CAD DATA FORMATS

What are CAD files?

The computer files which stores the geometric information of a part,

component,assembly or even an architectural plan, which are generated by a computer Aided
Design (CAD) software called CAD files. These files are used for storing, retrieving and
exchanging the designs. The design may be 2D like a factory layout plan or 3D model like an
operating handle of an industrial valve. DWG, DXF etc are some examples of 2D file format
while IGES, STEP, SLDPRT,STL,OBJ are some examples of 3D CAD files.

Generally speaking, there are two main categories of CAD file format: native, which
means they’re the copyrighted intellectual property of the system for which they’re used,
and neutral, which means they’re open-format and not copyrighted by any specific CAD
program.

NATIVE FILE FORMATS

Many of the most popular 3D CAD file formats are native CAD formats. That’s
because native formats create and let you access the most information possible about your 3D
CAD file. Since they’re based on a specific program, they’re able to take full advantage of all
the features of that program instead of skipping over aspects that more generic or neutral 3D
CAD file formats don’t pick up. The more information that’s stored in your file format, the
more detail and functionality you’ll get out of your 3D CAD file.

AutoCAD (.dwg): This is the most popular 3D CAD file format because, as
we mentioned above, it’s the original. It’s the native file format for Autodesk’s
AutoCAD program, the first widespread CAD program in the field. The
extension is short for “drawing” and is a compact binary format. In the
header, it stores metadata like the file name, version, dimensions, and style,
and in the object data, it stores object entities and non-graphical objects,
such as dictionaries. The file also saves object class and object map
information.

Blender (.blend): Blend files are special beasts. They’re a scene description
format from the 3D modeling and animation software Blender. These files
make themselves compatible with other programs by loading their “Struct
DNA” metadata code, which makes compares its structure to the current
program’s metadata structure and adapting. It’s primarily used for design
drawing and model creation as well as a master format for deriving
renderings in two or three dimensions.
Parasolid (.x_t): Parasolid is a geometric modeling program, and its file
extension contains 3D CAD file information like geometry, topology, and color
from your drawing. The cool part is that .X_T files export as text files, which
makes them easy to import and export into different CAD programs.

SolidWorks (.sldprt and .sldasm): These two file extensions, coming

from SolidWorks, are short for “SolidWorks Part” and “SolidWorks Assembly”.
.sldprt provides details on specific parts within an entire system, allowing a
comprehensive study that can then be reassessed with an overview of how it
fits into the rest of the 3D CAD file. It’s also good for protecting intellectual
property, as it lets you share only the necessary parts of a system with
collaborators. .sldasm is basically the opposite; it’s a 3D CAD file format that
puts together your parts into one file to see how they all mesh. .sldprt and
.sldasm files work best together for a holistic picture of your 3D CAD file.

Inventor (.ipt and .iam): Much like SolidWorks, Autodesk Inventor has
complementary formats for parts and assemblies. .ipt represents a single
item of design, like one ball bearing in a wheel setting, while .iam is meant for
assemblies, or files with more than one interacting part, like a screw going
through a latch. You can import these Inventor files into Autodesk’s 3DS Max
program to animate your 3D CAD files, with some limitations.

SketchUp (.skp): Originally developed by @Last Software, SketchUp and its

3D CAD file format was bought by Google in 2006 and by Trimble in 2012.
Since then, the latter company has continued to develop it into a beginner-
friendly way to create and share CAD files. The SKP format also gives you
archive and backup options, which are great if you work on multiple projects
at once or are building on details from previous versions. The cool thing
about SketchUp is that you can save your 3D CAD files as single
components that you can use over and over again in your other drawings.

NEUTRAL FILE FORMATS

Neutral 3D formats are useful for sharing between different CAD programs.
These 3D CAD file formats don’t inherently collect as much metadata as
native CAD files, so there’s some level of fine detail loss when using them,
but they’re great for collaborative work.

Stereolithography or “Standard Tessellation Language” (.stl): Originally

developed by 3D Systems, the STL file format uses rough triangles to
describe the surface shape and area of your 3D CAD design. It describes the
raw data without specific units and is used for rapid prototyping, 3D printing,
and computer manufacturing. It’s often used in its binary form to become
more compact, and it works with a wide range of other CAD software.
Additive Manufacturing (.amf): This is an open standard for describing
objects within additive manufacturing and is most commonly used in 3D
printing. It’s a 3D CAD file format based on XML, which allows any CAD
program to describe any 3D object to build on any 3D printer. It works by
representing one or more objects in a constellation; each object is described
as a set of non-overlapping volumes, which are in turn described by a
triangular mesh with a set of reference vertices. These vertices can be
shared among volumes belonging to the same object. Unlike its predecessor,
STEP, the AMF format also specifies the color and material of each volume.

STEP (.stp and .step): STEP stands for Standard for the Exchange of
Product model data, and it stores 3D images in an ASCII format. Although
the AMF 3D CAD file format stores more information, many manufacturing
companies prefer STEP for pricing parts before they make them. Its ISO
standard exchange distributes 3D data so that it can be viewed by a variety
of CAD software. .stp and .step are interchangeable extensions for STEP
files.

Wavefront (.obj): First developed by Wavefront for its own Advanced

Visualizer animation software, the OBJ file format has been adapted by
scores of other 3D graphics software. It’s in an open-source data format that
only represents 3D geometry, and it’s a popular CAD file format for 3D
printing because of its ability to store information about multicolor printing
within a single object.

3D Manufacturing Format (.3mf): Recently developed by the 3MF

Consortium, 3MF is an open-source file format striving to become a standard
in the additive manufacturing world. Among other benefits, it provides ideal
parameters for manufacturing and easy communication between a variety of
platforms. The 3MF Consortium, which comprises companies like Autodesk,
Dassault Systèmes, 3D Systems, EOS, and Stratasys, developed the file
format in reaction to AMF, which presents several issues when it comes to
interoperability.

Initial Graphics Exchange Specification (.iges): Invented by the US Air

Force as a national standard CAD file format, IGES lets users exchange
circuit diagrams, wireframe, freeform surface, or solid modeling
representations of product models. It was designed to make integration of all
aerospace design files automatic, and that functionality can now be utilized
by civilians who work with traditional engineering drawings, models for
analysis, and who have other manufacturing needs. You can also use its
plug-in to view files from any point in the system’s history, which gives you an
idea of the stability of this CAD file format.
CAD MODEL PREPARATION
CAD Technology is improving rapidly. The following are the points that describes about the
importance of CAD Modelling.
 Lattice Generation: Because additive manufacturing can create shapes that couldn’t be produced by
traditional subtractive manufacturing techniques, you can now design with structures like lattices. By varying
their size and shape, you can reduce weight but still provide strength. Less material (compared to a traditional
solid) means lower material costs and typically better performance, especially in fields like aerospace and
defence.
 Lattice Analysis: Once you’ve incorporated lattices into your 3D model, you need to validate your design
using structural analysis and simulation. You wouldn’t want to model the lattices with solid elements in your
finite element analysis (FEA) package; the mesh would be too complicated and the solving time would be
impractical. You want a CAD package that automatically applies simulation idealizations like beam elements,
mass elements, and 2D shells to your model as appropriate to allow for efficient analysis that you can perform
in conjunction with the design process.
 Tray Configuration: You want to print your model. Will it fit in the tray of your 3D printer? Can you print
multiple models at the same time? What will the support material look like? In the past, you would have to
export STL files from your CAD package, import the data into the printer’s utility software, and set up for
printing. Your CAD package should allow you to set up your tray assembly with as many components as can
fit, assign materials and colors, and save the tray assembly for reuse.
 Connection to 3D Printers: Data translation between design, analysis, and manufacturing has historically
been one of the biggest wastes of engineers’ time. Your computer and desktop applications can connect
directly to 2D printers; your CAD package should be able to connect directly to a 3D printer.
CAD MODEL PREPARATION... Contd..
 Topology Optimization: Practically every industry wants products that are as light as
possible while meeting their intended objectives for strength. In the past, this involved
multiple rounds of iteration using an engineer’s intuition regarding where material could
be removed – and the engineer was restricted by what could be removed using traditional
subtractive manufacturing techniques.
 Topology optimization integrates analysis parametrically with the design process. You
define your loads, boundary conditions, and design constraints (e.g., stress,
displacement), and it optimizes for your mass and shape. It automatically computes what
works best for performance, instead of you designing traditional prismatic shapes that fit
your manufacturing methods. As such, topology optimization is the perfect partner for
additive manufacturing.
 Engineering content: Since CAD is almost an essential part of a modern engineer’s
training, it is vital that the software includes as much engineering content as possible.
With solid modelling CAD it is possible to calculate the volumes and masses of models,
investigate fits and clearances according to tolerance variations, and to export files with
mesh data for Finite Element Analysis. FEA is often even possible without having to
leave the CAD system.
CAD MODEL PREPARATION... Contd..
 Realism: With lighting and shading effects, ray tracing and other photorealistic imaging
techniques, it is becoming possible to generate images of the CAD models that are
difficult to distinguish from actual photographs. In some ways, this reduces the
requirements on AM models for visualization purposes.
 Usability and user interface: Early CAD software required the input of text based
instructions through a dialog box. Development of Windows-based graphical user
interfaces (GUIs) has led to graphics-based dialogs and even direct manipulation of
models within virtual 3D environments. Instructions are issued through the use of drop-
down menu systems and context-related commands. To suit different user preferences
and styles, it is often possible to execute the same instruction in different ways.
Keyboards are still necessary for input of specific measurements, but the usability of
CAD systems has improved dramatically. There is still some way to go to make CAD
systems available to those without engineering knowledge or without training, however.
 Speed: As mentioned previously, the use of NURBS assists in optimizing CAD data
manipulation. CAD systems are constantly being optimized in various ways, mainly by
exploiting the hardware developments of computers.
CAD MODEL PREPARATION... Contd..
 Accuracy: If high tolerances are expected for a design then it is important that calculations are
precise. High precision can make heavy demands on processing time and memory.
 All AM parts must start from a software model that fully describes the external geometry. This
can involve the use of almost any professional CAD solid modelling software, but the
output must be a 3D solid or surface representation. Reverse engineering equipment (e.g., laser
scanning) can also be used to create this representation.

Following are the key important factors that are required to prepare the CAD Model for
Additive Manufacturing.
 Tolerance optimization for mating parts
 Maintaining Resolution
 Resizing holes
 Water tight geometry
 Minimizing use of support material
 Balancing Part density and strength.
Part Orientation Introduction...
Part Orientation Introduction...
Designers often overlook the importance that part orientation plays in the final quality of
a 3D printed part. This section discusses how part orientation impacts the part accuracy,
manufacturing time, strength and surface finish of 3D printed parts and addresses the
importance of build orientation by technology.

IMPORTANCE OF PART ORIENTATION

Part accuracy
 Consider a cylinder with a hole (10 mm outer diameter, 6 mm inner diameter, 30 mm
length) that is printed with FDM with its center axis vertical. The 3D printer would
construct this part as a series of concentric circles layered on top of one another. This
would produce a final cylinder with a relatively smooth outer surface.
 If the same cylinder is reorientated with its center axis horizontally, the part will be built
as a series of rectangles (with slightly different width) layered on top of each other. Also,
the surface of the cylinder that touches the build platform will be flat, because the
material would as the initial first layers were printed.
 By orientating the part in different directions, there is a significant difference in the print
quality, as can be seen in the photo below.
Part Orientation.... Contd..
Part Orientation.. Contd..
Build time
 Orientation can also have a significant impact on print time.
 Using as an example the cylinder of the previous section, the horizontal orientation will
take significantly less time to print than the vertical, as the total number of layers is
significantly reduced: at a 100 μm layer height, the horizontal cylinder will be printed
with 100 total layers and the vertical with 300 layers. This can add up to significant time
differences for large parts.

Part strength
 Some 3D printing (notably FDM) build parts that have inherently anisotropic
properties, meaning they are much stronger in the XY direction than the Z direction.
 For functional parts, it is important to consider the application and the direction of
the loads. For example, FDM parts are much more likely to delaminate and fracture
when placed in tension in the Z direction compared to the XY directions (up to 4-5
times difference tensile strength).
Part Orientation.. Contd..
Part Orientation... Contd..
Support Structures
 Support material adds extra time and cost to a 3D print.
 Often a lot of designing time is spent to the optimal part orientation to reduce the
likelihood of print failure and the amount of required support. More information on how
to optimize the use of support in a design can be found here.
 Surface finish
 Generally, the top or upward facing surfaces of a 3D printed part will have the best
surface finish, but this varies from process to process:
 For FDM, the top surface is smoothed by the extrusion tip, the surface in contact with the
print bed will usually be glossy and the surfaces above support structures will have
support marks.
 For SLA, the lower surfaces will have support marks and require post-processing, while
the top surfaces will be smooth and free of support marks.
 Parts printed with a powder bed 3D printing processes, like SLS and Binder Jetting, will
have a more grainy finish on their lower surfaces.
 Parts printed with Material Jetting will have a matte finish at surface printed on supports
and a glossy finish otherwise (a homogeneous matte finish is also available).
Part Orientation by process
Rules of Thumb
 Orientate cylindrical features vertically for a smoother surface finish.
 Consider the direction of the loading when choosing part orientation of a functional part.
 Part orientation is most important for FDM and SLA/DLP 3D printing processes.
Purpose of Part Orientation
 Finding the best suitable part orientation helps achieving:
 the shortest build time ie minimizing the number of layers
and part height
 the minimal amount of supports
 an easy access to supports so that they can be easily removed
 the best possible surface roughness and minimal staircase
effect
 the minimum level of residual stresses which can lead to part
distortion
 SUPPORT STRUCTURES
 Support structures are one of the most important elements for successfully producing 3D printed
parts. While a key advantage of 3D printing is its ability to create freeform and intricate geometries,
much of the design freedom offered by 3D printing wouldn’t be possible without the use of support
structures.
 Supports are vital for preventing distortion and collapse within a part, among other uses. In this
tutorial, we’ll be taking a deep dive into the world of support structures, the requirements for
different technologies and how to minimise their usage
What are Support Structures
 Used with almost all 3D printing technologies, support structures help to ensure the
printability of a part during the 3D printing process.
 Supports can help to prevent part deformation, secure a part to the printing bed and ensure
that parts are attached to the main body of the printed part. Much like scaffolding, supports
are used during the printing process and then subsequently removed.
 Parts with complex design features like overhangs, holes and bridges are more challenging to
print. Since these features are likely to collapse if not supported, support structures can aid in
preventing collapse during the printing process.
 Supports can also work as heat dissipators in processes where high temperatures are
involved, as is the case with metal 3D printing. With metal AM technologies, support
structures help to draw heat away from the part preventing residual stresses that occur due to
high temperatures experienced during the printing process.
Purpose of Support Structures
Support structures have several functions:
 support the part in case of overhangs,
 strengthen and fix the part to the building platform
 conduct excess heat away
 prevent warping or complete build failure.
SUPPORT STRUCTURES.. Contd.
SUPPORT STRUCTURES.. Contd..
AM Processes and Support Structure Requirement
 Support Structures... Contd..
 Metal 3D Printing
Powder Bed Fusion (SLM, DMLS, EBM)
 With metal powder bed fusion technologies, 3D printed parts are surrounded by loose powder. However, these technologies will always
require supports to ensure that they are anchored to the base plate and to mitigate the effects caused by residual stresses.
 Supports can be added to the contact area between the bottom of a printed part and the print bed, which is where the highest concentration
of residual stress is found. This helps to draw heat away from the part, thereby minimising thermal distortion which can lead to cracking,
warping, sagging, delamination, and shrinkage.

 Direct Energy Deposition (DED)

Direct Energy Deposition covers a series of metal 3D printing technologies that work by melting and fusing material to create a part. Like
powder bed fusion technologies, parts printed using DED will always require support structures to ensure part stability, the printability of
complex features and for thermal dissipation.
 Support removal

Support removal for metal parts is typically more difficult than polymer-based processes, and cutting tools will typically be required.
Additionally, if the appearance of the finished part is important, metals parts will also require post-processing (e.g. sanding) to achieve a
smooth surface finish.

Design
 When designing supports for parts produced with powder bed fusion techniques, it’s important to ensure that they are easy to access,
otherwise they cannot be removed during the post-processing stage. Supports for metal parts are generally printed as lattice structures.
 In this manner, they act as a heat sink, transferring heat away from the part, allowing it to cool in a more controlled manner and avoid
distortion as well as save material costs and build time. Adding more supports will generally result in a more accurate part, but this will
also add greater costs and post-processing time.
Support Structures... Contd..
Stereolithography (SLA)
 Stereolithography works by using a light source to solidify liquid resins. For this
technology, support structures are required to securely attach a part to the print bed and to
prevent warping.
 Supports used in SLA are very thin and, to save material, only slightly touch the part.
This means that they are quite easy to remove manually, either by hand or using pliers.
However, since removing supports can leave marks on the final part, sanding will be
needed to ensure a smooth surface finish.
Design
 SLA is very often used for applications where appearance or a smooth surface finish is
required, such as visual prototypes, moulds and hearing aids. If this is the case, it’s
important to design your part to ensure that the forward-facing areas of your print are not
in contact with support structures. This is where part orientation comes in.

 Part orientation is an important consideration in the design stage, as reorienting a part can
help reduce the amount of support needed. For example, horizontal orientation for a
tubular part will take up more space and therefore require more supports. In contrast, a
vertical orientation of the same part will ensure that the part is attached to the build plate
with minimum supports needed.
Fused Deposition Modelling
 With Fused Deposition Modelling, parts are created by extruding heated filament layer by layer.
As each layer cools, it solidifies, bonding with the previous layer.
Design
 Each layer in the FDM process is printed slightly protruding so that it can expand beyond its
previous layer width. This means features with angles up to 45° can be created without
supports. However, when an FDM part has an overhang of more than 45° or includes features
like bridges and protruding surfaces greater than 5mm, supports will be needed. FDM supports
can take the form of a lattice structure or, alternatively a tree-like structure.

Support Removal
 One of the techniques used to remove supports from FDM prints is a dissolvable solution.
Typically, industrial FDM 3D printers (with two print heads) use dissolvable support materials
like Polyvinyl Alcohol (PVA) and High-Impact Polystyrene (HIPS). These are added by a
separate extruder.
 While PVA dissolves in water, it can be affected by temperature changes, which can lead to
blockages int he printer head. HIPS dissolves in limonene instead of water, and is less
susceptible to temperature changes.
 Using dissolvable supports is hands-free and doesn’t require further sanding and polishing to
remove the marks left by supports. On the flip side, this process can be time-consuming (taking
several hours) and costly.
Downside of Supports
Despite the necessity of support structures, they will add additional printing time and material costs
to the overall production process.
 Material costs: Support generation will require additional material during the printing process,
increasing both time and material costs. It’s also important to note that supports are not reusable
and usually disposed of, resulting in a wasted material.
 Limited geometric freedom: when removing supports manually, hand or tool access needs to
be factored in when designing supports. This, however, can restrict you from designing certain
geometries which will require support structures but cannot be reached by hand or tool.
 Extra time: designing a part to accommodate support structures and subsequently designing the
supports themselves requires extra time. Although there are software offering automated support
generation, creating support structures for industrial applications will still need some manual
touchup and a certain level of design expertise.
 Additional post-processing: Once a part is complete, supports will have to be removed,
sometimes manually, increasing the time needed for post-processing.
 Risk of damage: Bear in mind that removing supports may leave marks on the surface of a part,
which can affect its dimensional accuracy and aesthetics. Additionally, when supports are incorrectly
placed, for example on fine features, these can break off along with the support structure – ruining
a part altogether.
 4 Ways to Reduce Supports
 It’s generally good practice to reduce the amount of supports needed as much as possible. This will help to save on both
material costs and production time. Here are 4 top tips on how to minimise their usage, saving you printing time and material.
1. Choose the optimal part orientation
 To date, experimenting with part orientation is one of the best ways to reduce the amount of support structures needed. Choosing the right
part orientation can have a significant impact on the printing time, costs and a part’s surface roughness.
 Depending on a part’s orientation (vertical, horizontal or angled), there may be fewer or more support structures needed. Consider a part
printed in the shape of the letter T. In its ordinary position, both branches of the letter will collapse without support structures in place. If
the part is oriented differently, i.e. ⊥, then supports will not be required.
 This example demonstrates that a part can be built up in different ways. Each side of a part can have a different surface attached to the print
bed, meaning that the need for supports can vary and be heavily dependent on the orientation of the part.
 Another example: when designing a part with hollow tubular features, horizontal orientation will take up more space, while a vertical or
angled orientation will save space and reduce the amount of supports needed.
4 Ways to reduce Supports.. Contd.
2. Optimise your support structures
 When supports cannot be avoided, they should be optimised to use as little material as possible, and
to speed up the printing process. For example, topology optimisation can be used to design, supports
with lattice structures, reducing the support volume of and saving material.
 With many 3D printing processes, commonly used support generation techniques are limited to
producing strictly vertical structures. These are not space-efficient, particularly when there are many
regions to be supported high above the print bed.
 Creating tree-like support structures instead may be a viable alternative. Such supports look like a
branching tree and arguably consume 75 % less material compared to straight vertical structures.
Autodesk Meshmixer is one of the software tools that can be used to create such structures for FDM,
SLA and DMLS processes.
4 Ways to reduce Supports.. Contd.
4 Ways to reduce Supports.. Contd.
 Materialise Mimics
• Materialise Mimics is an image processing software for 3D design and modeling, developed
by Materialise NV, a Belgian company specialized in additive manufacturing software and
technology for medical, dental, and additive manufacturing industries.
• Materialise Mimics is used to create 3D surface models from stacks of 2D image data. These
3D models can then be used for a variety of engineering applications.
• Mimics is an acronym for Materialise Interactive Medical Image Control System.

Process
• Materialise Mimics calculates surface 3D models from stacked image data such as Computed
Tomography (CT), Micro CT, Magnetic Resonance Imaging (MRI), Confocal Microscopy, X-ray
and Ultrasound, through image segmentation.
• The ROI (Region of Interest), selected in the segmentation process is converted to a 3D
surface model using an adapted marching cubes algorithm that takes the partial volume
effect into account, leading to very accurate 3D models. The 3D files are represented in the
STL format.

Uploading Data
• DICOM (Digital Imaging & Communications in Medicine) data from CT or MRI images can be
uploaded into Materialise Mimics to begin the segmentation process. From this data, 3
different views are present: the coronal, axial, and sagittal views. Another window is present
to display 3D objects.
Industries
• Mimics has been adopted by biomedical engineers and device manufacturers for R&D purposes in
various medical industries:

• Cardiovascular

• Craniomaxillofacial

• Orthopedic

• Pulmonology

These industries use patient-specific 3D data to improve their implants and devices or to get a better
understanding of biomechanical processes. Also non-medical industries like materials science use
Mimics in image-based R&D.

Applications of Mimics
• Materialise Mimics is a platform to bridge stacked image data to a variety of different medical
engineering applications:

• 3D measurements and analyses

• Computer Aided Design: 3-matic, SolidWorks, Pro/E...etc.

• Computational Fluid Dynamics: FLUENT, CFX,...etc.

• Customized implant design

• Finite Element Analysis: ABAQUS, ANSYS,etc.

• Rapid Prototyping: EOS, Stratasys, 3D Systems, Z-Corp, Dimension, Objet, etc.

• Surgical simulation
 MATERIALISE MAGICS

Materialise Magics is an industry-leading data preparation and STL editor software for
additive manufacturing that allows STL file conversion, errors repairing, design editing, and
build platform preparation. With Magics and its modules, you can:

• Import all data types and formats and repair and prepare files for all technologies
• Optimize laser sintering and other AM processes
• Simulate metal and polymer 3D prints
• Create complex lattice and support structures for both polymer and metal 3D printers
• Create models optimized for specific applications like investment casting
• Rely on reports and measurements for quality control

FEATURES OF MATERIALISE MAGICS

Import Data Types and Formats

Import almost any file formats, retain native colour information and stay in control of your original
data.

STL FILE REPAIR

 APPLICATIONS OF MAGICS

• Repairing and Optimizing of 3D Models

• Analyzing Parts
• Making process related changes on STL files
• Designing fixtures
• Projects documentation
• Production Planning