workplane.
• Select the Y principal plane.

• Generate two circles of radius 10 with their centres snapped to the end
of the lines.
The Drive Curve and each Cross

Section must be single entities before
the required Drive Curve surface can
be produced. The sections are already
single Full Arc entities but the Drive
Curve is a series of arcs/lines which
must first be made into a single
composite curve.

• Create a single composite curve out of the Drive Curve entities and mid
section entities.
• Select all three sections and the drive curve.
• From the surface menu select the surface wizard.
The surface wizard recognises that the

wireframe selection is suitable for
creating a drive curve surface and
changes the pull down menu accordingly.
A preview of the surface is also
displayed.
• Click OK.
This generates a surface with a changing

section from the first circle to the defined
section and then back to the last circle.
To maintain a particular cross section at a

position on the drive curve extra sections may
be added.
• Select and Delete only the surface.

• Select the composite curve section at the top of the racket and select the
Z principal plane.
• From the Edit Toolbar select Rotate object.
This opens the rotation toolbar
A circle and arrow is drawn around the centre of the selected

object. This is the rotation centre and can be dragged to the
required position.
Alternatively the option reposition the rotation option can be

used which attached the arrow and circle to the cursor for
positioning.

• Select reposition rotation axis.

• Click on the keypoint at the centre of the racket.
• Click the copy button, enter No. Copies as 1 and Angle as 90 and press
Return.
• Leave No. Copies as 1 and Angle as 180 and press Return.
Between these three shaped cross sections the

surface shape will remain the same.
• Press Select .
• Generate a Surface from drive curve using all five sections.
Note: The Drive Curve and

individual sectional,
wireframes must be single
entities such as Composite
Curves, a single line or
single arc.
• Select File Save As:-

D:\users\training\COURSEWORK\PowerSHAPE-Models\my-racket

Pump Project Example….continued

Using the pump example we can use the round and arc geometry to make a dome surface.
• Open the model:-

D:\users\training\Coursework\PowerSHAPE-Models pump-project2
• Switch on all Levels.
• Select the dome geometry and use Blank Except. (Ctrl + K).
Section
Drive Curve
• Create two Composite Curves, the first to represent the Drive Curve and
the second to represent the Section.
• Generate a Drive curve surface.
• Select and use the Right Mouse button menu to reverse the red
surface. Unblank (Ctrl + L).
The ribs across are going to be created using Drive Curve Surfaces.
Drive Curves
Sections
• Blank (Ctrl + K) everything apart from the wireframe shown.

• Select all of the drive curves and select Edit Convert Wireframe
to Composite Curve.
• Select all of the arcs and select Edit Convert Wireframe to
Composite Curve.

• Create individual Drive Curve surfaces from the composite curves,

using Apply on the form to keep it open until all are completed.
The new Drive Curve surfaces are as shown. It

is essential that the insides (red) face inwards so
that they are all set up ready to create Draft
surfaces in Chapter 7.
• Select and use the Right Mouse button menu to Reverse any red
coloured ‘inside’ surfaces
• Unblank (Ctrl + L).
The pump project can now be saved.
• Select File
Save and Select
File Close.
Surface From Separate Curves

If separate curves are selected the Automatic surfacing wizard will use create a surface
From Separate curves option.
The separate curves are defined across the surface (laterals), which are then linked with
curves of best fit along the surface (longitudinals).

Lateral Curve Example

• Create a workplane at 0.
• Create a continuous line from the workplane, 10mm in Y, 10mm in X,
and 10mm in -Y to produce the 'n-shape'.
This section will be the basic for the other sections so it will be
copied up the Z-axis as individual lines.
• Select the three lines.
• From the Edit toolbar select Move/Copy Object.
This opens the Move form.
• Enter 2 for the number of copies and the value of 0 0 5 in the position
window, giving you three sets of lines.
• Dismiss the form.
Each composite curve will be filleted

by a different radius.
• Make composite curves from each set of lines (Alt key and left click).
• Create a fillet radius of 1mm on the bottom curve.
• Create a fillet radius of 2mm on the middle curve.
• Create a fillet radius of 3mm on the top curve.
An additional two curves will be copied to produce a total of 5

curves.
• Select the lower composite curve and Move/Copy it up the Z-axis by

20mm.
• Select the second from bottom composite curve and copy it up the Z-
axis by 10mm.

All of the shapes have been turned into composite curves, ready for
surface generation. Each of the composite curves will be turned into
a lateral on the surface.
• Select all of the composite curves.
The Wizard analyses the selected

wireframe and selects the surface
type to be created as From
Separate
• OK the form.
The surface From Separate curves is as shown left.
• Select File Close and select No.


Using the pump example we can use the two curves to make a surface from laterals.

• Blank everything apart from the two swept curves required for the
defining the shape across the top face.
It is not necessary to make these into composite curves,

as they are both already single curve entities.
• Select both curves.

The Wizard analyses the selected wireframe

and selects the most likely surface type to be
created which in the case is From Separate.
• OK the form.
• Select Unblank.
The new surface is as shown. The upper

and sidewall surfaces now need to be
trimmed back to each other (Limit
selection).
Note: A more comprehensive range of

Limit selection options are covered in
Chapter 8.
• Select and Blank all of the wireframe.

• Select the new top Surface and in General Edits select the Limit
selection icon (as shown above right).

• Select the sidewall surface and (if required) keep clicking next solution
until the correct trimmed surface choice (shown below) appears before
closing the form.
The sidewall and top have been trimmed. It is

also required to trim the domed and upper
surfaces to each other.
• Select the new top surface and in General Edits (as before) open the
Limit selection options.
• Select the domed surface and (if required) keep clicking next solution
until the correct trimmed surface choice appears before closing the form.
The Upper and domed surfaces have been

trimmed back to each other.
• Select File Save and Select File Close.
Surface From-Network of Curves

A Surface from Network creates one or more 4 sided, surface patches over over a network
of wireframe. Surface definition will not occur on any open ended parts of wireframe that
extend beyond the network.

Surface Gap Example

The following example applies the, from Network - Automatic surfacing option to blend
across a gap in the model.

• Select File > Import, and select the model:-
D:\users\training\PowerSHAPE_data\psmodels_n_dgk\
network_example.dgk
• Select an ISO 1 view.
Gap to be filled in using Surface from

Network.
To fill the gap with a smooth surface additional wireframe curves will be created. By default
the tangencies of the existing surfaces will be inherited into composite curves defined along
exiting surface edges.
• From the Curves menu select Composite Curve.
• Select the Define Start Point

button then click on the key-
point on the corner of surface 1
as shown.
• Select this edge with the left mouse button to create the first part of the
Composite curve.
Note: the curve continues to the first branch point awaiting further interaction from the user.
• In the Composite Curve toolbar click the Backwards button once to

go back one span.

• Click on the opposite corner Key-point of Surface 2 with the left mouse
button as shown below.
• Check that the default Use tangents to create the curve is ticked before
Selecting Yes.
The composite curve jumps to the selected point while

maintaining the tangencies relative to both surfaces.
• Select the Save button on the Composite Curve form.

• Create a new composite curve along the three

remaining edges as shown.
When a composite curve is created along a surface edge it also

inherits the tangencies of the surface. These will be reproduced
by default if the curve is subsequently used to create a new
surface from appropriate Surface Wizard options.
Although enough wireframe is now available to create a Surface - from Network, a more
accurate alignment will be obtained if additional curves are created across the void.
• Select and Blank the last Composite Curve.

• Create a new composite curve along one of the intermediate curves on
the right hand surface and as before attempting to bridge the gap to the
corresponding curve on the left hand surface (as shown below).
Note: the end of the composite curve is

aligning to the surface edge and not as
required, along the intermediate curve!
• In the Composite Curve toolbar click the Backwards button once to

go back one span.


• Create another Composite Curve along the next surface curve on the
right hand surface.
• Create 2 composite curves along the corresponding surface curves on

the left hand surface as shown below.
• Select and Blank all surfaces on the model.
• From the Curves menu select Composite Curve.

• Select the Define Start Point button then click on the key-point at the
start of the existing composite curve as shown.
Start Point
• Click on the curve to include it as part of a new one and then click on the
continuation at the end of the corresponding curve, across the gap.
• With the Use tangent to create the curve ticked select Yes in the
Composite Curve Creation form (shown above).
• Repeat the last procedure using the other 2 intermediate curves.
• Delete the 2 curves that are

not part of the required surface
network.

• Select the remaining curves and from the surface menu select
surface wizard.
The wizard selects the most likely

option to create a surface from the
selected wireframe, which in this
case is from Network.
• Select OK.
• Select and right mouse click on the new central curve running down the
surface and in the local menu click on Free tangents and magnitudes to
provide a smoother transition.
The gap in the model has been filled in

with the new surface (shown in lighter
shade), which flows smoothly into the
adjoining surfaces.
• Close the model without saving.

Surface from Two Rails

A surface can be generated from a section, which is scaled along two drive rails, defining
the edge of the surface.
The section is scaled across corresponding points along the drive rails to generate the
surface. Drive rail pairs must contain the same number of points and can both if required
form a closed loop. The end points on an open section must be positioned exactly on the start
point of each drive rail. Both the section and the drive rails must be defined as composite
curves.
Surface from Two Rails Example

• Select File > Import and then select the model:-
D:\users\training\PowerSHAPE_data\psmodels_n_dgk\
two_rail_data.dgk.
• Double click on one of the drive rail curves to bring up the curve toolbar.
• Shift-select the other composite curve.
• Select show point labels.
Each drive rail must have the same direction and

number of points. The section curve will be scaled
in relation to the distance between the start and end
points and corresponding points on the two drive
rails.

• Select the top curve (10 points).

• From the curve toolbar, select Create a point.
The Insert point into curve form appears. For

this example the Parameter Value tab is used.
This enables the user to insert a point positioned
at a proportional distance between 2 existing ones.
For instance 5.5 is half way between points 5 & 6.
• Select the parameter tab and enter 5.5 and press Apply and then OK.
When adding each point, the curve is

renumbered and it is therefore easier to add
points from the last number backwards.
• Select the bottom curve (6 points).
• Select Reverse curve then Create a point

• Select the parameter tab and enter 4.5 and press Apply.
• Enter 3.5 and press Apply.
• Enter 2.5 and press Apply and then OK. Select both curves.
Each curve has the same number of points so

when the surface is generated it will align
smoothly.
• Select all of the composite curves.

This time the wizard recognises that a Two

Rails surface is the best choice for surface
creation.
The preview of the surface should appear as

in the picture to the left.
Note: The section height has scaled in

proportion to the distance between the drive
curves at each section position.
• Select the Advanced button from the bottom right of the form.
This form provides the user with more control

over the way in which the surface is defined
from the selected wireframes.
• Tick the option Maintain Depth and

Preview again.
This time the height has been maintained to

that of the original section.
• Select OK.
• Select and Delete the surface.

PowerSHAPE 7. Limit Selection
7. Limiting Selection
Limit Surface using a Surface as the Cutting Object
When the Limit selection option is applied with Surfaces they are trimmed back to their
common intersection. The Next Solution option enables the user to toggle through all
possible, alternative trim combinations. When a Surface has been included in the Limit
selection process, a Boundary is created and only the part of the surface either inside or
outside will be displayed. Several Surfaces can be limited with a single cutting object.
• Select Open new model.

• Create a Plane Primitive surface on the 0 datum of size X 50, Y 50.
• Create a Cylinder Primitive surface of Length 40 and Radius 5
positioned at Z-20.
The Cylinder will be limited by the Plane.
• Select the Plane surface (Cutting Object).
• Select the Edit Toolbar followed by Limit selection.
The limit selection toolbar

appears.
• Click anywhere on the top side of the Cylinder surface.
The Plane and Cylinder are

automatically trimmed back to their
common intersection.
Note; this is one of several solutions
the others being obtained by clicking
the Next Solution icon. When the
desired option appears, the user can
then exit the limit selection toolbar.

7. Limit Selection PowerSHAPE
• Repeatedly select Next Solution until the following trim combination

is obtained.
Note: If the lower half of the

Cylinder had been clicked during the
original selection process, then this
would have been the initial solution.
• Select Undo.
• Select the Plane surface as the Cutting Object and then Limit.
• Click on the icon to change to the ‘keep both’ option.
• Select the Cylinder surface.
When the keep both, icon is active

limit selection will split the
secondary surface selection to
become two surfaces one on each
side of the Cutting Object.
• Close the Limit selection form and select the lower Cylinder surface to
show that it is separate from the upper Cylinder surface.
• Select Undo.
• Select the Plane surface as the Cutting Object and then Limit.
• Click on the icon to switch off the ‘trim both’ option.

• Select the Cylinder surface.

When the ‘Trim both’, icon is

switched off the Cutting
Object (primary selection) is
not trimmed back to the
secondary selection.
Limit Surface using a Curve as the Cutting Object

A Wireframe geometry entity can also be used as the Cutting object as shown in the
following example.
• Close the existing model (no need to Save it).

• Select File - Import and locate the wireframe model:-
…..\PowerSHAPE_Data\psmodels_n_dgk\Limit2.dgk
The imported model consists of a component made up of 6 separated surfaces along with
some wireframe defining the 2D trimming requirements.

• Right mouse click on the workplane (1) located at the base of the
component and in the local menu, tick both Active and Master.
Workplane (1) will default as the

Active coordinate system if
another workplane is
deactivated.
If a workplane is not assigned as
the Master then the (invisible)
World coordinate system is the
default.
• To the lower left of the graphics area select X as the operational direction.
• Pre-Select all Surfaces and the Composite Curve aligned on to the left on
the above illustration.
• From the main toolbar, select Curve and then Curve projection
to open the form as shown below.
Due to the pre-selection of the surfaces and composite curve, the form has defaulted with
the option Through surface/solid/component.
• Select OK to apply the Curve Projection option to create the new split,
composite curve as shown in the above right view.
• To the lower left of the graphics area select Z as the operational direction.

• Select the new split line, composite curve and then, in general edits
select the Limit selection option.
Note:-The curve is the cutting object.
• Select all the surfaces and if required, click next solution to produce a
trim retaining the parts of the surfaces above the split curve.
Limit Surface using a Workplane as the cutting object
A Workplane can also be used as the Cutting object as shown in the following example.
• Activate and select, workplane (2) and in general edits select the
Limit selection option.
Note:-The workplane is the cutting object.
• Select all the surfaces and if required, click next solution to produce a
trim retaining the parts of the surfaces below the workplane (-Z).

• Close the limit selection toolbar by clicking the cross at the top right
corner.
• Drive a new composite curve around the upper edge of the surfaces.
Exercise
• Create a flat Fill-in surface (Tangent to surface unticked) within the upper
Composite Curve and a 3D Fill-in surface within the existing lower split,
Composite Curve.

PowerSHAPE 8. Advanced Surfaces
8. Advanced Surfaces
Introduction
The Advanced Surfaces options are located in the Surfacing toolbar after the Automatic
Surfacing Wizard, Primitives, Revolution, and Extrusion icons.
The Advanced Surfaces options shown horizontally above include from left to right:-
Bead, Patch, Draft, Split, Extension, Fillet, Blend, and Wrap Triangles.
The above options displayed in bold print are covered in the following chapter.
Fillet Surfaces
PowerSHAPE will create both, fixed or variable radius Fillets between 2 or more surfaces.
A fillet surface is best described as the developed outside contour of a ball if rolled between
the surfaces. Where the ball makes contact defines the outer edges of the fillet to where, by
default the original surfaces are trimmed back to the fillet edge. It is also possible to create a
fillet between a composite curve and a selection of surfaces.
Before Filleting After Filleting
PowerSHAPE will create concave fillets running from the outside (User defined colour
side) or convex fillets from the inside, (Red side) of the host surfaces. The concave filleting
direction for each surface is marked by an arrow, which if clicked will reverse the surface
causing a concave fillet to run from the other side. Otherwise the convex option is applied.
Concave Convex

8. Advanced Surfaces PowerSHAPE
Basic Fillet Example

This example demonstrates the basic filleting options between 2 surfaces.
• Create a Plane Primitive of length 100 and width 100 at 0 0 0.

• Create a Cone Primitive of base radius 30, top radius 15 and length 50 at
0 0 0.
• Right click over the cone and select Convert Surface.
A selected Power Surface shows

more information.
The small arrow points outwards

from the surface, indicating that this is
the outside edge of the surface. The
large arrow indicates the operational
direction for editing surface points
(Note; the large arrow does not affect
Filleting).
Another way to show the inside and outside of the surface is to shade the model. By default
PowerSHAPE displays the outside of surfaces as the user defined or default, material
colour (Gold in this case) and the inside as Red.
• Select Shaded view.
Both surfaces must be shaded (Gold in

this case) on the outside. If not then,
right mouse click on any red surface
and select Reverse from the local
menu.
• Select both surfaces and select the Wireframe View.
• From the Surface menu select Fillet Surface.
Once this option has been selected, the Filleting form appears with a pre-defined, Concave,
Fillet Radius.

The surface direction arrows are displayed

which if clicked will turn the surface inside
out. The small arrow points away from the
outside (user defined colour) face of surface.
• Select Preview on the Fillet Surface form.
The Fillet track is displayed as the centreline

of the rolling ball as it runs along the
selected Surfaces. If it is acceptable then
select OK, otherwise enter alternative values
and select Preview again until the end result
is acceptable.
• Select OK on the form.
The Fillet track form appears.
The single drive curve now turns yellow

to show that it is selected. As there is
only one track available in this case, just
select OK to create the Fillet.
For examples where more than one track
exists, none of them will be pre-selected.
Select each one and Apply in turn, until
all required fillets have been created.
Then select OK to finish thus ignoring
any further tracks that are not required.
• Select Apply followed by OK in the form.

The fillet surface is produced and the cone and

plane trimmed back to the fillet.
• Create a Plane Primitive at 0 0 40 with a length and width of 80.

• Double click on the plane and in the plane form select a Y-Twist angle of
10 degrees.
This top surface will be filleted to the cone, but this

time the fillet will be on the inside of the cone.
• Select the Cone and the angled plane surface.

• Enter a fillet radius of 3mm, select Convex and press Preview.
• Select OK (fillet route) and then OK (fillet surface).
The fillet is produced trimming back the top of the

cone and the plane.
Fillets can also be produced with several surfaces.

• Select X as the operational axis and create a Cylinder Primitive at –30 0

20.
• Change the radius to 6, length to 60 and rotate it with an X-Twist of –15.
• Select and reverse the surface (red on outside).
• Select all of the surfaces apart from the lower fillet and plane.

• Enter a fillet radius of 2mm, select Convex and press Preview.
The available fillet tracks are displayed.

The cylinder needed to be reversed to
control where the fillet appeared.
• Select OK.
In this case, PowerSHAPE has identified two complete

fillet tracks along with a few small, fragmented ones.
As PowerSHAPE allows you to specify which track
you wish to use you can use as little or as many tracks
as required. To elliminate unwanted tracks from
appearing it is possible to separate the surfaces into
two groups as a Primary and Secondary Selection.
Fillet tracks will only be created between the two
separate groups and not surfaces within the same group.
• Select the first fillet track nearest the plane (lowest one), which turns
yellow.
• Select Apply.
The first fillet is produced and then PowerSHAPE

waits for another fillet track to be selected or for the
form to be closed (OK).

• Select the second track nearest the top and press Apply and then OK.
All of the other tracks are ignored and the surface is

limited back to the fillets. By reversing the cylinder, the
fillets are produced inside, rather than outside.
Filleting using Primary and Secondary sets of Surfaces

The Filleting option will check every selected surface to find all the potential tracks. Where
there are a large number of surfaces involved, this could take some time, and it may be
awkward to identify the required fillet tracks.
By using the Secondary Selection option, it is possible to register the two separate sets of
surfaces for the fillet to run between. With this option, the first pre-selection of surfaces
(Yellow) will be registered to the Primary (ticked) set. If the Secondary box is then ticked,
any further surface selection will be registered as the Secondary set of surfaces (Pink).
PowerSHAPE will only attempt to create the fillet tracks between the two separate groups.
• Select the lower plane and fillet and delete them.

• Select the X plane and create a Plane Primitive at 0 0 20 with a width of
110 and a length of 60.
• Change the direction of the plane, if required, so the gold side is on the X+
direction as shown.
This set of selected surfaces will become the

secondary set. The fillet routes are calculated only for
the intersection between the primary and secondary
surfaces. This results in a quicker calculation for the
fillet routes. As less routes are produced it is also
easier to select the right ones.
• Drag a box over the surfaces on the left as indicated.

• Select fillet surface.

• Set a radius of 2mm and Convex.
• Select the Plane surface.
The selected surface turns pink and the secondary surface option is ticked.
• Select OK.
• Select the first track and then select the Apply button.
• Select the last track and then select the Apply button.
The fillets are produced and most of the other surfaces

have been trimmed back.
• Delete this remaining surface.
• Limit the bottom of the plane back to

complete the model.
Hint: create a line from the bottom ends of the cone. Limit
the surface to the new wireframe.
• Select File
Close and then No.

Further Filleting using Primary and Secondary sets of Surfaces

The following example uses a simple tap design to demonstrate fillet creation between a
Primary and Secondary set of surfaces.

• Generate the following wireframe on the XY Plane.
• Select the Y plane and create a surface of revolution from the above
wireframe profile.
• Rotate the new Surface, 90 degrees about the X Axis to align it to the Z
direction.
• Create a workplane at 0 0 44.
• Generate a Sphere Primitive of radius 7.5 at the new workplane.
• Select the Workplane then from the edit toolbar, select Limit.
• Select the Primitive Sphere and if necessary select Next Solution to
retain the top half before closing the form.
The Primitive Sphere is limited back to the workplane

with the top half being retained. Limiting occurs in the
direction of the active Principal Plane.


• Create the following Wireframe geometry for the tap lever shape around
the workplane.
• Create a surface of revolution around the X Principal Plane.

• Rotate and copy this surface 3 times by 90 degrees around the Z
Principal Plane to make the four levers.
The four arms need to be filleted to the central section. Make sure that when shaded, all of the
surfaces are gold. We do not want to fillet each arm to each other or waste time generating
the route so we are going to use the Secondary surfaces option.
• Select both the shaft and sphere surfaces.
• Select Fillet surface.

• Select the four lever surfaces.
On the form the Secondary option

becomes ticked.

• Enter a Concave Fillet of Radius 2.

• Press OK.
• Select the fillet tracks in turn and press OK to finish the model.
• Select File
Close and then No.
Variable Radius Fillets

Variable radius fillets can be created along the fillet track using the mouse to identify KEY
points or by applying specialist options to position the fillet arcs either by Parametric,
Relative or Absolute values.
Example

• Create a Workplane at 0.
• Create two circles with radius 8.5 at X 30 and X -30.
• Create an arc through three points of radius 50 either side of the two
circles to form the following shape.
• Create a Composite Curve from the wireframe.

• Generate a Surface Extrusion.
• Change the Length to 60 and from Sketch, select Create a Copy of the
Sketch.

When an Extrusion surface is created the

default option causes the wireframe used to be
deleted. This default status can be altered to
retain wireframes by ticking a Keep
Wireframes box found in:-
Tools - Options - Object – Surfaces
To retrospectively, retrieve the wireframe used,

select the Edit tab followed by Create a copy of
the sketch option. This returns a copy of the
original composite curve to be used to create a
Fill in surface at the base of the Extrusion.
• Press OK.
• Select the composite curve and create a Fill in surface.
• Reverse the surface so the red side is facing up the Z axis.
• Delete the composite curve.
• Select both surfaces.
• From the surface menu, select Fillet surface.

• Input a fillet radius of 3 select Convex and press OK.
• Select a view down Z.
The fillet track is displayed with circles showing KEY points that can be snapped to using the
mouse. By snapping at these KEY points an arc of the initial radius is created. The value of
this radius can be modified in the Arc Radius area of the form.
• Snap to each of the 6 circles when the word KEY appears.

• Create 6 arcs by snapping KEY points around the fillet route starting at the
right and working your way around clockwise as shown below.
A radius appears for each point and this becomes numbered in

the current arc part of the form. Individual arcs can be selected
from this form or by manually clicking on them. The radius can
be changed in the form or dragged manually.

New points to place radii on the fillet track can be entered by clicking on the track or by
entering a parameter position. To enter a parameter position, select the nearest
fillet and, check the number on the form in the Current Arc box, work out the
number required, change the ABS to PAR, enter the value such as 4.5 and press Return.
• Insert two new radii between the two at each side, as shown.
While the form is active the values for individual

fillet arcs can be changed or deleted if required.
The radius will progressively change between the

two arcs assigned with different values
• Select the new arcs in turn and change the radius to 5mm.
• Select the arcs (in turn) either side of the new larger arcs and select
Delete off the form (4 arcs in total).
When there is an arc the fillet value is fixed at that

point. If the next radius value is different the
radius will change smoothly along the distance.
• Select Apply.
The variable radius fillet has been produced.
• Select File
Close and then No.

Creating a Fillet from a Surface to a Composite Curve

A Composite Curve can be selected instead of Surface data as the Secondary selection in
the Fillet Surface form. The direction of the composite curve will dictate which side the
fillet appears. The Composite Curve can be reversed (while the form is active) by clicking
on the purple direction arrow located at one of the ends.
• From the main menu select File > Import and select the model:-
D:\users\training\PowerSHAPE_data/psmodels_n_dgk\
Fillet-Surface2Curve.dgk
It is required to run a 20 Radius, Fillet from the formed top edge onto the lower surface of
the recess.
• Left click near the left hand end of the formed top edge of the recess
while the Alt key is depressed (This is a short cut to create a Composite
Curve).
• Select the lower recess, Surface and Composite Curve before selecting
Blank Except (Ctrl K).
• Select the Surface, followed by the Fillet Surface option.

• Insert Fillet Radius 20 in the form

• Click on the Composite Curve to register it as the Secondary filleting
entity.
• Select Preview to display the Fillet Surface that would occur with the
current settings
The preview Fillet is displayed on the correct side of the curve. If it were required to be on
the other side then the user would have to click on the arrow head at the left hand end of the
Composite Curve.
• Select OK to accept the Preview Fillet Surface.
• Select OK to bypass the Variable fillet options.

• Select File
Close and then No.

Bead Surfaces
A Bead Surface is defined by specifying a Length and a Bulge across a drive curve. They
can be used to quickly form decorative features on products or more functional features such
as ‘Draw Beads’ on press tools.
Drive Curve
Bead Example
This example creates a curve from manually input points, which are then used to generate a
bead surface.
• From the workplanes menu, input a Single Workplane at 0.
• From the Curve Menu select Create a Bezier Curve.
• In the Data Input box type in (and press the return key) the following 5
absolute, coordinate positions.
-50
abs 0 30
abs 65
abs 0 -30
abs -50
The above closed Bezier Curve is produced.
• From the surface menu select Create a bead surface.

Each Point displayed in the Bead Surface

form is relative to a position along the curve
length. It is these positions that can then have
Bulge and Length applied to them to create
the surface.
• Select Point 1 from the list and set Length 4 and Bulge 2.
• Select Preview.
The surface is previewed with a

Bead Length of 4 and Bulge of 2
through all points. The form is
aligned with the open end along the
normal (vertical in this case) to the
curve.
• Set the Direction to Radial and select Preview.

The surface is previewed with a radial

form along the length of the curve.
The form is aligned with the open end
across the base.
Additional points can be inserted from within the form along the curve for a more specific
surface definition.
• Insert a point halfway between the existing points 2 and 3 by entering 2.5
and pressing Return.
• Insert a point halfway between 4 and 5 using a value of 4.5 and pressing
Return.
New points have been created along

the curve and the curve
renumbered.
Length and Bulge can be modified
at these points.
• Delete any values remaining in the Insert field box.

• Select OK to create the surface.
The surface is created with a varying

section along the Bead form.
• Select File Close and No to ‘Do you wish to save the changes’.

Split Surfaces
Split Surfaces are an essential feature required in applications such as mould tools. The
component wall thickness is formed by the gap between the separate Punch and Die
Impression Blocks. The edges of the plastic component are formed by a Split Surface
common to both halves, accurately bedding out when the Punch and Die Impressions are
pushed together.
Die - Impression Block Split Surfaces Punch - Impression Block
Split Surfaces are generated from split lines previously created around a component model.
The split line is the curve around the model where the surface passes through the vertical.
In areas where the surface model is vertical or does not

reach the vertical angle it will be necessary for the user to
manually construct a suitable curve. This is not always
evident until after the Create a Draft Curve with the
Draft Angle value as 0 is applied. These areas will then be
identifiable as gaps along the Draft Curve.
In the following example the Split Line will be obtained by

using the Create a Draft Curve option to obtain a curve
for the natural split. This in turn will then be used with the
Split Surface options.
Split Surface Example 1

In this example a primitive Cylinder will be modified to produce a simple part. A split line
for the part will be calculated for the surfaces and a new split surface will be made.

• Set the X as the active Principal Plane.
• Create a Cylinder Primitive at 0 with a radius of 30mm, and length
100mm.
• Scale the surface by 0.3 in the Z-axis (Lock the X & Y values).

• Right mouse click on the surface and from the local menu select Convert
Surface to create a Power Surface.
The surface will undergo further

modifications to make it more
interesting to illustrate split surface
creation.
Moving lateral 2 upwards would re-

float the longitudinals giving them a
straight
To give a curved flow along the surface a spine will be added. A spine is a curve which can
be used to control the alignment of sections on a surface. A spine will have a spine point for
each section along the surface. If a spine point is moved the corresponding section will
move with it retaining the same tangency, if ‘Apply smoothing to point edits’ is switched
off.
• Double click the surface to bring up the surface edit toolbar.
• From the surface edit toolbar select Create Spine (located in the
Add curve options).
This will create a spine running through the cross sections of the surface, shown as a dotted
line. This spine can be deleted without affecting the surface.
• Select Spine Point 2 on the spine by left clicking on it.

• In the Surface/Curves editing toolbar, switch Off ‘Apply smoothing to
point edits’ (It may already be switched Off).
ON OFF
• With Spine Point 2 selected type 0 0 10 in the Data Input window and
both the Spine Point and corresponding Section will move up Z by 10mm.
The Tangent angle along the surface will remain the same, as shown in the
next illustration

• Set the Y Principal plane and rotate the surface by -10 degrees.
• Generate a composite curve for each end lateral.
• Right click over each composite curve in turn and select Delete
Dependencies.
When composite curves are traced from surfaces, the curve remembers the tangency of the
underlying surfaces. This means that when a further surface is generated from these
composite curves they match perfectly. To remove that relationship, delete dependencies is
used on the composite curve before a new surface is generated.
• Create a Fill-in surface for each composite curve.

• Delete the composite curves and select the Z principal plane.
• Reverse any surface to have the gold outside.
• Create a Convex Fillet on each end of Radius 2mm.
The model now is completed but before a split surface can be generated the appropriate Split
Curve must first be created.
For a Draft Curve suitable for split surface creation, the Z principal plane must be set.
For a draft angle of 0 degrees (as marked

by a cross) it will appear exactly half way
down the sphere (equator).
For a positive angle of 25 degrees then the
draft curve appears on the upper half of the
sphere as indicated.
For a negative angle of –10 degrees the
draft curve appears on the lower half of the
sphere.

• Select all Surfaces.
• From the Curve menu select Draft Curve.
The draft angle is specified in this form. If the

composite curve option is ticked PowerSHAPE will
generate composite curves of the natural draft,
otherwise ordinary curves are generated.
• Enter a Draft Angle of 0, tick Create Composite curves and OK.

• Select the composite curve just generated and Blank Except (Ctrl + K).
The split surface can now be created from this composite curve.
• From the Surfaces menu, select Split Surface.
The Split Surface form appears and two arrows appear on the split line.
The blue arrow indicates the direction in which the split surface will flow from the curve
The brown arrow indicates the direction in which any optional Draft Angle will be applied.

• Click on the arrows if necessary to change the Split Surface directions to

be as shown in the illustration below.
• Enter an offset value of 40 and select Preview.
A 40mm wide split surface is previewed tangentially outwards form the curve.
It is likely that the new split surface will contain localised ripples, especially where there is a
group of surface curves that are close together. This is not an acceptable condition to achieve
a satisfactory bed-out between the 2 halves of a mould, and as a result steps must be taken to
prevent or edit out the ripples to achieve a smooth surface form.
• Select the Smooth Surface option and then press Preview and then OK.
This produces a smoother surface on the outside edge by allowing the surface curves to
rotate away from the original perpendicular direction from the draft curve. Although this
will help to improve the smoothness the split surface may still benefit further from further
editing, This would be carried out retrospectively by moving/inputting points,
removing/inputting curves, and editing tangent angles.
• Cancel the form.

• Select Unblank and Delete the Surfaces and Workplane.

Split Surface Example 2

Split_surf_example.dgk ’.
The file contains a surface model and a

predefined Composite Curve, which will
be used to generate the split surface.
• Select the Solid and then Blank (Ctrl J).

• From the surfaces menu select split surface.
On the Split Surface Form:

• Enter an offset distance of 50 and set the horizontal arrow to point
outwards from the surface (if not already the case).
• Set the split direction to Radially Out and press Preview.
The Surface Curves are converging in

4 places due to the shape of the draft
curve and the in-out length of the split
surface. One way of improving this is
to use the Align to Axis option. This
will align appropriate sections of the
split surface along the X or Y
directions.
• Set the ‘split direction’ option as ‘Align to axes’ and press Preview.

The split surface is now aligned to the X & Y

axes giving an overall smoother split
surface. Further improvements can be made
to the surface by using a combination of
Radially out and Aligned to axes.
• Select the Advanced option from the form.
The Split Segments form appears.
• Select clear to remove any

existing segments from the curve.
• Using the mouse click at breakpoints at the positions indicated.

• Untick the Insert Breakpoints box to toggle the curve segments option.
• Select segment 1 from the dropdown list and set the Split Direction to
Radial.
Segment 1 will indicate a radial split.
• Select segment 3 from the dropdown list and set the direction to radial.
• Repeat the process for segments 5 and 7.

• Select OK to close the form.
• Select Preview from the split surface form.

The Preview indicates a combination of radial and align to

axis.
Do NOT cancel the form
Automatic Stepped Split Surfaces

Stepped Split Surfaces can be applied to reduce the extent of the ‘shut out’ required to
ensure correct matching of the two halves of a mould. Split Surfaces can be defined with: -
1. A Land Distance, which is the length from the outer edge of the part to the ‘step’
2. An Angle of inclination for the step.
3. A Total Distance across the split surface.
In addition the user may specify different radii from the joins between the various segments,
or use chamfers.
• Select the Stepped Split Surface option.
The form allows values to be defined for the

stepped split.
• Enter the values in the form (as

shown left) and press OK.
The Split Surface is produced with the

defined step. An impression block will be
created to be trimmed back to the split
surface.

• Create a Rectangle from -60 -60 -60 of width 120 and length 120.
• Select Tools
Options, Object and then Lines.
Chamfers are created from the Default

Creation Mode setting in the option form. If
required, a chamfer can be retrospectively
edited both, dimensionally or as defined by any
of the 3 available Creation Modes.
• Set the Chamfer Distance to 10 and press OK.
• From the line menu select create a chamfer and click each
corner in turn.
• Generate a composite curve.
The curve will be used to generate the side walls of

the block.
• Select the lower composite curve and create a Fill-in surface.

• Select the composite curve and create a surface of Extrusion with a
Length of 80.
The sidewalls will be trimmed back to the split surface as shown above.

• From Edits Limit the side walls to the Split Surface.

• Select Unblank (Ctrl L).
The basic Impression block design is complete. However, in the model shown above the
handle solid currently includes the whole of the plastic component and not just the Punch
half. To do this, the Solid must now be converted to surfaces and the relevant punch and die
components separated on to 2 separate Levels. The Die components can then easily be
separated from the Punch -Impression block.
Introduction to Levels
Levels provide the user with a ‘one click’ method to temporarily remove groups of entities
from being displayed in PowerSHAPE without deleting them. It is easier and more
permanent than Blanking as the data concerned is previously assigned to a Level by the user.
It is easy to assign entities to a different Level if required. Imported models will often
include data that is pre-assigned to more than one Level.
Note: A more detailed example on Levels is found in Chapter 11 – Model Analysis.
The original component is a Solid model which must first be converted to surfaces if it is to
be separated into the relevant punch and die entities.
• Left click on the Solid and from the Solid Wizard select Convert selected
solids to surfaces.
• Open the Level form by selecting located to the bottom left of the
graphics area.

• In the Level form below name Level 6 as Punch and Level 7 as Die.
• Separate the Punch and Die models and assign them to Levels 6 and 7
respectively (eg select the Punch surfaces and middle mouse click on
the Level 6 icon to the bottom left of the graphics area and repeat for the
Die surfaces, this time assigning them to Level 7).
• Left mouse click on the Level 7 icon to switch Level 7 (Die) off.
The Die components (Level 7) are no longer

displayed leaving only the Punch form
(Level 6) as shown left.
Note: The newly created split and sidewall
surfaces are assigned to the default creation
Level 0.
Generating a Split Surface does not automatically trim the model. A piece of software has
been included in PowerSHAPE called Die Wizard. The Die Wizard uses the Active Solid
and automates the Split Surface definition and creation of the separate Punch and Die
inserts. This is covered later in Chapter 15.
• Select File
Close and then No.

Draft Surfaces
A Draft Surface is created, either from a Composite Curve or from one or more Surfaces.
Draft surfaces. A Draft Surface is projected relative to the active Principle Axis, either
onto the 0 plane, or onto one or more additional Power Surfaces, selected after the original
data has been taken into the open Draft Surface creation form.
The Draft Surface is generated

tangentially from the original surface
dependent upon the angle selected, similar
to the Draft Curve command.
Where the split line is generated with an angle above

or below 0 degrees, the resultant split surface edges
on both the top and bottom may be miss-matched.
PowerSHAPE increases the lower draft angle so the
split surfaces edges match as shown.
Draft Surfaces from Composite Curves Example

• From the Arc menu create a Three point arc using the
following co-ordinates:
-15 10 4
-15 -10 10
-15 0 8
• Create an extruded surface along the X-axis of length of 50mm.
This extruded surface will be used to project a draft

surface on, later in this example.

• Convert the surface (right click over it and select Convert Surface).
• Blank the surface and select a view from the top.
• Select the Z principal plane.
• Generate the following wireframe.
This section will be used to generate a

Draft Surface.
• Create a composite curve and Move up in Z by 20mm.

• Select Unblank (Ctrl + L).
• Ensure the composite curve is selected.
• From the Surface menu select Draft Surface.
The Draft Surface form appears.
The Draft Angle box allows the user to specify the taper angle of the surface to be produced.
As with split surfaces, the direction in which the surface is created is determined by the two
arrows displayed on the composite curve or surface selection.
• Set the Draft Angle to 2 degrees.

• Change the arrows by clicking on them so they point down and outwards.
• Select Preview.

The draft surface is generated and

projected onto the XY plane of the
active workplane.
• Select the extruded surface.
When selected the surface will appear pink, and the Split Surface option on the Draft Surface
form will change to Project onto Selected Surface.
• Set the Draft Angle to 20 degrees, and set the projection arrows to
inwards and downwards.
• Select Preview.
The draft surface is

automatically
trimmed to the lower
curved surface.

Draft Surfaces from Existing Surfaces

Draft surfaces can be created tangential to existing surfaces.
• Create a Primitive Sphere of radius 4 at X18 Y0 Z20.

• Right click over the Sphere and select Convert Surface.
• Select the Sphere.

• Enter a draft angle of 10 degrees.
• With the arrow pointing downwards as shown select Preview.
The draft surface that would be

produced is displayed.
• Select the Extruded surface and then press Preview.
A new draft surface that project onto

the curved surface is generated.
• Select Apply and Dismiss the form.

Variable Draft
There is the ability to generate a variable draft surface from a selected profile. The variable
draft surface may not be always tangential to the original surface, as it has to generate the
draft from a fixed defined profile.

• Select the extruded surface and make sure that the arrows are pointing
down and out.
• Enter a Draft Angle of 3 and tick Variable.
• Select Apply.
The variable draft form appears. This is an

interactive command where lines to display the
draft surface are generated by clicking on the draft
curve. The draft angle is changed at these lines.
• Select a View from Top (down Z).
We will create a variable draft of 5 degrees along the

sides and 6 degrees around the ends.
• Click 8 points around the draft curve as shown using the intelligent cursor
to snap onto End, Key and Mid Points.
You can change the draft angle for each of the

numbered draft lines on the form.

• Set the left hand end projection lines to 6 degrees.

• Select Interpolation as Smooth select Preview and OK.
The Draft Surface is shown.
• Close the model without saving.

Generate a draft surfaces for each of the ribs and then fillet the model together.
• Open the ongoing model:- pump-project2.

• Select and Blank all wireframe.
• Select all of the rib surfaces making sure that they all shaded with the
outside colour displayed on the outside, and generate a Draft Surface of 3
degrees for each onto the datum level.
Fillets can now be generated

around the base of the fillets and
domed form.
• Blank Except the draft surfaces, the dome and the top surface.
• Generate a fillet radius of 1 mm by selecting all the surfaces shown.

• Select Unblank and shade the finished model.
• Save and then Close the model.

Surface Extension
A Surface Extension can only be created from a Composite Curve that has been driven
along, and is still in contact with, the edge of one or more Surfaces. This causes the
Composite Curve to inherit the tangencies of the Surfaces which will then control the
directional flow of the Surface Extension. A typical application for the Surface Extension is
in the creation of Electrodes or Slides which must extend tangentially, outwards from the
main, tool model.
Electrode Example
The imported model of a punch insert will be used to illustrate the application of Surface
Extension as the main option to create an Electrode model.
InteriorTrimPUNCH.dgk ’.
• Activate the Workplane named datum (This re-orientates the model in

the correct tooling alignment).
• Zoom into the rib area and Blank all surfaces outside the rib detail.
• Drive a Composite Curve around the top edge of the rib detail.
The Composite Curve inherits the tangencies from the

host Surfaces. For this reason it is essential that the actual
rib recess surfaces are used and not the main body
surfaces when creating the Composite Curve.

• With the Composite Curve still selected, from the Surfaces Toolbar, click
on the Surface Extension icon.
• In the Surface Extension form, select Along Principle Axis and enter
Distance 35 before selecting Preview for a view of the proposed Surface
Extension.
• Select the circular fill-in surface at the bottom of the rib form and create a
Workplane at centre of selection.
• Name the new Active workplane as Electrode.
• Create a Temporary Workplane at 0 0 40 (relative to the currently

Active workplane named Electrode).
• With the new temporary workplane Active select the general edits
toolbar and click on Limit Selection .

• With the Limit selection form open click on the upper part (above the
temporary workplane) of the new extension surface to trim it back.
• Create a Primitive Cylinder surface of Rad 40 and Length 25 from the

top of the extension surface and central to the circular fill-in surface at
the bottom of the rib form.
• Create composite curves around the top and bottom edges of the
Primitive cylinder and use the Automatic Surfacing Wizard to create
Fill -in surfaces for each one in turn.


PowerSHAPE 9. Editing Power Surfaces
9. Editing Power Surfaces

The following chapter uses a design exercise as the platform to illustrate some of the
comprehensive editing options available to Power Surfaces.
Food Container Design Example

The project will start by importing the model shown below left and will progress to the
finished outer form of the food container shown below right.
• Import the pre-defined CAD data located in:-

D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\
SurfaceEditStart.dgk
• Save the model to:-

D:\users\training\COURSEWORK\PowerSHAPE-Models\FoodContainer
Conversion of primitive to Power Surface

• Right mouse click on the Primitive Torus Surface before selecting Blank
Except in the local menu.
The Surface is a Primitive in which an editing form appears in which the options purely
apply to the dimensional values of a Torus.
Before it is possible to make changes to the actual shape the torus must first be converted to a
Power Surface.

9. Editing Power Surfaces PowerSHAPE
• Right mouse click on the surface again and in the local menu select
convert surface.
Depending on the settings the surface will either convert to a NURBS surface (default) or
directly to a Power Surface.
NURBS surfaces still exhibit limited editing capability but are more effective at initially
defining awkward shapes, which explains why they are applied as the default option. If a
NURBS surface is selected with the right mouse and modify selected in the local menu the
above toolbar appears and a framework appears around the surface. Note the fact that only a
few of the editing options are available (not greyed out!) in the toolbar.
• Right mouse click on the surface again and in the local menu select
Convert Surface.
The NURBS surface will be

converted to a Power Surface.
Note the fact that this time all of
the surface editing, options are
active in the toolbar.

• Select a View From Top.
Dynamic editing of a surface curve
First Second
Two additional surface curves are to be added aligned to the end points of the fillet radius
along the route of the lip (as identified on the First and Second construction lines). Any
original surface curves not aligned to key points on the lip form in this area will then be
deleted.
• Select the Workplane and dynamically rotate it to align the Y Axis with
the first of the construction lines that run from the centre to the ends of the
radius on the modified corner geometry.
• Set the operational direction to and make sure that the Workplane is
Active.
• Quickly double left mouse click the Power Surface to open the
surface/curve editing toolbar.
• Select one of the cross sectional, surface curves followed
by the Add curve option to open
the following form.
• In the Add surface curves form

select Workplane intersection.
By selecting a cross sectional, surface curve

prior to opening the form the Insert option has
preset to Lateral.

• Select Apply to insert an additional lateral flush with the workplane YZ

plane.
• Dynamically rotate the workplane to align the Y Axis with second of the
construction lines that run from the centre to the ends of the radius on the
modified corner geometry.
• Insert a second additional Lateral flush with the workplane YZ plane.
Surface/Curve editing toolbar
• Select and Delete the 2 laterals that a not aligned to key points on
the lip form composite curve.
• Select the middle surface point on the outer longitudinal in the top right
quadrant and drag it to the corresponding point on the new lip form
composite curve (as shown below).

• Repeat the Drag Move process on the adjacent surface points to create
the following (Note the tangency and magnitude through the three points
requires freeing up to achieve the most natural alignment).
• Select the longitudinal followed by the three points (Shift Select) through
which correct alignment is required.
• Right mouse click on the longitudinal and in the local menu select Free
tangents and magnitudes (This creates the most natural geometric flow
through the selected surface points taking into account the adjacent non
selected points).
• Select the longitudinal running around the inside of the rim.
• In the surfaces/curves editing toolbar select Break surface to split

it into 2 separate upper and lower halves.
• Select and Delete the upper half, surface.

• Select a view from top (down Z) and select the alternate 6 surface points
around the outside of the lid as marked below.
If one or more surface curves or surface

points are selected it is possible to select an
Edit Sub-Item option. This will cause the
General Edit options to apply to the
selected sub items and not the surface as a
whole.
• Select the general edit options and click the edit sub-item icon.
• Select the Offset option and input a value –2 before clicking the
Return key.
The selected surface points have offset

inwards normal to the surface.
• Select and Delete the current, inner most surface curve.

• Create a Composite curve along the new, inner most surface
curve.

• With the curve selected open the Automatic Surfacing wizard, which in
this case will pre-select the Fill-In option.
• Select Apply to accept the new Fill-in surface and then select OK to close
the form.
• Rotate the Workplane 180 degrees about the X Axis and select a view
along Y.
• Select the Composite Curve defining the outer profile of the container
body.
• Select the, create a Surface of Revolution option.

• Select an Iso 1 view to display the following food container design, outer
form.
Jug Exercise
• Create a Surface model of the outside of the jug shown below and Save
as:-
D:\users\training\COURSEWORK\PowerSHAPE-Models\my-jug

PowerSHAPE 10. Boundaries and Pcurves
10. Trim Region Editing

Parameter Curves and Boundaries
Parameter Curves (pcurves) are made up of linear spans the run between Parameter
Points (ppoints). There sole use is to define the route that surface trimming could follow.
By default, they are created, automatically during Surface limiting or filleting. They are also
created manually by projection of wireframe entities onto a Surface. As moves between
ppoints are linear, any curvature is controlled by the proximity of adjacent ppoints within
the tolerance setting.
Ppoints are defined as a proportional distance between surface points. A ppoint defined at
2.5 1.5 is half way between points 2 and 3 along the longitudinal (T) direction and halfway
between points 1 and 2 along the lateral (U) direction.
Boundaries are generated along the pcurve network to define trimmed areas on a Surface.
Individual pcurves and boundaries are unique to a Surface and can be accessed only by
opening the Trim Region Editing, toolbar (Right click on a Surface for menu options or
alternatively access directly from the Surface Edits toolbar).
Definition of Boundaries
• Import the model m0_switch_housing.psmodel from Powershape_data.
• Select the upper surface (shown below) and select Blank Except.
• Double left-mouse click on the surface to display the Surface Edits

toolbar.
The Turn Trimming On/Off icon toggles the trimming of the selected Surface(s). It is not
active unless a surface is selected the default setting being ON.
• Select Trimming On/Off to switch the trimming OFF.

10. Boundaries and Pcurves PowerSHAPE
The Surface is displayed without trimming.
• Select Trimming On/Off to switch

the trimming back ON.
• Right Click on the surface and select
Surface Trim Region Editing.
The Trim Region Editing toolbar appears:-
The Trim Region Editing toolbar appears. This has two modes, Boundary Edits and
Pcurve Edits. The user can switch between modes using the pull down menu to the extreme
left of the toolbar.
Boundary editing (default).
Pcurve editing.
• Select Boundary Edit Mode.
The whole Surface is displayed with

the trimmed area identified by a mesh
of grey detail lines. All existing
Boundaries are displayed marking the
edge of the trimmed, surface area. The
pcurves are not displayed in this mode.
If a Boundary is deleted from a

Surface the associated pcurves remain.

• Select Pcurve Edit Mode.
The pcurves are shown along with

trimmed areas. The actual Boundaries are
not displayed in this mode.
If a pcurve is deleted from a Surface any

associated Boundary is also deleted.
Note: not all routes defined by pcurves are

necessarily included in the Boundary
definition.
• Select Boundary Edit Mode then the Boundary Selector.
When a Boundary is selected it is displayed in a different colour

and the name is displayed in bold text in the Boundaries form.
Several Boundaries can be multi-selected by holding down the

shift key. Using the Crtl key in a similar way toggles the
selection of a Boundary.
A Boundaries can also be selected from within the graphics area.
Note: Trimming will only occur if a Boundary forms a closed

loop.
• Select both Boundaries by selecting with the shift key depressed.
• Select OK.
• select Explode.

With the Boundaries Exploded the trimming is

removed, showing the full surface area. The
pcurves remain intact but are no longer in use as
part of a Boundary definition.
The pcurves still exist and will be displayed by

toggling into Pcurve Edits.
• Select Autocreate and the partially trimmed model will appear as

shown below.
Part of the required Boundary has not

appeared. This is due to the existence of a
branch point along the network of pcurves
making it impossible for PowerSHAPE to
determine which route to take.
The easiest way to create the required trim

option is to manually define the route
around the pcurve network as illustrated in
the following section.
• Select Recreate to open the toolbar and display all unused pcurves
on the surface.
The Create Trim Boundary toolbar appears and this is used to trace along the pcurves to
define a Boundary. It is similar to the Composite Curve creation toolbar.
All of the pcurves are displayed on the surface and are available for selection. To form a
Boundary the pcurve must form a closed route. The edges of a Surface can also be used as
part of the route of a Boundary.

• Click on a pcurve along the require

route and sequentially, click on the
direction arrows to produce the
required closed Boundary.
• Click Save and Eject.

• Deselect the surface.
Deselect the Surface to see the trimmed surface more clearly.
The next stage is a repeat of the above, but this

time excess pcurve data is removed, allowing
Autocreate to make the required trim
Boundaries automatically.
• Select the surface.

• Select the two Boundaries.
• Click Explode.
This deletes the selected Boundaries.
• Select Pcurve Edit Mode.

• Select the long pcurve along the part not required for Boundary
definition.
When a pcurve is selected the ppoints are

displayed. These can be labelled, selected,
repositioned or and deleted, as required.
• Shift-select the four extra ppoints.

• Click Delete Point.
• Select Autocreate.
• Deselect the surface.
As a result of removing the unused ppoints

future automatic, trimming operations will
immediately produce the desired results and
not stray along a path defined by redundant
pcurve data.
• Select File
Close.
• Select No when asked whether it is
required to save the model.
Fixing Incorrectly Trimmed Surfaces
• Import the model, locationlug.psmodel from Powershape_data.
The imported model shown includes several incorrectly trimmed surfaces requiring a
combination of Pcurve and Boundary editing to correct the faults.
The more complex the network of pcurves on a Surface, the less likely it is to obtain a
Trimmed Surface automatically. The following worked example shows the stages of pcurve
and Boundary editing, required to produce the correctly trimmed model shown above right.
• Select the curved, base Surface and select Blank Except (Ctrl + K).
• Right click the surface and select Trim Region Editing.

• Select Boundary Edit Mode and Boundary Selector.
The current Boundary is displayed on the

Surface.
• In the form select Boundary 1 and press OK.
• Select Explode.
• Select Pcurve Edits.
The surface contains two pcurves. One is correctly

defining the intersection with the vertical face of the
location lug.
The other, U-shaped pcurve is defining the path of an

old fillet prior to an amendment, and needs to be
deleted.
• Select the 'U' shaped pcurve and select Delete a pcurve.

• Select Unblank (Ctrl L).
With the Surfaces displayed, a Composite Curve

can be created from the lower edge of the fillet.
This new Composite Curve will then be turned

into a pcurve.

• Create a Composite Curve by using ALT + left mouse button on the

lower side of the fillet Surface.
• Blank all apart from the Composite Curve and the curved Surface.
The Composite Curve is used to create a pcurve by

projecting it onto the Surface.
• Select the lower curved surface and select Pcurve Edit Mode.
• Select Make pcurves from projecting wireframe.
The Make Pcurve form appears with the options

available.
• Select the option Projected and click on the composite curve.

• Select OK.
• Deselect the Surface and delete the composite curve.
• Select the lower curved surface.
The linear pcurve need to be extended.

• Select the straight pcurve and select Extend pcurve.
The Extend Pcurve form

appears.
• Select extend at both ends and method as tangentially to a pcurve.

• Select the other pcurve and press OK.
The new Boundary will be manually created

using Recreate based on the current pcurve
network.
• Select Boundary Edit Mode and select Recreate.

• Click along the arrowed direction markers on the pcurves to define the
new Boundary.
• Click Save and Eject.
The new Boundary has been created

If the trimmed surface appears within the 'D'
shape, select Reverse the Boundary icon
to create the result shown.

• Blank all surface apart from the front vertical and fillet surfaces.

The planar surface needs to be correctly trimmed.
• Select the vertical surface and click on Select all boundaries.
• Select Explode.
• Open the Edits Toolbar and select the fillet surface (Cutting
Object).
• Select Limit selection followed by the vertical Surface and click
next solution until the fillet Surface is trimmed correctly.
The correct trimming option for the fillet is

achievable using Next Solution, but not for
the vertical surface due to the complexity of
the pcurve network.

• Select and Blank Except (Ctrl + K) the vertical Surface.
• Open the Boundary Edits Menu.
• Select and Explode the Boundary.

• Select Pcurve edits to display all existing pcurves.
• Zoom into the lower left corner and select the vertical pcurve.
• Delete the last ppoints from the end up to one before the curved join.
• Label ppoints by clicking Turn point labelling on/off.
• Select ppoint 24 and press Edit parametric value at ppoint.
• Click the branch point situated before the last ppoint (24) and note the
updating of the values in the above form (zoom in as close as possible).
• Click OK and the position of the last ppoint (24) will update to the new
parametric values.
The ppoint is now repositioned to match the

existing branch point exactly.
• Select Boundary edits and Recreate a new Boundary.

• Trace a new Boundary.

The vertical 'D' section surface

shown below is the final surface
that requires re-trimming.
• Blank all surfaces apart from the fillet and the vertical 'D' section.
• Select the vertical 'D' section, surface and Delete the existing Boundary.
• Select P-curve Edit Mode and delete all pcurves except the 2 running
vertically from the ends of the fillet surface (shown dotted below).
• Create a Composite Curve on the upper edge of the fillet Surface.

• Blank the fillet from the view and select the vertical 'D' section Surface.
The composite curve will be used to project a

pcurve on to the Surface.
• Open the P-curve Editing toolbar and select make pcurves from
wireframe.
• Select the option Projected and click on the Composite Curve.

• Select OK.
• Select the vertical 'D' section Surface.
• Select the icon Recreate and manually generate the Boundary to

create the correctly trimmed, Surface shown below.
The Surfaces are now correctly trimmed.
• Select File
Close and then No.
Pitcher Trimming Exercise

In this example an IGES file is imported that contains a badly trimmed split Surface. With
the help of the following suggestions, re-trim the Surface.
• In Tools - Options, under Data Exchange/Delcam Exchange, tick IGES

in the Import section and then select OK.
• Import the file jug_split_surfaces.ige from PowerSHAPE_data/iges.
To bring in the unused pcurves

the PowerSHAPE IGES
translator is used, not Delcam
Exchange.
The first stage is to select the

planer, split surface and to
Explode the incorrectly
defined Boundary.

• Blank all surfaces except the split Surface.

• Open the Trim Region Editing toolbar and select Boundary Edits.
• Select Boundary 1 and delete it by left clicking on the Explode icon.
• Select the P-curve Edits menu.
The Surface contains a complex network of

Pcurves. The network is to be simplified by using a
combination of options including Delete Pcurve,
Delete ppoint, Extend Pcurve, etc.
Pcurves need to be perfectly trimmed to enable
future, automatic generation. When defining a
Boundary manually the Pcurves do not have to be
previously trimmed back as the required route is
defined using cursor hits (similar to creating a
Composite Curve).
• Modify the P-Curves until the trimming is the same as below.
The next step is to create the Boundaries. Although

an automatic Boundary could be applied, it is a
better idea to apply the Recreate, Boundary option.
This will identify if there are any geometric faults
around the route.
• Use the Recreate icon and trace and Save the route for the outer
Boundary.
• Trace the route of the inner Boundary and then, Save and Eject.
The Surface should now be trimmed correctly, but

if not, Reverse the Boundary. In this case a
quicker way of producing this result would have
been to create Composite Curves around the top
edges of the jug form surfaces. These could then
be used to Project pcurves onto the split Surface.
• Select File Close and then No.

PowerSHAPE 11. Levels
11. Levels
Model entities can be assigned to Levels which simplify such operations as the display and
selection of groups of items. For example, these could be distinct groups of component
surfaces, or different types of entity. A typical application would be to assign the inner wall
surfaces of a plastic component on to a different level from the outer wall surfaces. Objects
can be assigned to different levels, which can be switched to be ‘displayed’ or ‘hidden’ to
manage the selection and visualisation of entities within a model. There are 1000 Levels in
PowerSHAPE which when required for use should be given more appropriate names. Levels
998 and 999 are for internal use.
Example
• Select File Import and then the file Corner_Bowl.dgk from
D:\Users\Training\PowerSHAPE_data\psmodels_n_dgk.
• Select an ISO1 view.
This model contains a mixture of

wireframe and surfaces. The model may
also contain duplicate entities that could
either be wireframe, surfaces or a mixture
of both. It is advisable to either move
these items to a level or to delete them.
• Select everything within the graphics area.

• From Tools Model Fixing select Find
duplicates.
• Tick the box Find duplicates in current

selection then press OK.
PowerSHAPE examines the model and selects duplicate entities. These can be wireframe,
surfaces or solids. To see what has been selected, the information icon can be used.

11. Levels PowerSHAPE
• From the selection fly out pick Selection information.
A list of the current selected items are shown.
These duplicates will be moved to another

level.
• Select OK.
• From the lower left side of the window, select the Levels button.
• In Level 5, enter the name Duplicates and press the big red X by the
number 5.
• Select OK.
• Select all the wireframe and middle mouse click over the new level 5.
Clicking the middle mouse will move the selected items to that level.
• Left mouse Click on level 5 button.
The left mouse will switch the level on or off. The duplicates disappear from the screen as the
level is switched off.
When an item is generated, the default level that it is generated

on is level 0, called the general level. If, for example you
wanted to always create surfaces on another level then, once the
option is selected, the level is picked from the pop up menu at
the end of the levels toolbar.
Choosing a level it will make it active. Be careful when doing this that nothing is selected
otherwise the item will be moved to that level.
• Open the Levels form and create two further levels, naming 6 as Core and
7 as Cavity.
This model contains solids. These are a different type of component with PowerSHAPE,
which can be used to make complex shapes. A solid can be selected by clicking on any part
of it.

PowerSHAPE 11. Levels
• Select the bottom solid and press Ctrl + K (Blank Except).
The bottom solid can be seen clearly by blanking

everything apart from the selected item/s.
• Click the middle mouse button over level 6.

• Select Ctrl + L (unblank).
• Select the top solid and press Ctrl + K (Blank Except).
The top solid is shown.
• Click the middle mouse button over level 7 and Select Ctrl + L.
The component solid and construction wireframe remain on level 0 (General).

PowerSHAPE has the ability to allow Grouping of levels. By grouping items together the
user can manage parts of the model more efficiently and effectively.
• From the lower left side of the window, select the Levels button.
• In Level 8, enter the name Components: Wireframe and press the big X
by the number 8.
• In Level 9, enter the name Components: Solid and press the big X by the
number 9.
The word Component represents the Group name and the

word Wireframe or Solid the level name.
• Select Dismiss
The two levels now belong to the group called Component. On the Levels toolbar, the
following changes can be seen:

11. Levels PowerSHAPE
A new button appears representing the group of levels. The buttons of the two levels have
changed to the same colour (Blue). The colour of the group matches that of the two levels.
Levels can be turned on and off using the group button. If a further Group is created then a
new colour will be assigned to it making it visually distinguishable from the original one.
• From the Select menu, select Quick select all wireframes.

• Press Ctrl + K (Blank Except).
The wireframe is selected.
Note: Whatever level is displayed in the Levels pop up

menu, any items created will be assigned to that level.
• Click the middle mouse button over level 8 and Select Ctrl + L.
• Select the component solid and place it onto level 9.
• From the Levels pop up menu select 0 : General Level.
In some instances it is advisable to make safe copies of surface or wireframe entities. For this
exercise we will copy the core solid and paste it onto the General level 0.
• Turn on Level 6 and select the solid.
• From the top toolbar, select Copy and then Paste.
It may appear as though nothing has actually happened, but the solid that is displayed yellow
are the new copies of the original.
• Switch off level 6. Toggle on and off Level 0 to see the new copy.
• Select File Close and select No to saving Changes.

Using the pump example we can put the blanked wireframe onto a named level.

• Name level 5 as Geometry.
• From the Select menu, select Quick select all wireframes.

• Press Ctrl + K (Blank Except).
• Move the selected wireframe to level 5 and switch the level off.
• Select File Save and then File Close.

PowerSHAPE 12. Shading & Model Analysis
12. Shading & Model Analysis

Basic Shading Options
Basic shading is displayed by clicking the various icons in the Views Toolbar. As surfaces
must be identified with inside and outside, the outside is displayed in a use defined colour,
and the inside as red. It is possible to switch the inside colour off (Both sides Shaded with
original outside colour),
• Open the model golf-fin. Activate workplane 2.
• Select view ISO 4 and select wireframe view.
The model is displayed with the surface skin invisible, enabling visual
access to the trimmed edges and surface curves.
• Select Shaded view.
The model is displayed with the surface skin shaded. The outside of
a surface will be the default or user defined colour with the inside red.
The use of shading will restrict visual access to internal detail.
• Select Toggle Transparent wire.
This view shows the model partially shaded (transparent) which

provides a compromise with visual access to the inner, wireframe detail.
• Select Shaded wire view.
This view is a shaded view, with the surfaces curves displayed .

12. Shading & Model Analysis PowerSHAPE
• Select Hidden wire view.
The model is displayed in wire mode, with all the internal wire removed
or hidden. This is a visual option to aid the user to see the model clearly.
This special view mode needs to be turned off for surface manipulation.
• From the View pull down on the main menu select Shade > Inside
Material.
This view turns on or off the mode which displays inside-out surfaces as
red. This allows the user to shade the model without having to reverse
‘inside out’ surfaces.
• With the model shaded, select Enhanced Shading.
This shows the model in Enhanced shading mode. This type of view
includes perspective and reflections on the surface giving a more true
to life appearance with model feature lines, visually converging
towards distant vanishing points.
• From the pop up menu under enhanced shading select Render the
View.
This displays a photo-realistic image of the model in a separate, newly

opened graphics window, using default light settings and render
options.
To switch between Lightworks or POV-Ray Render Systems and

customise the way that the rendered image is generated, a dedicated
options form is opened by clicking on the Raise the render form icon (left).
• Select the golf_fin :1 from the Window pull down menu.

Format – Shading Materials

Shadings materials are accessed from Format >Materials pull down on the main menu.
By default all surfaces are shaded using the same material. There is a comprehensive range of
pre-set Material types available, such as metallic, glass, neon, etc. Individual surfaces can be
modified to use a shading colour and/or material type directly from the standard range or as
customised by the user.
To change the material of a selected surface(s):

1. Ensure that shaded images are displayed
2. Select a surface or group of surfaces.
3. Raise the Materials dialogue box and select a new material.
To change the default material:

1. Ensure that no surface is selected.
2. Raise the Materials dialogue box and select a new material.
3. Click OK and the new material will be used for subsequent surface colour shading.

Customising Materials
The user can create a custom material to their own specification.
• Select Format -Materials form, select Spring and pick Spring13.

• Select the option Custom.
The materials Editor form appears. This form

allows the appearance of the shading effect to be
altered using various sliders.
• Select New. Leave the name as Spring13copy.

• Alter the material using the sliders and observe on the preview bead at the
top of the form.
• Once a visually suitable material is obtained Apply the form.
• Select any surface and the material is changed to the new one.
Shading Tolerance
When models are shaded, the whole surface is covered in a triangular mesh, which is set at a
certain tolerance i.e. the smaller the value, the finer the mesh. These values are found under
the Shading Option, found under options in the Tools pull down menu.
• Select Tools Options and from View, select Shading.
Tolerance to current view is a quick way

of entering the ideal value for your
particular screen resolution and current
zoom. PowerSHAPE will use the new
tolerance the next time the shading is
regenerated. If you want to see it
immediately, click the button, Force
regeneration of triangles.

• Set the Shading Tolerance to the excessive value 5.

• Press Force Regeneration of triangles. Press OK.
The shaded surface model visually, appears very faceted. If it is

required to check a surface model for tangencies or ripples
along the surface it is essential to apply a suitable shading
tolerance. This in turn depends on the physical size of the
model but a more suitable value is 0.01 for an accurate visual
representation.
• Set the Shading Tolerance to the more acceptable value 0.01.
Model Analysis Toolbar

The Model Analysis toolbar is opened by clicking the icon located along the row 3rd from
the top of the left hand toolbar.
The new left hand toolbar will contain the Model Analysis
options. It is shown below repositioned to a horizontal
alignment.
Advanced Shading Options

Smoothness Shading - visually exaggerates the degree of smoothness over the
model surface with dual coloured stripes. A break in continuity along the stripes
indicates a sharp transition form one face to another.
Note:- A Sharp cornered transition across adjacent

surfaces is indicated by break in the continuity along
the stripes.
• Select the above option and have a closer look at the displayed model.

Undercut Shading – Used to check for correct draft angle on a moulding

component or to check for undercuts.
The area of the model surface

shaded green does not exceed the
draft angle alignment.
The small area of the model

surface shaded yellow is exactly
aligned to the draft angle.
The area of the model surface

shaded red represents an undercut.
By default the Draft Angle is set to zero. If it is required to use a different value it can be
modified in Tools - Options –Tools – Analysis - Surface Analysis.
Minimum Radius Shading – displays internal radii with a value less than the
specified minimum radius in Red and external Radii in green with the remainder of
the model being Grey.
This illustration represents

Minimum Radius Shading
using a minimum radius
value of 2.
By default the Minimum Radius value is set to 5. If it is required to use a different value it
can be modified in Tools - Options –Tools – Analysis - Surface Analysis.

Volumes
PowerSHAPE calculates a volume of an enclosed surface, such as a sphere, based upon the
direction of the principle plane.
With an open surface, then PowerSHAPE generates a

projected volume, from the active Workplane or the
world origin.
The volume value given depends upon the axis in

which the projection takes place, for example with
the principle plane set to the XY plane; the project
volume is along the Z-axis.
Bottle Volume Example
• Generate a workplane at 0.
• Create the following 2D geometry.
• Generate a composite curve of the wireframe and make a copy.

• Create a new level (5) named Wire Copy and place this copy onto it.
• Switch level 5 off.
• Create a surface of revolution around the Y-axis.

• Shade the surface and reverse if necessary to have a gold outside.
• From the bottom of the window, select the calculator.
• Pick the volume icon and then pick the surface.
The calculator works out the volume for you as

6,370062.9499 cubic mm. To alter the volume to
7,000,000mm cubed, we can expand the surface
to this volume.
• Select the surface and from the Edits toolbar select Scale.
• Select the ‘To Projected Volume’ option and change the volume to 700
(don’t enter the commas).
A new surface is produced which is scaled in all three axes. If the X and Z movement had
been locked (by clicking the padlocks) the scaling would occur only along the Y axis.
Another way to change the volume would be to locally increase the length of the bottle from
just beyond the top recess to the cap. By trial and error you could get close to the desired
volume. The following sequence will attempt to reach the target by locally stretching by 20.5.
• Delete the surface and switch on Level 5 Wire Copy (do not select).
• Select Stretch Object in the Edits toolbar.

• Box over the all elements of the composite curve including and above the
R35 Radius (these will turn to yellow) and enter 0 20.5 in the command
input window to stretch this part of the wireframe (as shown dotted below).
• Generate a new surface of revolution. (reverse if required).

• Measure the Volume.
To find the volume between two surfaces to find the wall thickness we can use the calculator.
• Offset the new bottle (keeping the original) outwards by 2mm.

• Select the calculator and measure the volume of the new larger, offset
surface.
• Enter a minus (-) on the calculator.

• Measure the volume of the original smaller surface by selecting it.
The answer, which is the volume of the wall thickness of the bottle, is displayed in the top
right hand box of the calculator.
Volumes of solids can also be generated in the same way. The method also works for
multiple selected surfaces.
• Save the Model as:-

D:\users\training\COURSEWORK\PowerSHAPE_Models\Volume-Ex1
• Select File - Close to close down the Model.

Identifying Modifications on a ‘new issue’ model

• Open a New empty PowerSHAPE Model.
D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\InteriorTrim-4a.dgk
• Open another New empty PowerSHAPE Model.

D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\InteriorTrim-4b.dgk
• From the main pull down menus select Window - Tile Vertically.
The separate models are arranged to co-exist side by side in the graphics area. At the
moment any differences are not visually obvious apart from the central pockets appearing to
be different depths.
Dynamic Sectioning
Dynamic Sectioning provides a fast means of visually taking a slice through the Surface or
Solid model with the option of creating a 2D Composite Curve as a permanent record of the
section.
• Left mouse click in the New_Model_2 window to activate it as the model

to be worked on and activate the Workplane RibCentre as the datum.

A similar workplane is positioned to a common position on each model, to enable a dynamic

section to pass exactly through the same plane.
• From the Model Analysis toolbar select Dynamic Sectioning.
• Select the Y axis from the drop-down list.
This controls the direction along which the dynamic section is created normal to.
• Use the left mouse key to move the Back slider and observe that the
model is visibly cut back as the slider is moved.
• Input 0 in the data input box to the right of the Back slider to make the
section exactly in line with the, active Workplane, RibCentre.

• Click the Create Wireframe tab to generate a composite curve

through the Dynamic Section.
• Create a similarly positioned Dynamic Section on New_Model_1, again

using the option Create Wireframe to generate a composite curve.
At this stage there is visual evidence that the central pocket is deeper on the component in
New_Model_1. For identifying smaller differences the two curves need to be superimposed
on each other. It will also be necessary to apply other specialist Model Analysis options
• Select the Composite Curves stored in New_Model_2 and change it’s

colour to Red.
• Ensure that no Workplane is Active in New_Model_2.
This is to make sure that the Composite Curve produced in New_Model_2 is copied exactly
to the same world coordinates as in New_Model_1.

• With the Composite Curves selected click the Copy icon on the
Main toolbar.
• Click in New_Model_1 and ensure that no Workplane is Active before

selecting Paste.
• Once the Composite Curves are Pasted into New_Model_1, activate the
Workplane and select a View from Front (-Y).
• Select and Blank all Surfaces to view the Workplane and the two sets of
Composite Curves.
The above view visually illustrates that the Surface Model stored in New_Model_2
possesses a reduced depth central pocket and a slightly larger core form in the rib area to
the right.

Model Visual Difference

This option provides a fast means of visualising design changes between two separate
models. Once two models are specified in the form, a new window appears containing the 1st
model displayed light grey with areas of ‘material on’ coloured Blue and areas of ‘material
off’’ coloured Red.
• From the Model Analysis toolbar select Model Visual Difference.

• In the Model Visual Difference form input NEW_MODEL _1 in the Name
of the old model box, and NEW_MODEL _2 in the Name of the new
model box.
• Select OK to apply the Model Visual Difference process.
A new window appears containing a Light Grey shaded image of NEW_MODEL_2 with
extra material existing in areas shaded Blue and material removed in areas shaded Red.
• Move into the new window and dynamically rotate the image to view the
other side of the model.

The base of the pocket is shaded Blue which confirms that extra material exists in this area.
Model Compare
This option provides a means of ‘identifying and selecting’ modified, model entities on an
updated model while comparing it with the original, model. The selected model data can
then be copied and pasted into the original model without duplicating existing, unchanged
model entities.
• From the Model Analysis toolbar select Model Compare.
The Model Compare Form appears requiring the user to identify the Primary and
Secondary models on which to Compare and Select the different model entities.

• With the Primary box ticked click in the NEW_MODEL_2 window to

register it as the Primary.
• With the Secondary box ticked click in the NEW_MODEL_1 window to
register it as the Secondary.
• Click the OK tab to apply the Model Compare process.
All entities in NEW_MODEL_2 that do not exist or are different from those in
NEW_MODEL_1 are automatically selected ready to be Copied and Pasted.
Note:- Copy and Paste options are included as icons in the Main toolbar.
• With the new items still selected in New_Model_2 select Copy.
• Click in New_Model_1 before selecting Paste.

The new data is Pasted into the original model.
• Rename Level 10 as NewData and assign the copied Model components

to it.
• Switch off all Levels except NewData.
Note: The inner form Rib Data has also been modified and has been copied to
New_Model_1 as well as the pocket.
To be able to assess the manufacturing work required to modify any existing mould tool it is
essential to place the new and old data on different levels. By switching the levels on and off

it will be more obvious whether the new data is to be material removed or added to the
existing tool.
• Rename Level 9 as Old Data, make sure it is switched off and assign to it
all the original model entities due to be replaced.
• Transfer the new model items currently assigned to the Level named
NewData to the appropriate Outer (Level 6) or Inner (Level 7) levels.
It will be observed that the Pocket will require more material to be machined off on the die
half of a mould tool. On the Punch half, Material needs to be added to reduce the depth of
the central pocket and removed to create the increased size for the core, central to the 4 Ribs.
• Select File - Save to update the model:-

(D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\InteriorTrim-3.dgk)
• Do Not Close the model as it will be used in the next section.
Surface Inspect
When active, the Surface Inspect option displays ‘live’ dimensional information to the user
as the cursor is ‘locked onto’ or moved along the surface model.
• Switch Off all Levels except number 6 - Outer.

• Select all displayed surfaces and click the Surface Inspect
icon on the Model Analysis toolbar.
• Left click on the model on or near to where dimensional information is
required.
• Run the cursor along the model to lock on to Key Points or other non
specific positions to give ‘live’ feedback on varying dimensions.

• Select File - Close to close down the Model.
Other Model Analysis Toolbar Options

Below is a summary of the remaining Model Analysis options.
Calculator
Show Model Contents List

These two Options operate on Solid Models only

PowerSHAPE 13. Model Fixing
13. Model Fixing

Model Fixing Toolbar
The Model Analysis toolbar is opened by clicking the icon 2nd along the row in the toolbar
opened by moving the cursor over the General Edits icon.
The new left hand toolbar will contain the Model Fixing
options. It is shown below repositioned to a horizontal
alignment.
Piston Crown Example

D:\users\training\PowerSHAPE_Data\psmodels-n-dgk\PistonCrown-Start
The imported model

contains surfaces
representing a quarter
segment of a Piston Crown.
The model is incomplete,
requires a few gaps to be
filled, some re-trimming of
existing surfaces, and the
identification and transfer
of missing data from
another model.
Before commencing on
additional surface
modelling it is necessary to
identify and delete any
duplicate surfaces as well
as to identify and repair
any badly trimmed surfaces
• Shade the model.

• Save the model as:-
D:\Users\Coursework\PistonCrown-Example

13. Model Fixing PowerSHAPE
Find Duplicates
• Move the cursor over the General Edits icon to open the local toolbar
and left click the Model Fixing icon to activate the toolbar options.
• From the Model Fixing Toolbar select Find Duplicates.
The Find Duplicates form appears. This

provides the option what to compare, exact,
trimmed, untrimmed surfaces. Click on the Help
button for a full listing.
This command identifies and selects duplicate

surfaces.
• Tick the box named find duplicates in current selection.

• Select All and Exact and press OK.
All instances of duplicate surfaces will become selected (coloured yellow).
• Select Blank Except (Ctrl K).
Only the selected duplicate surfaces will remain visible

in the graphics area.
• Select Delete to get rid of the selected duplicate surfaces.

• Unblank (Ctrl L) to display all surfaces hidden from the view earlier.

Identify Badly trimmed Surfaces

The next action is to check the model for any Badly Trimmed Surfaces. These are surfaces
that contain invalid Boundaries. These could be due to the inherent pcurves not forming a
closed loop, or geometrical faults along one or more of the pcurves.
• Select all surfaces.

• From the Model Fixing Toolbar select Identify Badly Trimmed Surfaces.
The above Information box opens advising of the existence surfaces with an incorrectly
defined trim boundary. All badly trimmed surfaces will become selected (In this case there
is one).
• Select Blank Except (Ctrl K).

• From the Model Fixing Toolbar select Surface trim region editing.
The Boundaries are now visible, but require rebuilding as they have failed to trim the
surface.
• From the Boundary Edits toolbar click on Select all boundaries followed
by Explode to delete all boundaries.

• Toggle into the Pcurve Edits toolbar.

The Pcurve shown dotted does not follow the

correct Trim and as a result will be deleted
from the surface.
The other Pcurve is following the correct
trim path but is not quite reaching the top
edge of the surface and this would result in a
gap in the trim path. The pcurve must be
extended to the edge before a Boundary is
created.
• Select and delete the pcurve (as shown above dotted).

• Select the remaining pcurve and open the Extend pcurve form.
• Select Extend at as Both ends of pcurve and Method as Tangentially to

nearest edge.
• Select OK and the pcurve will be extended as required to reach the edge
of the surface.
• Toggle into the Boundary Edits toolbar.
• Select Auto Create boundary and visually check which side of the
pcurve is trimmed away.
• If the trim appears as above left select Reverse the boundary to

change the trim to that shown above right.
• Close down the Boundary Edits toolbar.

The surface model is now correctly trimmed.
Repairing Gaps and Ovelapping surfaces

By shading and dynamically rotating the view of the cavity model, 3 gaps will be seen that
require patching.
Gap1
Gap2
Gap 3
Filling in Gap1 – Surface from Network of curves
• Zoom into the area labelled as Gap 1.

• Create a composite curve using the edges of the gap.
A patch surface from a

network of curves will be
generated from the new
composite curve.

• Using the Surface Wizard create a Fill-in Surface.
Filling in Gap2 – Stitch surface
• Zoom into the area around Gap 2.

• Select the bowl surface and Convert it to a Power Surface.
The bowl surface is a NURB surface, which

must first be converted to a Power Surface
before any major editing can be performed.
This gap will be filled by using the stitch

surface option.
Stitching will move selected surface points to match the edge of other surfaces or
composite curves. It is not possible to apply stitch surface from a trimmed edge. The
process will benefit if further laterals are inserted to provide a more accurate edge match for
the stitch surface operation.
An easy way of inserting an additional lateral is to select a surface point followed by first
depressing and holding down, the CTRL key and then the LH mouse key. A new lateral is
then dynamically dragged along an existing longitudinal. This is repeated as required until
sufficient surface points exist along the edge to be stitched.
• Select the surface to bring up the Surface Edits toolbar.

• Select a lateral/longitudinal point and drag a new longitudinal near to
the end one using Ctrl and left mouse button as seen below.
Surface Point.
New Longitudinal.

• Select Add Curve.
The Through nearest point option allows the user

to pick a point on the model. Once picked the XYZ
co-ordinates are loaded into the form.
• Select Insert – Lateral using the Through nearest point option.

• Click on the Surface Point indicated earlier at the end of the surface to be
stitched to.
• Apply the form and then OK. match edge
The new lateral is generated.
The Stitch command uses the selected

surface curve and matches it along the
surface edge of a selected secondary
surface. It is also necessary to specify a
value for the maximum gap to stitch
across.
• Select the match edge (end longitudinal) of the round surface and then
Stitch.
The Stitch form appears. It is essential to estimate

and specify a value for the maximum gap to
stitch. This is used to eliminate any ambiguity
with regard to which surface edge to stitch on to.
• Enter 2 in Max gap to stitch.

• Pick the edge surface on the edge
curve to stitch onto.
The Green Tick next to Surfaces indicates that the target surface has been selected.
• Press Preview to view in advance and OK to perform the stitching.

The fillet surface needs to be trimmed back

to the Stitched surface to finish off this area.
• Select the two surfaces shown and Blank Except (Ctrl +K).
• Create a composite curve from the edge curve of the flange surface as
shown below.
Use Define Start and End points on the Composite Curve

dialogue to create the curve shown.
• Select the bowl surface and enter into Trim Region

Editing.
• Select the Pcurves menu and make
pcurves from projecting wireframe.
• In the form select the option Projected.
• With the new pcurve selected, open the extend pcurve option.
• Select:- Extend at - Both ends of pcurve

Method – Tangentially to nearest edge
• Select the composite curve and select OK.
• Select the Boundary menu and Recreate.
• Create a Boundary along the fillet edge to leave the result shown.

The bowl surface is now trimmed neatly to the flange.
Before Gap 3 is filled, a split surface needs to be generated. In

this case it can be achieved by selecting the top trimmed surface
and then altering the trimming to produce the required surface.
• Unblank all of the surfaces.

Gap 3 is a large hole in the model, due to missing data, to be supplied later via another IGES
file. By initially loading it into a New Model it can be checked before copying the data into
the original piston model.
Selection and Import of Surface Data for Gap 3
• Create a new model and Import the file cyl1_1_2.igs.

• Rearrange the models using Window Tile.
Most of the surfaces in the New Model already exist in the original PistonCrown-example.
Model Compare
Model Compare will analyse 2 models and select items on the first model that are different
or do not exist on the second model. The criteria relating to Trimming options can be
specified as required within the form.
• From the Model Analysis toolbar select Model Compare.
The Model Compare form appears.

This form allows the user choose which
model is the Primary (old) model and
which model is the Secondary (new)
model. The different model entities are
then selected in the Primary model.

• Select the Primary box (ticked) and then left click in the New Model
window.
• Select the Secondary box (ticked) and then left click in the
PistonCrown-example window.
• In Surface Trimming Comparison select None.
• Select OK.
Some wireframe and a couple of surfaces

highlighted in the Primary - New Model window.
New surfaces.
Wireframe.
• Blank Except the selected items (Ctrl K).

• Select and Delete the wireframe.
• Select the extruded surfaces followed by Copy Selection.
• Select the model temp-piston and select Paste from clipboard.
A Copy of the new, different surfaces will appear in the original model.
• Close the New Model leaving the PistonCrown-example model open.
The deep pocket will be filleted to the main

surfaces with a 3mm radius and the bottom edge
of the pocket will be filleted with a 2mm radius.
Note:- The creation of the 3mm fillet will not trim

the tapered pocket or some of the adjacent
surfaces correctly due to poor surface edge
matching across the original model. Surface
editing of the 3mm fillet surface along with
Pcurve and Boundary editing on the tapered
pocket and some of the adjacent surfaces will
have to be applied to fix the problems
• Select the newly copied surfaces and those that intersect them.
• Select Blank Except.
• Generate a 3mm concave fillet between the original surfaces and the top
of the new tapered pocket surface.

• Select the taper surface and the surface defining the flat base of the
pocket.
• Create a 2mm convex fillet between these surfaces.
Now that the quarter of the Piston Crown is

complete a workplane will be created to provide
a datum to mirror a copy of the surfaces to end
up with half of the full Piston Crown.
• Select Unblank and create a workplane at 0.

• Select all of the surfaces.
• From the General Edits toolbar select Mirror.
• From the Mirror toolbar select mirror in YZ.

• Select File - Save to update the Model.

• Close the model.

Further Model fixing
Imported iges file of a PC Front Cover surface model

On import an iges format model will contain Nurbs Surfaces, which as explained in the
earlier chapter have very restricted editing capability. As will be illustrated during this
example when a Nurbs is converted it can end up with an excessive number of
laterals/longitudinals on the resultant Power Surface. It will also be observed that several
of the surfaces are in an orientation with the inner (red) side on the external faces of the
model. Apart from the visual presentation this would cause problems if the model is to have
additional surfacing work carried out on it (eg. Filleting).
D:\users\training\PowerSHAPE_Data\iges\PC_FrontCoverSurfaces.igs
• Save the model as:-
D:\Users\Coursework\PC-FrontCover-example
Note:- A form appears displaying

the progress as an Import IGES
report.
• Select all of the Surfaces in the model.

• From the pop up menu in General Edits select Model Fixing Options.
• From the Model Fixing Toolbar select Find Duplicates.
The Find Duplicates form appears. Various options allow

the user to control the criteria of what to compare, and
whether to consider exact, trimmed or untrimmed
surfaces. Click on the Help button for a full listing.
• Tick find duplicates in current selection.

• Select All and Exact and press OK.
In this case no duplicate data is found, but it is still essential to perform the test.

• From the vertical toolbar click the Quick Select all Surfaces option.
• In the Model Fixing options click on Orient surface normals to

arrange for the outer faces of the surfaces in the selection to be on the
outside of the component.
Note:- In some instances it may not be obvious which way a surface should be orientated (If
the model is missing data causing a surface to be isolated, or the outer face of a surface
exists on both the inside and outside of the model). If any such surfaces remain in the wrong
orientation then they can be selected and reversed individually via the local menu.
• Display the Surface model as wireframe.

• With all the surfaces still selected, right click over them and from the local
menu, select Convert Surface to change all of the selected Nurbs to
Power Surfaces.
Shown below :- One of the Surfaces before and after conversion to a Power Surface.
Depending on the type of file originally translated into iges format, the resulting Power
Surfaces are often created with an excessive number of surface curves (as illustrated above
right). If a large number of surfaces are involved it can result in reduced processing times
and excessive memory consumption. As a result it is good practice to apply the Approximate
Surface option to reduce the amount of curves while keeping the surface definition within a
specified tolerance value.
• With all Power Surfaces selected click the Approximate surfaces

option located in the Model Fixing toolbar.

All surface curves are deleted

that are not required to keep the
model form within the general
tolerance value (default 0.01).
This value can be modified on
the instrument toolbar located
below the graphics area.
The model is now ready for further operations such as constructing the components required
for a suitable mould tool design.
Core/Cavity separation
This Core/Cavity separation icon is located in the Main toolbar – Wizards options.
It operates on the selected surfaces and discriminates surfaces that are out of view if
looking down the Z Axis.
Depending on which of the 2 icons are applied it leaves the user either with the outer or
inner surfaces as selected and ready for transfer to another level.

• Open the Levels form and enter the Name CAVITY for level 6 and CORE
for level 8.
If a level is assigned with a Name it appears in the Levels

toolbar at the bottom left of the graphics area.
• Keep these two levels switched off until advised otherwise.

• Select all of the surfaces in the model.
• Open the Wizards options and click on the Core/Cavity separation
split visible icon.
The surfaces that are hidden from view if looking down Z become deselected while the
others remain selected.
• While the upper surfaces are still selected, middle mouse click on Level
6 on the levels toolbar and they will disappear from view (Level 6 is
switched off).
• Select all the remaining surfaces and middle mouse click on Level 8 and
these will also disappear from the view (Level 8 is also switched off).
• Toggle levels 6 and 8 on and off while checking that the surfaces have
been assigned to the correct side of the moulding.
LEVEL 6 - CAVITY LEVEL 8 - CORE

PowerSHAPE 14. Basic Solid Modelling
14. Basic Solid Modelling

Introduction
Solid modelling applies a completely different approach in the creation of a CAD model. The
main physical difference is that a Surface model is formed by a hollow, zero thickness skin,
whereas a Solid Model is a mass of material. There main advantages of using Solid
Modelling are the model creation speed and the history tree, in which the user can
reposition or edit operations performed earlier resulting in the automatic update of other
affected items. PowerSHAPE is unique in the ability to convert Solids to Surfaces and vice
versa depending on which approach is most suitable at the time. Open Surfaces can be
converted to a Solid, an extremely useful capability which would not be available with a
dedicated Solid Modelling Package.
Boolean Operations
As an Active solid is built up other solids/surfaces can be absorbed into it, which is best
illustrated via the basic Boolean operations ADD, REMOVE and INTERSECT.
Active solid sphere

(Coloured Red)
Selected solid cylinder

(Coloured Yellow)
Adds the selected solid to the active solid.
The solid cylinder is joined onto, and becomes part of the Active
solid sphere.
Removes the selected solid from the active solid.
A hole appears through the active solid sphere caused by the removal of
the solid cylinder, which again is now part of the Active solid sphere.
Creates the intersection of the selected solid and the Active solid.
The active solid becomes the common volume of both solids, in this case
producing a solid tube with spherical ends. As before the cylinder is now
part of the original Active solid sphere.

14. Basic Solid Modelling PowerSHAPE
Simple Solid Model Example

The following example illustrates the creation of a simple solid
model. It emphasises the benefits with the ease of creation, and
the ability to retrospectively make changes to existing features,
causing the remainder of the solid to be automatically updated
to comply.
• Open a new model.

• Create a workplane at 0 and set the principal plane to Z.
• Select the Solid creation options icon from the main toolbar.
• From the Solids toolbar select Create Solid Block.

• Centre the base of the solid block about the workplane by typing 0.
• Press ESC on the keyboard to break out of the command.
• Double click on the solid block in the graphics area opening the form
shown below.
• Input the length as 100, width as 50 and height as 50 and press OK.
The newly created solid block will automatically become active (red).
• Select the Solid icon from the main toolbar.

• From the Solids toolbar select Create Solid Cylinder.
• In the coordinate input window to the bottom right of the graphics area
input the values 0 0 –20 to position the base of the solid cylinder.
• Double click on the solid cylinder in the graphics area opening the form
shown below and enter:- Radius 10 and Length 90.
• Left click on the solid block to identify it in the Solid History Tree, and
then click on the Grey flag to change it to Red (Active Solid).

• With the left mouse, select the solid cylinder and from the
main toolbar select the Feature option.
The Feature icon is next along from the solid creation icon in the main toolbar. It contains
options for performing constructional operations on the initially created active solid.
• In the Feature toolbar select the Boolean option, Remove the

selected solid … to create the solid cylinder as a hole through the
active solid block.
• In the Feature toolbar select the Create solid fillet option.

• In the form input Radius 5 and with the shift key held down multi-select
(left mouse key) the vertical edges of the solid block before selecting
Apply.
All 4 vertical edges will now have a Radius 5

fillet.
• Select File - Save As and store the model to the following location:-
D:\users\training\COURSEWORK\PowerSHAPE_Models\SolidBlockExample1

Solid History Tree

As an active solid evolves it absorbs other solids/surfaces/symbols. All these items are
added to a history tree located on a dedicated explorer window that appears to the left of the
graphics area (if it is not there double left click on the active solid). The last operation to be
performed appears at the top of the history tree. These items/operations stored in the history
tree can be modified retrospectively resulting in an automated update of the active solid
(provided the changes are physically possible). It is also possible to defer the update if
required to allow a series of changes to be implemented at the same time.
• If the history tree is not already displayed open it by double left clicking
on a solid displayed in the graphics area.
A solid can be made Active or deactivated by left

clicking on the flag (Red flag = Active).
If sub-items are not displayed click the open the

sub-directory. To switch off the display of sub-items,
click on the .
As is clear from the illustration the first action; create

solid block operation is at the bottom of the history tree
whereas the final solid fillet operation is at the top.
• Double click on the solid fillet at the top of the history tree.
A box appears around the selected sub-item in the history tree and the Edit Solid Fillet form
opens. The selected fillet changes to a blue colour on the Solid displayed in the graphics area.
• Input a new Radius 10 and click the OK tab.
The selected Radius in the on the solid is

changed to 10 and the affected area of the solid
model automatically re-trimmed to suit.
Note: It is also possible to select solid, sub-items

using a double left mouse click directly on the
solid in the graphics area.

As well as the ability to modify the original parameters used in the creation of a sub-solid, it
is also possible to apply the General Edits options to preceding Boolean operations.
• Select the cylinder, sub-solid with a single mouse click and identify where
it is located (boxed) in the history tree.
If a sub-solid is selected it changes to a different colour from

the main solid (this also applies if a wireframe view is
displayed). The sub solid is also identified by being enclosed by
a box in the history tree.
• Shift - Select the boolean Remove operation in the history tree such that
both the solid cylinder and the Remove operation are selected (boxed).
• Select the General Edits options followed by Edit Sub Item (if not already
active).
• Set X as the operational axis.

• Select the Rotate object option, entering values in the form to Keep
original, with No of Copies 1, Reposition rotation axis as 0 0 25, and
Angle 90 before pressing Return.
The original sub-solid cylinder has been copied and

rotated within the active solid. The new sub-solid
cylinder appears at the top of the history tree.
• Select File – Save to update the content of the stored model file.

A Solid Modelling example
The Mounting Block base dimensions are

X100 Y50 centrally positioned, relative to
the Workplane at a Depth of Z-50. The
Draft Angle up all 4 walls is 5 Degrees.
A cylindrical section of Rad 15 runs with
its axis along and central to the sloping
upper face.
All Fillets are Rad 5.
• From the Main pull down menus select File - Save As :-
D:\users\training\COURSEWORK\PowerSHAPE-Models\SolidModelling-1

• Create a single Workplane at 0.
• From the Main toolbar select Solid to access the Solid options toolbar on
the left of the graphics area.
• From Solid options select Create solid block.

• Left mouse click on the workplane to locate the new solid block on to it.
• Right mouse click on the solid block and select Modify from the local
editing options.
• Fill in the form exactly as shown above and then select the Workspace
tab.
• Enter -50 in the third coordinate box (Z) as shown below and select OK.
When a Solid is created it becomes Active by default and its Wireframe will be coloured
Red. Only one solid can be Active at any one time. Other entities can interact with the Active
solid which will also register them within a History Tree.
• From the Views toolbar select a View from Front (-Y).

• From the Main toolbar select the Line options to access the Line
• Select the Create a single line option.

• Enter the coordinates -50 -50 -25 for the start of the line into the
Command Input box located below the graphics area.
• Enter the coordinates abs 50 -50 -10 for the start of the line into the
Command Input box located below the graphics area.
• Select the angled line.
• From the Main toolbar select the Surface option to access the Surface
• . From Surface options select Extrusion.
With the Line pre-selected an extrusion Surface is immediately created. Note that the upper
side of the Surface is shaded Red (inside) while the underside is the current default colour
for Surfaces (outside). The Surface must extrude fully through the Solid.

• If the extrusion Surface does not pass fully through the Solid then
double left mouse click on the Surface to open the Surface Editing form
• Insert a Length value of 100.
• Select OK.
Note:- It is also possible to dynamically drag the arrow at the end of the selected, extrusion
Surface to increase or decrease the Length.
• With the Surface selected and the Solid Active click on the Feature
option on the Main toolbar.
• Select the Boolean Remove option as shown above and the part of the
Solid on the Red side of the Surface will be removed.
The Surface Removal is registered in the History Tree.

• Select Create solid fillet form the Feature toolbar.
• With the Fillet form open and default Radius 5 set, Shift select the 4
curves linking the upper and lower rectangles before left mouse clicking
on Apply.
• Dismiss the Fillet form.

• Repeat the same Filleting process on the upper rectangle.
The two separate filleting processes will

keep the Fillet running around the top
independent from the 4 running up between
the sidewalls. This will make it easier to
implement any future changes to any of the
5 individual fillets.

• From the Main toolbar select the Line options to access the Line
• Select the Create a single line option.
• Using the left mouse key snap the line to the 2 lower corners of the planer
sloping face.
• From the Views toolbar select the Shaded View option.
• From the Main toolbar select Workplanes to access the Workplane

• Select Create a single Workplane aligned to geometry and left click

anywhere within the top sloping face to create a Workplane with its Z Axis
normal to the solid at this point.
Note: When a new Workplane is created it

becomes Active (coloured red) by default.

• Use the left mouse key to select and dynamically Drag the Workplane to
the Mid-point of the recently created line across the lower end of the
slope.
Note:- If there is no response check that Drag Move is ticked in the above View menu (To
Open, right mouse click in an empty part of the graphics area).
• From below left of the graphics area select X as the operational direction.
• From Solid options select Create solid cylinder.

• Left mouse click on the new workplane to locate the new solid cylinder
on to it.

• Right mouse click on the solid cylinder and select Modify from the local
editing options (Or Double left mouse click on the solid cylinder).
• Fill in the form exactly as shown above and then select the Workspace
tab.
• Enter -20 in the first coordinate box (X) as shown below and select OK.
The Solid Cylinder will now be removed from the main Solid using a Boolean operation.
• With the Solid Cylinder selected and the main Solid Active click on the
Feature option on the Main toolbar.
• Select the Boolean Remove option and the selected Solid cylinder
will be removed from the main solid.

• Activate the Workplane at the top, centre of the component.

• From Solid options select Create solid cylinder and in the Command
Input box enter -35 -25 -50 to define the base/centre position.

• Right mouse click on the new solid cylinder and select Modify from the
local editing options (Or Double left mouse click on the solid cylinder).
• Modify the Radius to 4 and the

Length to 40 before selecting OK.
The new Solid Cylinder will now be removed from the main Solid using a Boolean
operation.
• With the new Solid Cylinder selected and the main Solid Active click on
the Feature option on the Main toolbar.
• Select the Boolean Remove option and the selected Solid cylinder
will be removed from the main solid.
Now that the first hole has been created the other three can be copied and mirrored across
the Workplane to the correct locations.

• Select the latest Boolean removal action displayed in the PowerMILL

explorer.
The most recent solid operation will be located at the top

of the History tree.
• Select Show general edits options

followed by Edit selected sub-items.
• Select Mirror items and select the Mirror in ZX option.
A copy of the hole appears on the

Solid mirrored across the ZX plane.
The new hole will now be displayed
at the top of the history tree.

• Select the Boolean removal actions for both holes as displayed in the
PowerMILL explorer.
• Select Show general edits options followed by Edit selected sub-items.
• Select Mirror items and select the Mirror in ZY option.
Copies of both the selected holes

are mirrored across the ZY plane
as shown left.
The solid component is now

complete. The existing Features
or operations in the History tree
can be edited or repositioned
retrospectively and the Solid will
automatically update to
accommodate valid changes.

Basic Solid Editing
• Double left mouse click on the original solid block symbol at the bottom
of the History tree to open the Block definition form.
• Modify the value for Width (Y) from 75 to 100 and all four Draft values to
-15 before selecting OK.
The Solid component has been fully

updated to comply with the above
dimensional changes.
The Holes now require moving to be

inboard of the fillets running around the
upper sloping face.

• Zoom into the area containing the 2 Holes in the +X direction.
• With the Shift Key depressed

accumulatively select the 2 Holes
using the left mouse key.
The 2 Holes will also be selected (Boxed) in the History tree.
• In general edits select the Edit selected sub-items option.
• Still in general edits select the Move/copy items option.
• In the Command input box type -5 to move the 2 selected hole features.
The 2 selected hole features

have been moved within the
Active Solid.
• From the Main pull down menus select File - Save to update the current
state of the stored PowerSHAPE model.

Die Example
The following Die example illustrates how solid modelling can produce parts more quickly
and easily compared with surface modelling.

D:\users\training\COURSEWORK\PowerSHAPE_Models\SolidDie
• Create a workplane at 0 and set the principal plane to Z.
• Select the Solid icon from the main toolbar.
• From the Solids toolbar select Create solid block.

• Position the solid block by typing 0 0 -40 in the coordinate input window.
• Double click on the solid block in the graphics area opening the form
shown below.
• Input the length as 100, width as 150 and

height as 40 and press OK.
PowerSHAPE also displays a History tree listing all the solid

operations. The red flag indicates that the solid named 1 is the Active
solid.
The first solid automatically becomes Active and will be

displayed in Red.
• Set the principal plane to X.

• From the primitive Solid options select Create solid cylinder.
• Position the cylinder with the co-ordinates: -55 0 0
• Change the radius to 2 and the length to 20.

The wireframe view displays all solids with a Grey

colour, with the exception of the Active solid which is
displayed in Red.
• Create a solid cone with the co-ordinates: -35 0 0.

• Edit the top radius to 1, base radius to 2, and length to 30.
This model contains 3 solids, the large Block solid

being Active.
The Active solid is identified in the history tree with a red flag.
• Left click on the solid cylinder to identify it in the Solid History Tree, and
then click on the Grey flag to change it to Red (Active Solid).
The cylinder is now the Active solid.
• Select the solid cone.
• From the Features menu, select Add the Selected Solid to the
Active Solid.
The cone will be added to the cylinder together as a new active solid.
In the history tree, the second solid is now active and it shows that
the solid cone has been added to the solid cylinder. This solid can be
temporarily removed from the active solid by left clicking on the
green tick (changes to a red cross). The suppressed, added solid, can
be returned again by clicking on the red cross.
The moulded component to be sunk into the die will be imported as surfaces and
subsequently converted into a solid.

• Blank all of the solids and import the model:-

D:\users\training\PowerSHAPE_data\psmodels_n_dgk\handle.dgk
The imported model is made up of various surfaces, which

are to be used to create a single solid.
• From the Solids toolbar select Solid from Surfaces.

The selected surfaces have become one single solid. If the surface
edges do not match a watertight wizard will appear automatically,
providing the opportunity to fix any gaps.
The original handle solid will become part of the Active insert block
solid. As a result a separate copy of the handle solid must be created
for use later as the basis for an electrode.
• Name level 5 as Solids, and leave the level switched off.

• Select the handle solid 8 and select the copy and then paste.
• Put the pasted copy (already selected) onto level 5.
This new solid can now be added to the original solids.
• With the ‘gate' solid Active, select the handle solid.
• From the Features toolbar select Add the Selected Solid to the
Active Solid.
To produce the cavity in the die block, the

selected solid is subtracted from the Active solid.
• Make the die block solid active and select the handle form Solid.

• From the Features toolbar select Remove the selected solid ….
A single solid is produced which has absorbed the

handle form solid. A copy of the handle form solid
was created earlier which will be used to make an
electrode.
• Blank the cavity solid and switch on level 5.

• Select the Z principal plane.
• Create a surface primitive plane at 0, width 80, length 120.
This Surface does not need to be turned into a

Solid to apply the Solid Split command.
• Make the handle solid Active.

• Select the plane and from the Features menu, select solid split.
The solid has been split into 2 new solids

on both sides of the planer surface.
• Delete the upper half of the handle.

• Create a composite curve around the upper edge of the handle.
• Make a solid extrusion 15mm up Z.
• Add the solid extrusion to the handle.

The solid extrusion forms a ‘run off’ to provide

clearance between the electrode form and the back
plate.
• Create a solid block at 0 0 15, length 60, width 130, height 20.
• Add the two solids together.

• Rename the solid as Cavity_Electrode.
• Put the new solid, on level 5 and switch the level off.
A Slide will be created to provide an undercut, hole in the moulding.
• Select Unblank and Activate the Cavity solid.

• Select Principal Plane along Y.
• Create a Solid Cone at 4 –52 -3 with:-
Top Radius 2 Bottom Radius 2.25 Length 5.
• Select the solid cone and Add it to the Active solid.
The solid now has a localised undercut,

core that is to be separated onto a
retractable slide. A workplane will be
created at the end of the core to assist
with the separation of the slide form.

• Create a Workplane between these 2 points.
Hint, create a line between the two points and the mid-point can
be used as the key point.
Alternatively, after selecting create a single Workplane, open
the position input form , select Between before sequentially
snapping the 2 points
• Select Principal Plane along Z and Lock the plane.
Locking the plane will cause new wireframe lines or arcs to be on the Z Zero plane.
• Unlock the Z plane.

• Select a view down the Z axis.
• Create a composite curve of a suitable slide
form around the conical core as shown
(linear sides are of length X6 with + or - Y0.5
to create a suitable draft angle).
• From general edits select Project the
composite curve onto the Z0 plane.
• Selects the Solid options and create an Extrusion surface.

• Double click over the extrusion surface to open the editing form.
• Enter a Negative length of 30, Draft angle 2 and Length 0.
• Select OK.
The extrusion surface will be used to split the main

solid extracting the slide form as a separate solid.
• Make sure the main Die insert solid is the Active solid.

• In the Feature Tree area expand all the + symbols so the full history of the
Active Solid can be seen working from the bottom upwards.
• Select the extrusion surface.
• From the Solid Feature toolbar select Split solid.
Both resultant Solids will retain their

separate associativities within the Solid
history tree.
• Select File - Save to update the content of the stored model file.
Burglar Alarm Box Example

D:\users\training\COURSEWORK\PowerSHAPE_Models\SolidAlarmBox
• Create a workplane at 0 and rename it as Datum.
• Create a solid block at the 0 workplane Datum with the dimensions of:-
Length (X) 250 Width (Y) 300 Height (Z) 130 and Draft 340 on all 4 sides.
This has formed the basic shape for the Alarm Box.
Further solid features will now be added.

• Create a rectangle of lines from -60 -80 130 with size:- (X) 120, (Y) 160.
• Create a composite curve from the rectangle.
• Create a Radius 10 fillet on all corners of the composite curve.
• With the composite curve selected open the Features Menu and
select Create Solid Cut.
The Solid Cut form appears, while the composite

curve is selected.
• Select Blind, Depth 1 and press OK.
A 1mm deep recess is created into the Solid

downwards from the composite curve.
The next stage is to remove the sharp edges from the main body by introducing Solid Fillets.

• From the Features menu select create solid fillet.
• Enter a radius of 10.
• Accumulatively Select all 4 steep edges and the 4 edges around the top
and Apply.
Note:- Unlike Surface filleting a solid fillet will run flush up to the solid edge
Next four screw apertures will be created using Remove solid.
• Create a default sized, primitive

solid cone at 80 -135 5.
• Quickly double left mouse click

on it to open the Cone edits form.
• Fill in the values (as shown right)

before selecting OK.

• Make the solid cone Active.
• From the Features menu select create solid fillet.
• Create a 2mm solid fillet around the base of the cone.

• Mirror the cone across YZ, XZ and YZ to produce a total of 4 cones.
• Select the Main body to be the Active solid again.

• Select all 4 cones and apply Remove selected Solid from Active.
All 4 Cone solids are removed from the Active,

Main Body solid.
• Create a 1mm radius solid fillet

around the outer edge of each conical
recess.

• From the Solid Features toolbar select Hollow Solid .
Once the Hollow Solid form is open the user will

be required to select the face from which the
hollowing out process is to occur. To do this the
solid must be shaded so that is possible to select
the middle of the base as the specified face.
• Select the bottom face of the model.
The red cross adjacent to ‘Removal Face Selected’

will be replaced by a green tick.
• Enter a Thickness of 3.
• Press OK.
The solid now has a uniform wall

thickness hollowed out from the original
base as shown left.
The next stage is to create air vent features

on the side walls.
• Select a view down from left -X and set the principal plane to X.
• Create Rectangle of lines at 0 -7 12 to 0 14 88.
• Fillet the 2 left hand corners with radius 10.

• Fillet the 2 right hand corners with radius 2.
• Create a composite curve of the profile.
• Select both the solid and the composite curve.
• From the curve menu select curve projection.

• Select Through surface/solid/component and press OK.

The composite curve has

been projected through the
entire solid in the direction
of the Principal plane.
Only the curves on the

outside faces are required.
• Delete the 2 curves on the inner face.

• Select one of the remaining outside curves.
• On the Solid Feature toolbar open the Solid bulge form.
• Enter an Angle of 10 and Apply.

• Select Dismiss.
The Solid Bulge appears in the solid as well as

a separate item in the history tree. As a result it
can be edited as a sub-item and be copied,
moved, mirrored etc within the solid.
• Click the Solid Bulge icon at the top of the Feature

Tree.
The Solid Bulge operation becomes highlighted.
• Select the General Edits toolbar and note that the Edit sub-item option is
already selected.

• Select the Move option and set copies to 1 and enter 0 30 in the bottom
right input window and press return.
• Then in the bottom right input window enter 0 -60 and press return again
before dismissing the form.
Three air vent forms have been generated for this

side. They will be mirrored in turn to the opposite
side of the main body.
• Shift select all 3 bulges and using

Edit selected sub-item, mirror in the
YZ axis, keeping the original.
Copies of the vent (solid bulge) forms are mirrored to the opposite face.
Additional geometry is now required as the basis for creating ventilation
slots for the vents.
• Create a Rectangle of lines at 0 -7 15 with sides 0 5 82.

• Create a composite curve from the rectangle of lines.
• Copy the curve by 30mm along Y on both sides of the
original.
The solid has been blanked to display the three new composite curves.
• Select all 3 rectangular composite curves.
• From the Solid Features menu select Solid Cut.
• Select Through.
• Select both directions.
• Select OK.
The ventilation slots are cut out of the main solid.

The next stage is to create a mounting for

the strobe light on the end face of the box.
In order to assist alignment of the
mounting, a workplane will be created
aligned normal to the angled face.
• Set the active principal plane to Z.
• Select the Iso1 View.

• Select Workplane Aligned to Geometry and select this face.
• Double-click the Workplane and modify the
workspace values to be 0 -135 65.
• Activate the Workplane.
• If necessary, twist the workplane about Z so
that it’s X axis is aligned towards the top of the alarm box.
The Z axis of the new workplane is aligned normal of the selected face. A boss complete
with a through hole will be created aligned to the workplane Z to provide access for a strobe
light mounting.
• Generate a Full Circle of radius 30 at the workplane 0 and create a solid

extrusion.
• Modify the extrusion with a length of 0 and a negative length of 20.
• Select OK.

• Generate a solid block primitive at 0 0 -20.

• Modify the block dimensions to Length 100, width 40, Height 30.
• With the circular extrusion, Active and the solid block selected, open
the Solid Features toolbar select Intersect the Selected Solid.
The new solid is jutting beyond the inner wall of the main solid. To trim it back to the inside
and at the same time, add the outer part to the main body solid the solid boss option will be
applied.
• Select the main casing solid and make it Active.

• With the Intersected Solid selected, select Solid Boss.
The Solid Boss form offers 2 possible

solutions. It allows the Intersected feature to be
split to exist either on the outside face or the
inside of the main body.
• Toggle to the solution (In this case 2) with the highlighted boss on the
outside and select OK.

The Solid Boss has been trimmed back. A hole

for the wiring will now be created through the
boss.
• From the Solid Features toolbar select

create a hole.
• Position the hole at 0.

• For Hole Category select Untoleranced.
• For Use select Plain.
• Enter the Plain Hole length as 50 and the diameter as 16.
• Select OK.
The finished Alarm Box Solid

Model.

Plastic Handle Example
• Open the Model - toy_handle.psmodel from:-

D:\users\training\PowerSHAPE_data\psmodels-n-dgk
The basic imported model contains a large handle form solid along with 6 small rib feature
solids, all of which are displayed in the history tree.
• Select File – Save As and store the model to the following location:-
D:\users\training\COURSEWORK\PowerSHAPE_Models\PlasticHandle
• Make sure the main handle solid is Active.
• From the Features menu select Solid Fillet.
The Solid Fillet menu appears. Unlike Surface Filleting, Solid Filleting directly, uses the
sharp edges on the Solid as the Filleting track. The order and extent to which the individual
Solid fillets are created is important, if the correct design specification is to be achieved.
In this case, to provide the correct shape of drive curve around the upper and lower edges of
the ‘D’ shape, it is essential to create the vertical corner Fillets first.
• Set a radius of 6 and select the 2 outer vertical edges shown.
The fillet path runs until it finds a sharp edge.
• Select Apply.

• Generate a radius 4 fillet along the top and bottom faces.
The outer edge is now complete. The

inner 'D' shape will be modified to include
a fillet of radius 4mm flowing out to
6mm at the mid-point of the curved
section.
• Zoom into the 'D shape'.

• Fillet the vertical internal corners
with a radius of 4mm.
• Select the top inner edge.
• Select the option Advanced in the
Fillet form.
This form allows you to select by mouse, an arc to represent the radius that the fillet will be at
that point. This works in a very similar way to variable radius filleting of surfaces covered
earlier in the course. By moving the mouse along the track, the word key will appear. Click at
that point and a numbered arc is generated. This arc can be stretched or changed in the form
to the desired radius.
• Select a View down the Z Axis.

• Click on the track to define locations for radius 4 and one place
(arrowed) where radius 6 is required.
Radius 4
Radius 6
• Modify the Arc Radii as indicated and press OK.

The variable fillet is produced.
• Generate a similar variable fillet on the

underside of the solid.
• Dismiss the fillet form.
The main fillets have been generated. The

solid ribs can now be removed from the main
solid to produce a grip effect on the handle.
• Select all the solid ribs and Remove from the Active solid.
The completed model of the outer form

is as shown left.
It is required to core out the outer form with a 3mm wall thickness. Due to certain
dimensional restrictions some of the features must be suppressed before attempting to create
a new solid to represent the inner form. It will also be necessary to perform additional
material removal on the inner form along the shaft to maintain the nominal wall thickness.

• In the Features Tree - Suppress all six ribs and the logo features from
the main handle solid (just click on the Green ticks next to each feature).
The ribs and logo recess have

temporarily been removed
from the solid.
• Using General Edits - Offset create a copy of the selected solid offset by
-3mm to provide the inner wall, excluding the rib and logo detail.
Now that the basic form for the inner solid has been created the original active, outer solid is
updated to include the rib and logo features again.
This is achieved by applying Unsuppress in Feature Tree to each rib in turn. (click on the
red crosses next to each feature).
• In the history tree left click on all red crosses adjacent to the suppressed
features one at a time to reinstate them onto the outer form solid.

Turning to the inner core solid, there are a couple of design modifications required. These
include extending the shaft through the end of the outer form and creating a 3mm wall
thickness below the logo recess. To show these requirements more clearly the Model
Analysis - Dynamic Sectioning option will be applied.
• Select both the inner and outer solid.
• From the left hand toolbar select Model Analysis followed by the
Dynamic Sectioning Option.

• Select the operational axis to Y from the drop-down list.
• Move the Back slider to exactly 50 (half way across model) and click
Create Wireframe (Note; for incremental steps use keyboard arrow
keys or mouse wheel)

• Create a View along Y.

• Quick select all wireframe and select Blank Except (CTRL K).
• Check the wirefame for acceptable wall thickness and then select the two
composite curves defining the section along the shaft centre.
• Snap a wireframe line to the outer composite curve as shown above and
edit the length to pass through the end wall (e.g. 200mm).
• From the right hand end of the existing line create another line of suitable
length (e.g. 15mm) at angle of 30 degrees as shown above.
• Select and Blank the 2 composite curves.
• Create a composite curve along both lines from left to right and from
General Edits select the Offset option.
• Select Round discontinuities, No. of Copies 1, and input a Distance 3

before pressing the Return key.
• With the new offset curve selected, create an Extrusion Surface of
length 40 (along Y).
• Edit the Extrusion surface - Workspace with a Y coordinate value of -20
to centralise the surface across the shaft.

• Make the inner core solid Active and select the new extrusion surface.
• In the Feature toolbar select Remove the selected solid/surface
… to remove the red side of the surface from the active solid.
The core solid illustrated also includes

revised wireframe obtained from a
further 50% dynamic sectioning
operation to show the new wall
thickness.
• Create a composite curve around the end of the core solid shaft.
• Set the operational axis to X and select the new composite curve.
• Create a solid extrusion and dynamically drag it along the -X direction
until it has passed through the end of the outer solid form (eg. length 20).

• Make the main inner core solid active.

• Select the new solid extrusion and from the Feature toolbar select Add
the selected solid….. to the active solid option.
• Make the outer form solid Active.

• Select the inner core solid and from the Feature toolbar select
Remove the selected solid….. from the active solid option.
The completed solid spade handle component is a shown above.

Rib Fillet Feature

The Rib Fillet feature directly creates a fillet across 3 faces of a solid. The full radius fillet
is created tangentially to all of these faces. The radius of the fillet will vary depending on the
angles between the faces and the distance between them. The cross section below illustrates
the way the full radius is formed.
Rib Fillet Example 1

D:\users\training\psmodels_n_dgk\Rib Fillet.dgk.
There are two ribs on the

model.
The curved rib has a varying

width; it would be difficult to
generate a full radius on this
rib using a varying radius
fillet.
• Select the solid and make it Active.
• Select Solid Feature.

• From the pop up menu under Solid Fillet select the Rib Fillet Icon.
• Ensure that Individual Faces is selected on the form as shown at the right.
• Select the top surface of the curved rib as

shown below.
The Rib Fillet feature will be formed

as in the picture to the left. Note that
the fillet changes with the width of
the rib to form a full radius.
• Create a Rib Fillet for the small rectangular rib.
Note how the corners of the Rib Fillet are mitred
• Close the model without saving it.

Rib Fillet Example 2

In this second example a series of rib fillets will be created on a model of a motorcycle
cylinder. The fins on the barrel are tapered in two directions giving a constantly varying with
to the fins and the troughs between them.

D:\users\training\psmodels_n_dgk\Barrel.dgk
Note the tapered form of the fins and the troughs in between
them.
• Make the solid active.
• From the Solid Feature menu select Rib Fillet.

• On the form select All Continuous Faces.
• Click on a face on the bottom rib.
When the option, All Continuous faces are selected

PowerSHAPE searches around the model finding all faces
that are tangential to the selected face. The whole surface
area of the rib will be highlighted.
• Press OK.
As is shown left, the Fillet has been created as

shown around all selected fins.
Note:- It is not possible to apply the Rib Fillet

option to all the Ribs in one go. The Continuous
Faces of each Rib must be dealt with by separate,
repeated use of the Rib Fillet option.

• Select a view along the Y Axis.
• From the Solid Feature menu select Rib Fillet.

• On the form select All Continuous Faces.
• Click on a face in the bottom of the

trough above the bottom rib.
• Select OK.
The bottom of the trough will be filleted as seen below.
• Repeat the process until all

of the fins and troughs have
been filleted.
The completed model is shown below. By using Rib Filleting this complex piece of
modelling has been done quickly and easily.

Thicken Solid
The Create a Thickened Solid option allows a wall thickness to be applied to an Open
Solid. It is used in applications where a model is required to have a constant wall thickness.
In the following example an open solid defining the outer surface of a pressing will be
thickened to produce the complete pressed sheet metal component.

D:\users\training\powerMILL_Data\psmodels_n_dgk\SheetMetal.dgk.
• Select all of the surfaces.

• From the Solids menu, select Make Solid From Surfaces.
Due to the original surface model consisting of an outer skin it is necessary to convert the
newly created Parasolid to a V8 solid before the Thicken Solid option can be applied.
Once the V8 Solid has become has been thickened to form a ‘solid mass’ then it should be
possible to convert it to a Parasolid.
• Select the option to Convert the Solid to a V8 Solid.
• Select the Feature toolbar and then click on the Thicken Solid
option.

The following form will open advising the user to make the V8 Solid Watertight.
• Select Yes to open the Make Watertight Wizard.
Several Large Holes plus a single Small Gap are identified by the wizard.
• Keeping the default Repair options select Next.
The Large holes have been retained

and the Small gap has been fixed.
• Select Next to move to the next form.

• Select Finish to accept the Watertight status and close the form.
• In the Thicken Solid form, enter a Thickness of 2 and then select OK.
The Solid is now thickened.

It should now be compatible for conversion to a
Parasolid so long as the Thicken Solid operation
has created the inside form accurately enough.
As a precaution it would be a good idea to run the
Watertight wizard again, prior to applying the
Parasolid conversion.
• In the Solids toolbar select the Convert to Parasolid option.
The Warning form appears advising of the failure to convert the V8 Solid to a Parasolid. As
a consequence, the thickening of the V8 Solid is removed.
• Select Undo to return to the Thickened V8 Solid.

• With the V8 solid selected

Solid Exercise 1
• Create the following component as a Solid model.
Solid Exercise 2

D:\users\training\PowerShape_Data\psmodels-n-dgk\JugOuterWall.dgk
The Imported Surface model defines the

outer skin of a jug.
Part 1 of the exercise is to create the 3mm

thick, inner wall and to modify the handle,
locally to be solid (no wall thickness).
Part 2 is to create a Rib Fillet around the

rim.
Part 1
• Create a Solid from the Surface Model.
• Create the inside form using Thicken Solid with a 3mm wall thickness.
The Solid is Thickened by 3mm (inwards)

which also applies to the inside of the
handle. Note:- The design specification
requires that the handle is a completely solid
form.
• Convert the Solid back to a Surface model.

• On the main part of the inner wall, Delete the Pcurves (and Boundaries)
that form the trimmed openings into the inside of the inner handle wall.

• Delete the Surfaces that define the inner wall of the handle.
Part2
• Create a Solid (again) from the remaining surface model.
• Apply a Rib Fillet Feature around the rim.
D:\users\training\COURSEWORK\PowerSHAPE_Models\SolidJug-Ex2


PowerSHAPE 15. Delcam Drafting
15. Delcam Drafting

Introduction
Delcam Drafting is included as part of the basic PowerSHAPE module. Delcam Drafting
enables the creation of fully dimensioned and detailed drawings including, cross sections,
dimensions, and text.
Delcam Draft is accessed by selecting Module>Drafting from the top pull down menu or
the Drafting Mode option on the main toolbar.
This changes the main Toolbar to Drafting mode.
Delcam Draft Example
In this example we will create a few views followed by a few simple dimensions.

D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\golf-fin
• Delete all the wireframe.

15. Delcam Drafting PowerSHAPE
• Select Tools > Options> Drafting > Drawings and set sheet size as A3.
• Select Enter Drafting.
Drawings are created and saved with the

model file.
As no drawings exist in this model the

list on the left is empty. A New Drawing
will be created.
• Select Create New Drawing.
A new empty drawing window is created with the name golf_fin: s1 which is sheet 1 of the
model golf fin.
A new view is automatically created and attached to the cursor.

This can also be created by selecting the view command.
• Move the mouse into the graphics area to the top left corner of the sheet
and Click with mouse button 1 to accept.

A front view is automatically

produced. This view is generated
looking down the Z-Axis of the
Active Workplane or World.
By putting the mouse on the edges of

the box an arrow appears which is
clicked and pulled dynamically to
create further views.
• Move the arrow to the bottom of the box.

• Click when the mouse turns to an ‘up’ arrow.
• Place the new view below the front view.
• Move the mouse into the front view and click the right mouse button to
open the Drawing View menu.
This Drawing View menu provides a choice of options

on the selected view.
• Select Active.
This displays a red border around the view and highlights

the datum. With the view Active it is possible to create
further geometry local to the view.

• Create a single line from 0 –20 to 0 60.

• Select Views to see the Views toolbar.
• With the line selected, from the Views toolbar pick Section View.
This puts two arrows on the section line showing which way you are looking at the view. The
arrows can be clicked with the left mouse key to change the direction, if required.
• Click to the right of the front view to place the section view.
PowerSHAPE automatically puts

the section lines on the model and
the text section A-A. Further
sections can be generated from this
view, including angled sections and
stepped sections. This section is
made up of wireframe and can be
deleted without affecting the
original model.
• Zoom into the section drawing and from the main toolbar select
Annotation.
• From the Annotation toolbar select Automatic Dimension.

• Move the mouse to the left hand end of the top line and click.
• Move the mouse (stretches a dimension) to the left hand end of the
bottom line and click.
• Move the dimension out to the left and click to locate the dimension.
The first dimension has been taken from two

selected points.

• From the Annotation toolbar select radius.

• Click on the top right arc and then Dog leg dimension from the
dimension toolbar.
• Click a point along the top right fillet radius, position the dimension as
shown below and click to Accept.
The radius dimension automatically appears with an 'R' in

front of the value. To modify a dimension double-click on
it to access the options in the dimensions toolbar.
• From the Dimension toolbar, select minor angle.

• Select the bottom end of the angled line when End appears and click.
• Move the cursor up vertically by a small distance (along the ghosted

line) and snap to accept the lower position for the first witness line.
• Click anywhere along the angled line to define the other side of the angle.
• Position the text (as shown below) and click to accept the 10-degree
dimension.
Surface data can also be dimensioned in exactly the

same way.

The Drawing is stored with the Saved model.
• Press Save.
• Close the Drawing by pressing the small grey cross at the
upper right of the screen.
• Save the Model.
• Select File > Close.
To access the Drawing, the model is opened and the drawing sheet picked from the list.
• Open the Model.

• Select Drafting mode.
• Select Open Drawing.

• From the list, select S1.
• Select OK.

PowerSHAPE 16. Mold Die Wizard
16. Mold Die Wizard

Introduction
An option has been included in PowerSHAPE, called Mold Die Wizard. Using the active
solid, the Mold Die Wizard will automatically split and trim the model creating cavity and
core inserts.

• Select File > Import, and then select the model:-
D:\users\training\Delcam_Draft data\Phone_Cover.dgk
The model contains the surface data of a mobile

phone cover. For PowerSHAPE to process the
data, through the Die Wizard, the model needs
to be in the form of a solid. After conversion
from a Surface model to a solid it is strongly
advised to check for any potential faults.

• From the solids menu, select create solid from selected surfaces.
• Double left mouse click on the Solid to open the Solid Editing toolbar.
• Select the ‘find and fix faults in the solid’ option and wait for a response.
• The message confirms that the Solid is free from any faults (Watertight).

16. Mold Die Wizard. PowerSHAPE
• Select a Wireframe view to see the areas that contain the small gaps
(displayed in Red).
• Select Next on the form.
• In the next page of the form

select Yes to heal the edges
option.
• Select Finish to heal the solid.

PowerSHAPE attempts to heal the edges of the model to the specified tolerance of 0.01 and
returns with the message:
This informs the user that all of the holes in the model have been
closed to the working tolerance of 0.01mm. The part is now watertight
and ready for the die wizard.
• Select OK to continue.
The model is now Watertight and ready for the Die Wizard. Although recommended, it is
not always essential for the model to be watertight for it to run through the Die Wizard.
• Select the solid.

• From main toolbar select Wizards then select Start Mold Die
Wizard.
The first page of the Mold Die Wizard allows

the user to select the objects to be used for die
creation. These can be in the form of
previously generated Split lines, Split
Surfaces and Die blocks. In this example,
Split lines, Split Surfaces and Die Blocks will
be automatically created by the wizard and the
object information area highlights the
selection of the product only.
• Select Next >
The second page allows the user to create and

edit split lines. The wizard has automatically
generated the split lines to be used for this
model.
Each split line is numbered and can be selected, and modified if necessary, from the Pull
Down list. As a split curve is selected, it is displayed in the Die Wizard graphic window.
The model can be dynamically manipulated in the Die Wizard graphic window in the same
way it can be manipulated in the PowerSHAPE graphic window.
• Select Next > to continue.
This form gives the user the opportunity to

change or create fill-in surfaces. In this case
the surfaces created by the wizard do not
need to be modified.
• Click the Preview button to display the fill-in surfaces on the model.

• Click the Preview button to display the fill-in surfaces on the model.
This page allows the user to

specify product shrinkage; the
amount by which the mould
cavity increases to allow for
shrinkage.
The drop down list displays the abbreviated names of the materials; when a material is
selected, the full name of the material is displayed below. A predefined value (dependent on
the material selected) will be automatically inserted into X, Y and Z. Uniform Shrinkage
can be switched off to enable the user to set different shrinkage factors for X, Y and Z.
• From Material Drop down select ABS.


This page of the wizard allows

the user to specify block size
for the die inserts. Size can be
set using overall dimensions for
the block or by setting a
minimum land dimension.
• Set a block length of 200 and a width of 100.

The next page allows the user to

edit the created split surface. In
this example the split surface is
required to use a combination run
off of radially and along axis.
• Select the ‘Advanced split surface options’.
The Split Segments form appears.
• Select Clear to remove any

existing segments from the
curve.
• Set the corner type to run in
both directions.

• Using the mouse create breakpoints at the positions indicated.
• Set the corner type to run in a single direction.
• Create a single breakpoint at the

position indicated.
• Untick the Insert Breakpoints box to toggle the curve segments option.
• Select segment 1 from the dropdown list and set the direction to be
Along Axis.
Segment 1 will indicate a split along the X-axis.

• Select segment 2 from the dropdown list and set the direction to be
Along Axis.
• Repeat for segments 3 and 5.
• Select segment 4 from the dropdown list and set the split direction to be
Radial.
• Select OK.
This page of the wizard allows the

user to define block heights for the
die inserts.
Values can be determined using

absolute or relative dimensions,
specifying an overall height or by
fixing maximum and minimum
values of the upper and lower parts.
• Set a Minimum Upper value of 30.

• Set a Minimum Lower value of 25.

This page of the wizard

allows the user to define
corner types. There are
three types of corner
definition, Radial,
Chamfer and none. These
can be applied either
individually or globally
to the insert corners.
• Set a 10mm Chamfer and tick Apply to all corners.

The final page of the wizard allows the user to simulate core and cavity separation.
• Move the slider to simulate separation.

• Select Finish to exit and complete the wizard.

PowerSHAPE 17. Further Solid Modelling
17. Further Solid Modelling

Solid Feature Relationships
An option exists to specify the position of some types of feature with respect to the solid by
using the Solid Feature Relationship dialog box. Relationships can be created for solid cut,
solid boss, Boolean, Boolean-boss and hole features and are defined by selecting a key point
on the solid, a key point on the feature and specifying a distance between the two.
Feature Relations Example
• Select Tools Options, select Object then Surfaces and in Primitives

Untick the option Create as NURBS.
• Create a solid block at 0 with dimensions, X 100, Y100 and Z 60.
A parameter is a user-defined variable, which is

used to store numbers and expressions.
In this example a parameter will be created and

used to define a depth and a diameter.
These parameters will then automatically update

the model when their values are changed.

17. Further Solid Modelling PowerSHAPE
• Create a solid block at 0, 0, 60 and open the Solid Block form.
• Set a length of 50, width of 50 and create a

parameter for the height as shown.
A Parameter with the name depth will be created with

an expression or numeric value of 30.
• Click on the Workspace tab and apply a Y twist of 180°
• Select OK in both forms to exit.
• Remove the inner solid block from the main outer solid block.
A Feature Relationship will be set between

the inner feature and the outer block.

• Right Click over the Feature in the explorer window and select Modify.
The Boolean Feature editing form appears.
• Tick the option Display primary and

secondary solids.
• Select Define the relative position of the secondary solid.
• Select Position the Relative

workplane.
The workplane is attached to the cursor and the

key points where a workplane can be snapped onto
the solid are highlighted by circles.
• Click on the corner shown.
When the workplane is located, the

Relationship Workplane text will be
marked with a green tick in the form.

• Select Specify the points on the feature to be used.
The key points are highlighted with circles.
• Click on the key point shown.
When the key point is selected, the form will update.
Dimensions will be displayed on the model, highlighting the

relationship between the two selected positions.
• Select OK.
• From the Solid Features menu, select Solid Hole.
• Attach the Solid Hole to the key point shown.
The Solid Hole form is displayed.

• Specify an Untoleranced Plain

hole.
• Use the previously created

Parameter depth to define the
length of the hole.
A second parameter will be created, and

used, to define the diameter of the hole.
• Click the cursor in the diameter

text box and input the parameter
dia=10.
• Select Plane Details…. button

and then Feature Relationship
With Hole Features the Feature Keypoint will always be the origin of the hole, therefore
the Feature Keypoint has been pre-selected and cannot be changed.

• Select the workplane icon on the form to attach a workplane to the

cursor and display key points on the Solid.
• Attach the workplane to the key point position as

shown and a green tick will confirm the action.
• Select OK at the bottom of the above

Solid Feature Relationship form.
• Select OK on the Plane Details form.
• Select OK on the Solid Hole form.

• Create a second hole at the position indicated.
The parameters for the depth and diameter are still in the hole form, this can be checked by
hovering the cursor over the relevant text boxes.
• As before, select Plane Details and then Feature Relationship.
• Attach the workplane to the key point position

as shown and Select OK on all three forms.
• Repeat the process creating 2 more Solid Hole features, using the
parameters to define length and diameter, to produce the model shown.

• Right Click on the Solid Block (The last item in

the history tree) and select Modify.
• Modify the Block length (X) to 200 and

select OK.
Note:- The pocket feature is still maintained at X25 Y-25 from the top left corner of the
main Block Solid (The pocket detail would otherwise have remained centrally located).
Next the X position of the pocket feature relative to the main Block will be changed by
editing the Feature Relationship.

• Right Click over the Feature and select Modify.
• Select Feature Relationship.
• Enter an X value of 40 and OK the form.
The first edge of the Pocket Feature detail is now positioned 40mm from the end of the
main Block.

The Parameters created defining depth and diameter can also be retrospectively modified.
• From the Object pull down menu at the top of the screen,
select the Parameter option to open the Parameter
Editor form.
The Parameter Editor allows parameters to be created and modified.
• From the top left, Parameter window select the depth parameter.
The value of the parameter (30mm) will be displayed in the form.
• Press to clear the value of 30.
• Enter a new value of 10 and press

Apply.
The model updates reflecting the change to the

depth parameter.

• From the Parameter pull down select the dia parameter.
The value of the parameter (10mm) will be displayed in the form.
• Press to clear the value of 10.
• Enter a new value of 15 and press Apply and OK.
The model updates reflecting the

change to the dia parameter.
Do Not Close the Model as it is

required for use in the next section
(Edit Solid Face).
Note: An important point to remember when working with parameters is that they are case
sensitive i.e. depth, Depth and DEPTH are three totally different parameters.
Edit Solid Face

Individual faces of the active Solid can be edited using the Surface Editing tools. When an
individual face of the Solid is selected for editing in this way, the main surface edits toolbar
is activated. The user can use the toolbar to add extra curves to the face, move seected
points, and change tangent angles and magnitudes.
• Right click over the solid in the graphics window and from the local
menu, select Edit Surface.
The Edit Face form appears.

• Select the front face of the Solid.
The form will indicate that the face has been
selected.
• Select Edit on the form.
Selecting Edit will activate both the general Edit and Surface Edits toolbars.
• Select the Add Curve options and insert 4 new surface curves to
the face in the order specified below.
• Apply a Lateral curve initially at the Parametric Value of 1.75 and then at
1.25
• Apply a Longitudinal curve initially at a Parametric Value of 1.75 and
then at 1.25
• Dismiss the Add Curves form.

• From the Selection Pop up.
• Select the Select Pattern of points.

• Enter the values into the form as shown overleaf.
• Select OK.
Points have been selected on the face using

the specified range.
• From the Edit toolbar switch on Edit Selected Sub-items.

• Move the selected Points along the Y-axis by -10mm and Accept the
Edit Face form.
The Solid face has been modified.


PowerSHAPE 18. Plotting
18. Plotting
Plotting
Plotting is done via the Print icon or Print under the File Menu.
Models and drawings can be printed out directly on a printer/plotter, or saved and exported to
a file in a number of formats.
• Open the drawing bracket_example.

• Select Tools Options and choose Drafting Views General
• Switch off the Display Boundaries option.
By switching Display
Boundaries off on the drawing,
you can visualise how the plot
will appear.
Note: It is not compulsory to

switch off Display Boundaries
before plotting.
• OK the form.
Plot Drawing
• To plot the drawing, select Print under File on the top menu bar.
This form is used to print the contents of

the graphics window and to control the
destination of the print (Printer, or
File). If OK is selected the contents of
the graphics area will be printed using
the current settings to the specified
printer or output file format, output file.
The output format can be determined

using the Print Setup option under File.
• Select OK to close the form.

18. Plotting PowerSHAPE
• Press File Page Setup.
Printer or plotter options can be set using

the Printer button on this form: this brings
up the Printer Setup form
File options can be set using the Files

button: this brings up the Print to File
Settings form
• Select the Printer and then Files button.

Print to File
Print to File option is selected on the Print form then the file can be saved in a number of
formats.
• Select the Print to File option and then the OK button.
The Print to File

form appears:
• Change the File Type to *.bmp and enter a suitable file name, such as
bracket_example.
• Click the Save button.
This file can now be viewed in an image viewer, such as Imaging or Paint Shop Pro.
Further plotting options can be found on the Plotting page of the Options menu.
Print to File can be accessed directly from File>Print to File

Standard PDF
Drawings or Model views can be saved as the now widely used PDF format (Portable
Document Format). Free Conversion tools are widely available to download such as PDF995.
Once installed (including a Printer driver), files can be converted quickly by selecting this
printer.
• Select Print under File on the top menu bar.

• Select the PDF Printer (PDF995 in this case).
• Select OK.
• Enter a suitable save Location and Filename.

• Select Save.

3D PDF
PowerSHAPE allows direct exporting to a PDF format but with real-time interaction.
• From File>Examples…, select the concept_aircraft.mac

• Select Export under File on the top menu bar.
• Select Export again
• Select Adobe Acrobat Document (*pdf) from the Save as type pull down
menu.
• Enter a suitable save Location and Filename.

• Select Save.

Locate and open the saved file on the computer. (Note: Adobe Acrobat
Reader must be installed to enable PDF viewing)
The view can be manipulated by using the mouse and selected icons.

PowerSHAPE 19. Exercises
19. Exercises
Radiator Valve Cover
Model the radiator component.

19. Exercises PowerSHAPE
Keyboard Button
Model the surfaces to form the keyboard button shown below. The button has a winding
angle along one edge, which can be difficult to visualise. It is a constantly changing angle
from one edge to the other.

PowerSHAPE 19. Exercises
Plastic Bottle
The shampoo bottle shown has a variable radius fillet blend at the base.

19. Exercises PowerSHAPE

PowerSHAPE 20. Parasolid Fixing
20. Parasolid Fixing

Introduction
PowerSHAPE 2010 is the first release to use Parasolid. To maintain compatibility with the
original Version 8 solids, an option exists to convert to and from both types of Solid. If new
solids are being created, the existing user will notice no obvious difference in the command
structure. What will be evident is a vastly improved ability to perform operations, a prime
example being Solid Filleting. When the user is checking and repairing faults with the new
default Parasolids, a new Solid Doctor is accessed instead of the old, Version 8 solid, Make
Watertight Wizard. The new Solid Doctor identifies and clearly labels all faults on the
parasolid, enabling the user to systematically view, select, and fix them.
Solid Editing toolbar
An old ‘version 8’ solid can be converted to or from a Parasolid by selecting .

The same option is also used to convert a Parasolid back into a ‘version 8’ solid.
The default conversion for a Surface model is also directly to a Parasolid. In both cases it is
more than likely that the new Parasolid will require further attention to remove gaps and
other inaccuracies.
If the ‘Find and fix faults in solid’ option is selected, the new Solid Doctor form will
open for Parasolids, or the original Watertight Wizard for the older Version 8 solids.
Solid Doctor Make Watertight Wizard

(Parasolids) (Version 8 Solids)

20. Parasolid Fixing PowerSHAPE
Speaker Core - Surface to Parasolid - conversion and fixing

A Surface model will be imported and converted to Parasolids. After the conversion process
some areas of the model will require fixing, for it to be fully compatible as a Parasolid.
These problem areas will be identified and fixed using the Solid Doctor.

D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\SpkrCore_Surfs.dgk
• Select File -Save as:-

• D:\users\training\COURSEWORK\PowerSHAPE-Models\SpkrCore-Parasolid
• With all of the Surfaces selected, and the Solids tool bar active,
select the option ‘Create solid from selected surfaces’.
PowerSHAPE will attempt convert all of the selected Surfaces into a Parasolid. It is more
than likely that parts of the original surface model will not be accurate enough to comply
with the requirements for a fully watertight, Parasolid. As a result the user is automatically
prompted with the following Query.
• Select Yes to start Solid Doctor.

The Solid Doctor wizard will appear with and all faults will be listed in the left hand,
explorer area.
The model will also be labelled with a purple coloured marker and descriptions, of any
corresponding faults.
• With the option Attempt automatic repair selected, left mouse click on the
Process the selected faults icon
Note: 3 faults have successfully

been repaired and the remaining 5
faults require further attention.

The 3 fixed areas of the Parasolid model will now be labelled with a green marker and
description. The remaining 5 faults stay purple identifying that they require a more specific,
alternative repair option.
• Select Recheck the Solids for faults to review and update the
information displayed by the Solid Doctor.
• Either left mouse click on one of the purple ‘Gap’ fault labels over the
Solid, or left click on a ‘Surfaces’ row in the Solid Doctor wizard.
explorer.

Only the selected fault will remain labelled, and the view of the Solid will automatically re-
orientate.
• Select the fault at the top of the list, and zoom into the problem area to
assess how best to make the repair.
Take time to repeatedly change the view,

shade the model, and assess the most
suitable method of repair.
In this case it looks like the best solution
would be achieved by filling the gap with a
Non-tangential patch. Should the result not
be acceptable, there is an undo option on the
Solid Doctor wizard.
• Select the option, Fill gap with non-tangential surface and left mouse
click on Process the selected fault .
The symbol to the left of the

selected Surfaces row in the
Solid Doctor, explorer is now
ticked as repaired. The action is
also confirmed in the
Information window to the
left of the Solid Doctor wizard,
form. Also, the Gap label on
the actual Solid is now
coloured green.

• Select the second fault in the list, and again, zoom into the problem area
to assess how best to make the repair.
On closer inspection, the fault is of a similar type to the last one, and should be easily fixed
by using a Non-tangential patch,
The Gap is now shown as repaired, and is also identified by a green label on the actual Solid.
• Select the third fault in the list, and again, zoom into the problem area to
•

This time, the fault is a tiny, triangular gap along the upper
edge of a rib, recess. In this case it would be a better choice to
attempt to redefine the existingsurface patch, rather than
adding a new patch to fill the gap.
• Select the option, Extract surfaces around gap and edit them and left
mouse click on Process the selected fault .
Separate Surfaces will be created from

the patches adjacent to the tiny,
triangular gap in the Solid.
• Select and blank the Solid and zoom into the locally extracted surfaces.
• Change to a wireframe view.
• Construct a composite curve (Starting in one of the corners), around the
outer edge of 2 smaller surfaces and locally along the edge of large
surface where it includes the gap (as shown below).
• Accept the composite curve.

• Select and now Delete the 2 smaller surfaces enclosed within the
composite curve.
• Select the Composite Curve followed by Ctrl K (blank except).
• With the Composite Curve still selected, click on the Merge and Spline
option in the curves toolbar to remove redundant points within the default
0.01 tolerance.
• With the Composite Curve selected select the Automatic Surfacing

option opting for the option from network (Do not Apply yet!).
The Preview for the surface has currently split it into 2 triangular patches instead of a more
viable, 4 sided patch. To achieve the latter, the corner points for a 4 sided patch will be
controlled from the Advanced options.

• Select the Advanced tab and left mouse click in the Corners box.
• Sequentially left mouse click on the 4 distinct (Tangency) corners of the

Composite Curve to control which spans will define the surface curves
and select Apply.
• Select Apply in the main Automatic Surfacing and close the form.
• Select Unblank to display all entities.
• Select and Delete the latest Composite Curve.
• With the Active, Solid displayed, select all local Surfaces and select the
Green tick to exit the Surface Editing process.
The modified Surface data will replace the original patches in the Solid.

The Gap is now shown as repaired, and is now identified by a green label on the actual Solid.
• Select the fourth fault in the list, and again, zoom into the problem area to
This Gap is rather unusual as the

purple label on the Solid is pointing
to what appears to be an empty space?
It is in fact the invisible trimmed part
of one of the original surface
components that was absorbed into
the Solid. To comply with the rules
governing a Parasolid definition,
even a gap in a trimmed away
surface is potentially a problem.

To have a closer look at the problem it will initially be a good approach to have a closer look
at the problem surface by using the option Extract surfaces around gap and edit them. Once
the fault is assessed it may well be that a different method of repair is more suitable, in which
case the current repair option will be aborted.
• Select the option, and left mouse click on Process the selected fault.
The extracted surface is as shown above with a tiny gap in the base. This gap must be filled
in, and the easiest way is to abandon the current fault fixing option, to opt for Fill gap with a
non-tangential surface instead.
• Select the Red Cross option to abandon the current surface edit process.
• Back in the Solid Doctor wizard, select the Fill in gap with a non-
tangential surface option before selecting the Process the selected fault
icon.

• Select the fifth fault in the list, and again, zoom into the problem area to
On closer inspection, this gap appears to be similar to the previous one but mirrored across
on the other side of the Solid. As a result it is not necessary to have closer look at the actual
surface this time but to go straight for Fill gap with a non-tangential surface.

• In the Solid Doctor, select the Re-check the solid for faults option.
If the Parasolid is fully repaired the above message will be displayed and the Solid Doctor
wizard will close.

Version 8 Solid to Parasolid - conversion and fixing

A Version 8 Solid will be imported and converted to a Parasolid. After the conversion
process some areas of the model will require fixing, for it to be fully compatible as a
Parasolid. These problem areas will be identified and fixed using the Solid Doctor.
Some repair options will result in the removal of the Solid History tree, and in these
instances it would be a better policy to apply an alternative method.

D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\RadTank-V8solid.dgk
• Select File -Save as:-

D:\users\training\COURSEWORK\PowerSHAPE-Models\RadTank-Parasolid
• Right mouse click on the Solid to open the local editing form at the top of
which the description confirms that it is a Version 8 Solid.
• Left mouse click on the solid to activate the Solid editing toolbar.
• Select the option to convert the V8 Solid to a Solid.

After the conversion to a Parasolid is finished, the following Query form is opened.
• Select Yes in the Query form to activate the Solid Doctor wizard.
In the Solid Doctor - explorer window, similar types of faults are organised into specifically
named folders (The contents of a folder are displayed on clicking on the ).
The faults are also labelled (purple) on the actual Solid in the graphics area.
• With Solid Faults selected and the default Attempt automatic repair
selected, click on Process the selected faults.
Note: Just one fault has been repaired and is now labelled green (instead of purple) on the
Parasolid. The same repaired fault is identified with a green tick in the Solid Doctor
explorer.
• Select the Re-check the solid for faults option.

The repaired Gap is now removed from Solid Doctor form, and is no longer identified by a
green label on the Parasolid.
• Select Large faulty surfaces (1) in the Solid Doctor explorer and note
that only the related faults (one in this case) are highlighted on the
displayed Solid.
Note: Only the repair options potentially valid for the selected fault(s) will be made available
• Select the option, Extract surfaces and edit them and left mouse click
on Process the selected fault.
The faulty surface will become the only selected item in the graphics area.
• Select Blank Except (CTRL K) to remove the Solid and Composite

Curve (Used to mark the outside of the faulty surface) from the view.
The surface trimming requires closer inspection

and repair to ensure an accurate edge match with
adjacent faces on the Solid.

• Select a Wireframe view and zoom into the trimmed areas of the
Surface.
There are two ‘microscopic’ bulges on the trimmed edge at the top of the spherical patch.
Even though they are almost invisible they still contravene the strict, accuracy rules for a
Parasolid and as a result must be fixed.
• Right click on the Surface and from the local menu select Surface Trim
Region Editing.
The Boundary editing options are displayed in the above toolbar.
• Select and Explode all Boundaries.

• Toggle the Trimming toolbar from Boundary to Pcurve options.
• Select and Delete the 3 pcurves (shown Red above) that run up to the top
of the Sphere (Note: Zoom in to locate the 2 tiny pcurves at the top).
• Close the Pcurve editing toolbar.

• Select the surface curve running around the ‘equator’ of the sphere.
• From the Curve editing toolbar select Turn point labels on.
Part of the required trimming is coincident with two of

the surface curves running up the sphere. As a result
part of the Surface can be removed to create a natural,
vertically aligned trimmed edge.
The order in which the vertically aligned, surface

curves are numbered needs to be changed. This is to
enable the Open Surface to be applied outside the
remaining pcurve structure.
• With the surface curve still selected click on Reverse the surface.
The Surface can now be opened and the redundant,

vertically aligned surface curve (Passing through point 4
away form the trim area) can de deleted.
• With the surface curve still selected click on Open the surface.
• Select and Delete the redundant, vertically aligned surface curve, outside
of the area to be trimmed.
• Right click on the Surface and from the local menu select Surface Trim
Region Editing.

• In the Boundary edits toolbar select Autocreate to produce the

correctly trimmed surface with the remaining pcurves. .
• Close the Boundary edits toolbar and Unblank (CTRL L) to redisplay the
solid along with the now, correctly trimmed surface,
• Make sure that the fixed trimmed Surface and Solid are selected and
then Accept all surface edit changes (Green Tick).
The repaired Surface will now be used to replace the faulty patch
on solid.
As shown above the Solid Doctor confirms that the fault has been repaired.

The 2 Large holes will be repaired next as the problem is likely to be more serious, requiring
a more complex procedure than for the 6 remaining Gaps.
• Select and open Large Holes (3) in the Solid Doctor explorer.
Three Large hole faults have been registered, and each one will be dealt with in turn until all
have been systematically repaired.
On closer inspection it is clear that the selected fault is due to the inside wall of the solid
overlapping beyond the fillet at the base. Note: Composite curve (purple) identifies the
edges of the Large Hole in the Solid.
• Select the option Extract surfaces and edit them and left mouse click

The faulty surfaces will become the only selected items in the graphics area.
• Zoom into a corner of the model to have a closer look at the fault.
The main, inner sidewall, Surfaces need

to be trimmed back as they are extending
upwards, beyond the tangency with the
blend surfaces.
• Select the Solid and apply Blank Exept (CTRL k) to remove the Surface
and Composite Curves from the view.
• From the Curves toolbar select the Create a Composite Curve
option.
• Click somewhere on the tangency path between the inner sidewall and
blend Surfaces.
• Select the Fast Forward option to create the required, closed Composite
Curve before selecting the red Accept option.
• Close the Composite Curve toolbar.

• Unblank (Ctrl L) all items and then select and blank (Ctrl J) the Solid.
• Select and Delete the (original)

composite curve running along the
top edge of the Surfaces.
• Select a View from Right (+X).

• Select the Composite curve and from General edits select Limit
Selection.
The pre-selected Composite curve is registered as the Cutting Object (green tick).
• Drag a box across all the Surfaces above the composite curve to trim
them back to it.
• If this action initially trims away the surfaces above the Composite curve
apply Next solution as required to reverse the trimming.

• Select Unblank (CTRL L) to redisplay the solid along with the now,
correctly trimmed surfaces,
• Make sure that the Solid and all Surfaces are selected and left mouse
click on Accept all surface edit changes (Green Tick).
The repaired Surface will now be used to replace the fault on

the solid.
As shown above the Solid Doctor confirms that the fault has been repaired. It should also be
noted that several other Surfaces, registered with faults in Large Holes (4) have also been
repaired as a consequence of the last operation.

• Apply Re-check the solid for faults.
All of the repaired faults are removed from the form.
• Select the remaining set of Surfaces registered in Large holes (1) in the
Solid Doctor explorer.
The process has exposed a Surfaces overlap problem at the base of the fifth rib, from the
non-pipe end of the tank.
• Select the option Extract surfaces and edit them and left mouse click on
Process the selected fault.
• Unblank (Ctrl K) all entities apart from the extracted Surfaces.
The fact that the base surface is

not trimmed back to the inside of
the rib suggests that there is likely
to be a small gap.

• Select a Wireframe View and zoom into the problem area.
• With the Alt key depressed left click a

Composite Curve on the top edge of the rib
surfaces.
• Delete the original Composite curve (purple) running along the base of
the rib surfaces.
• Select the Composite curve at the top of the Rib Surfaces.
Note the 2 points (6 & 7) that are almost coincident with each
other. This needs a closer look to investigate why?
• Zoom into the area around points 6 & 7.
The extra point (7) is where the side of the rib starts to follow the non-linear part of the main
body form. This will be dealt with as a triangular Fill-in surface.
• Delete point 7 from the upper Composite curve.

• Create a new Composite curve around the small triangular patch.
• Create a new Fill-in surface inside the tiny triangular

Composite Curve.
• Select and Delete the small triangular Composite
Curve.

• Select the Composite Curve running along the top edge of the rib
surfaces.
• In general edits select Move and in the form select Keep Original along
with Reposition move origin .
• Click on the top right corner of the Composite Curve and then the
corresponding key point at the base of the rib (as shown below).
• Select and delete all the original rib surfaces (Keep the base form
surface).
• Select the 2 Composite curves that define the top and base of the rib
form and in the Automatic Surfacing form select From separate (curves)
and Apply.
• Select and Delete the 2 composite curves used to create the new, single
rib surface
• Use Point Limit to dynamically extend the lower end of the rib surface
through the base surface.

• Use Limit Selection to trim back the new rib form to the base Surface.
• Select Unblank (Ctrl L) to display all entities.

• In the Selection options click on Quick select all surfaces and solids.
• With all Surfaces and Solids selected, left mouse click on Accept all
surface edit changes.
The repaired Surfaces will now be used to replace the

faults on solid.
As shown above the Solid Doctor confirms that the fault has been repaired.

• Select the Re-check the solid for faults option.
The process of re-checking the Solid for further faults has exposed an additional Surfaces
overlap problem on the outside of the pipe form.
• Select the option Extract surfaces and edit them and left mouse click
The most reliable way to repair this fault is to replace the

trimming of the outer pipe Surface using a new
Composite Curve run along the side of the adjacent
Fillet Surface.

• Select the outer pipe form, Surface and apply Blank Except (Ctrl K).
• Right mouse click on the outer pipe form, Surface and from the local
menu select Surface Trim Region Editing.
• Delete all existing pcurves (and the Boundary) from the Surface.
• Unblank (ctrl L) all items and then Blank all items except the fillet
Surface.
• With the Alt key depressed, click on the side of

the fillet Surface to create a new Composite
Curve.
• Unblank (ctrl L) all items and then Blank all items except the outer pipe
form Surface and the new Composite Curve.
• Right mouse click on the outer

pipe form, Surface and from
the local menu select Surface
Trim Region Editing.
• Select make pcurves from projecting wireframe.
• Select Projected and click on the new Composite Curve to create a new
pcurve on the outer pipe form Surface.

• Toggle to Boundary Editing and select Autocreate to re-trim the outer

pipe form Surface to a new Boundary (Reverse trim as required to
obtain the correct side of the pipe form Surface).
• Select Unblank (Ctrl L) to display all entities.

• In the Selection options click on Quick select all surfaces and solids.
• With all Surfaces and Solids selected, left mouse click on Accept all
surface edit changes.
The repaired Surfaces will now be used to replace the faults on

solid.
• Apply Re-check the solid for faults.
If all of the faults have successfully been fixed the

Information form (shown left) will be displayed.

PowerSHAPE 21. Assembly Modelling
21. Assembly Modelling

Introduction
Assembly Modelling enables the user to combine a group of separate Solid models to form
the Assembled item. First of all an empty Assembly is created, and then the Solid
Components are registered to it by creating Relations to dictate the relative, positional
requirements. Not only can the individual solids be put together as an Assembly but specific
values can be included as default parameters within the Relations. This enables positional
movements of individual components to be displayed within the Assembly which can then be
checked for clashes.
To access the Assembly toolbar the Assembly option is selected from the main
PowerSHAPE toolbar.
Create a new Assembly
Select components (solids) to include in the Assembly.
Add components
Component Wizard
Create a relation
Power Features (Not licensed to basic PowerSHAPE)
Distance/Angular exploding
Check components for intersections
Manage source models of imported components

21. Assembly Modelling PowerSHAPE
Parameterised Assembly Example

Parameterised Assembly enables the user to combine 2 or more separate, solid models to be
positioned and orientated as they would be on the fully assembled product. It is also used
automatically, within the Delcam Toolmaker software to provide automatic updating of
related features if an existing feature is moved or modified.

D:\users\training\PowerSHAPE_Data\psmodels_n_dgk\Assy-Start.dgk
t_gib
lifter_blade
u_couple
• Select File - Save as:-

D:\users\training\COURSEWORK\PowerSHAPE-Models\Assy-Ex1
• Select an ISO1 view (as shown above).

• Double left mouse click on one of the Solids to open the history tree.
• Select the Assembly icon from the main PowerSHAPE toolbar.
• Select create new empty assembly from the Assembly toolbar.
The Create New Assembly form will appear.

• Input the Name of new assembly as Lifters and then select OK to close
the form.
The new, empty Assembly (Lifters) will be registered in the left

hand, Solid history tree.
• Select all three solids in the graphics area and from the Assembly
toolbar select Create components from the selected solids.
The components are now registered to the assembly (Lifters)
and are identified by the symbol which signifies that they

currently do not have any relations with each other.
• Select and Blank the lifter_blade solid.

• From the Views toolbar select the resize to fit option.

Create the 1st Relation
• From the Assembly toolbar select Ceate relation using attachments.
The Create Relation form appears with the Select first

attachment option active and ready for use.
• While the Select first attachment option is

active, left mouse click on the Top Face of
the t_gib solid (Master).
u_couple
t_gib
• With the Select second attachment option

now active, left mouse click on the inner
face of the u_couple solid (Slave).

The selected face of the t-gib solid is shaded pink with a red border and arrow to show that
it is assigned as the Master relation.
The selected face of the u_couple solid is shaded pink with a blue border and arrow to show
that it is assigned as the Slave relation.
Coincident
Angular
Perpendicular
• With the (default) Coincident option selected, left click on Apply, but
do not close the form.
The u_couple has moved upwards such that the previously selected face is now at the same Z
height as the, upper face of the t_gib.

The u_couple must now be turned through 180 degrees to be in the correct alignment to the
t_gib.
• Select the Align or Anti-Align icon to produce the correct vertical

alignment for the u_couple.
The u-couple has been turned the right way

up with the selected plane still on the same
Z height as the selected plane on the t_gib.
• Select OK to close the Create a relation form.
The (First) completed Master relation for the t_gib and the Slave relation for the First,
u_couple are saved in the left hand, Solid history tree.

Create the 2nd Relation
• From the Assembly toolbar select Create relation using attachments.
The Create Relation form appears with the Select first

attachment option active and ready for use.
• While the Select first attachment option is

active, left mouse click on the Inner Face of
the t_gib solid (Master).
• With the Select second attachment option

now active, left mouse click on the lower,
outer face of the u_couple solid (Slave).

• Select the Align or Anti-Align icon to flip the u_couple around 180
degrees.
• Select OK to accept the relation and close the form.

Create the 3rd Relation
• Select an ISO 4 View.

• While the Select first attachment option is active, left mouse click on the
End Face of the t_gib solid (Master).
• With the Select second attachment option now active, left mouse click
on the lower, end face of the u_couple solid (Slave).

Note:- the default Relation Type is Coincident with a default Distance value of 0. This will
later allow the user to display the u_couple at different positions along the t_gib
• Select OK to accept the relation and close the form.
The Third completed Master relation for the t_gib and

corresponding Slave relation for the u_couple are
saved in the left hand, Solid history tree.

Changing the position of the Slave item relative to a Master
• In the PowerMILL explorer, right

mouse click on Coincident(2) t_gib
• From the local menu select Edit.
The following toolbar will appear with the Distance 0 displayed.
• In the Distance/Angle box enter 100.
The u_couple moves 100 along

the t_gib.

Create the 4th Relation
If a Solid is selected and the cursor is then clicked on it, a yellow arrow will be displayed
relating to the local face. If the cursor is then moved over the Solid, the yellow arrow will
keep moving to inherent key positions and alignments. If the cursor is carefully moved on to
the yellow arrow and then held down, the solid can then be dynamically moved and aligned
to key positions and alignments on a different solid. Once the desired result is achieved the
left mouse key is released to accept the move. Although this method of repositioning requires
more skill on the part of the user, it does avoid the need to create multiple relations to get to
the final assembly alignment.
• Select an ISO 4 View.

• Unblank the lifter_blade solid.
• Select and blank the t_couple solid.
• Select the Transparent shaded view.

• Left mouse click on the lifter_blade solid to display a yellow coloured
arrow relating to the local face of the solid on which the cursor is located.
• With the left mouse key released, move the cursor over the solid and

note how the yellow arrow keeps moving to new key positions and
alignments relating to planes and axes relating to the individual solid
faces.
Drag Move
• Move the cursor over the arc shaped form at the base of the lifter_blade
solid until the label, Plane Axis appears.
• Slowly move the cursor to the left of the yellow arrow head until it locks
onto the end of the face.
• Then, with the left mouse key depressed, dynamically drag the lifter
blade solid onto the corresponding arc shaped form on the u_couple
solid.
• When two opposing arrows plus the word Combine appear on the
u_couple solid (and the lifter_blade is visually aligned) release the left
mouse key to accept the move.
• Select the Partial Box icon to deselect the dynamic move options.

• While the Select first attachment option is active, left mouse click on the
top Face (shown) of the u_couple solid (Master).
• With the Select second attachment option now active, left mouse click
on the top face of the t_gib solid (Slave).

With the relation type set to Plane an error

message is issued, informing the user that The relation
conflicts with existing relation.
• Change the Relation type from Plane to Angular.
• Input the Angle as 30 and select OK to

accept the changes and close the form

Editing the parametric values
The Third completed Master relation for the u_couple and

corresponding Slave relation for the lifter_blade are saved in
the left hand, Solid history tree.
This relation has also been given a Parametric Angular value
(a=30) to enable the Assembly.
• Select Unblank from the local screen menu to display all of the solid
components.
Note: As well as the lifter_blade being cranked

over at 30 Degrees the u_couple is also
displaced by 100mm from the Plane-Plane
relation with the t_gib
• In the explorer, right mouse click on:-

t_gib – Master Relations – Coincident[2] u_couple
• Then, from the local menu select Edit.
The Distance/Angle value is currently 0 (Distance ).
• Change the Distance value to 200 and then select to close the toolbar.

The u_couple and lifter_blade has now moved

a further 100mm along the t_couple.
The angular alignment of the lifter_blade will be cranked over to an angle of

-15 Degrees
• In the explorer, right mouse click on:-

u_couple – Master Relations – Angle[2] lifter_blade
• Then, from the local menu select Edit.
• Change the Angle value to -15 and then select to close the toolbar.

The lifter_blade has now cranked over to the

new angle of -15 Degrees.
Exercise
• Try entering different values for the Parameter to illustrate further

positional moves of the Assembly.

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Training Centre Customer Support

Issue PSHAPE 2010 1

2 Issue PSHAPE 2010

• To open PowerSHAPE, double click on the desktop icon.

Once loaded, the screen looks as shown.

Pulldown Menus Main Toolbar

Command Options Graphics Area

PowerSHAPE automatically starts a New Model

Issue PSHAPE 2010 1.1

• Select the File menu, using the Left mouse button.

This menu contains a comprehensive list of

Sub menus accessed by clicking on symbol.

1.2 Issue PSHAPE 2010

• Select the menu for line creation.

Issue PSHAPE 2010 1.3

The options are stored within several

It is possible to make changes to the

1.4 Issue PSHAPE 2010

Help Contents and Index

• Press F1 on the keyboard followed by Getting Started – What is

Issue PSHAPE 2010 1.5

Left Mouse button 1: Picking and selecting

Middle Mouse button or wheel: Dynamics

If available, the middle mouse wheel can be used to scroll text.

Mouse button 3: Special Menus

When this button is held down a menu is opened dependant

1.6 Issue PSHAPE 2010

Exercise 1: Dynamic mouse controls.

• Import the model:-

When a model is loaded into a new PowerSHAPE

The view toolbar, on the right hand side of the

• Select the view Iso 1.

The model is now displayed using the first of 4

Issue PSHAPE 2010 1.7

• From the available options pick Shaded View.

The surfaces have been shaded to show

The underside can now be seen clearly.

• Select Views Single [about selection].

There is also an enhanced shading option that displays the model in

1.8 Issue PSHAPE 2010

• Select Back [+Y].

Another view is displayed. The

Selecting and Blanking PowerSHAPE Entities

Issue PSHAPE 2010 1.9

• In the Selection toolbar select the option Quick select all

A message box appears asking if it is required to save

1.10 Issue PSHAPE 2010

• Select File Exit.

A message box appears asking if it is okay to exit PowerSHAPE.

A new model is automatically opened.

Issue PSHAPE 2010

1.12 Issue PSHAPE 2010

Wireframe Line and Arc Options

Rectangle Arc Through Three pts.

Polygon Swept Arc About Centre

the Open New Model icon from the main toolbar.

A new model will be opened in the current PowerSHAPE session.

Issue PSHAPE 2010 2.1

Wireframe Lines and Arcs Exercise

• From the Line menu select Single Lines.

The next part will be generated using continuous lines.