Technology and Future Trends in CAD Data Translation

By Todd Reade

The 3D CAD market is rapidly changing and maturing. Less than 10 years ago 80% of the manufacturing market was still designing in 2D. Now, 2D drafting is quickly becoming obsolete. Software companies are creating new products and new 3D file formats on a regular basis, hoping to find a silver bullet that will be the next Universal File Format (*.uff ?). The IGES and STEP formats were once thought to be ‘universal’ but their many drawbacks often overshadow their benefits as data translation formats. Consumer confidence in CAD data translation is low. Every company has toiled over the ‘IGES file from Hell’ with missing surfaces that takes a week or more to get into a usable form. For years to come the need for 3D file translation and compatibility will become more complex, not to mention the need to read and write new file formats. What common CAD data exchange challenges face the manufacturing industry today?
• Most manufacturing companies spend a significant amount of time trying to transfer files between different CAD/CAM/CAE programs.
• There are fundamental interoperability barriers between most 3D software packages. For example, different levels of precision, which increases the complexity and difficulty of data exchange.
• Many 3D software products output poor quality IGES and STEP files with missing surfaces and edges.
• New 3D software products with proprietary file formats are being introduced.
• Time wasted on poor quality translated files can impact delivery schedules and reduce profits.
• Companies consume valuable human resources to manually re-draw important models for use in their software programs.
• Some large companies have several different internal systems that can not communicate with each other without first re-drawing the CAD model.
• Companies that change CAD platforms face the daunting task of migrating whole libraries of parts and assemblies.
• The inability to read specific file types can cause lost job opportunities.
• The cost of maintaining multiple CAD systems can be prohibitive and does not solve the problem.

Many companies do not realize that CAD data translation products are available today that address all of the above issues and can quickly save a manufacturing supplier thousands of dollars in outsourced translation costs or hundreds of man-hours. The return on investment for a company using CAD data translation software can be as short as a few months.

Best practices for CAD Data Translation:
• Avoid using IGES files whenever possible. Think of IGES as a last resort.
• Whenever possible always use the original native CAD file.
• Understand the usefulness of robust file formats, such as Parasolid and ACIS, which "natively" support a vast number of applications.
• "Roundtrip then zip." Avoid sending corrupt files to customers or vendors. Test files before sending them. Re-open files in the originating CAD system to make sure they are good and then zip files before attaching them to an email to avoid file corruption.
• Avoid translating files multiple times. Instead, go back to the original file and translate it to a different file format.
• Invest in CAD data exchange products from companies that specialize in CAD file translation. An important realization is to understand that data exchange is not the specialty nor the objective of the major CAD software developers. To make matters worse some old school CAD developers attempt to hold customers captive to their product line by routinely encrypting their file formats in an attempt to prevent interoperability.

What should you expect from a CAD data translation product?

1. High quality file translation.

– This means a good usable solid-to-solid translation of any model created in any 3D software.

1. Semi-automated geometry repair technology that improves productivity.

– End users need the ability to increase model tolerances so data is usable as a solid model in their target system.

1. Affordable multiple format support.

– In today’s competitive market, companies need to be able to read and write a wide variety of 3D files formats.

1. Good visualization capabilities.

– Powerful communication tools help avoid errors, save time and cut costs. A picture is worth a thousand words.

1. Ease of use.

– Data translation software utilities should be intuitive and quick to master. Companies do not have time for long learning curves with peripheral software products.

1. "Missing surface" replacement tools.

– A missing surface means that a model will not be "solid". In many CAD systems, the model must be ‘solid’ or it is unusable.
7. High speed unattended batch file translation capability. Jobs can be done overnight and not tie up company resources.
8. Mass properties and other useful tools for quoting manufacturing jobs.
– Many companies rely on quick access to customer models from different sources to win new business, even though they do not have the same CAD software as their customers. A quick turnaround is paramount in this competitive world.

Where is the technology going from here?
As manufacturers and CAD products continue to evolve, it will become commonplace for companies to include all the data required for manufacturing a product in a single CAD file. CAD interoperability products will have to lead the way to support many types of data.

Things to look for in future CAD data exchange/translation products:
1. Enhanced support for product manufacturing information (PMI) including GD&T materials, color, and other manufacturing meta data.
2. Elimination of 2D drawings as a method of representing 3D models (except maybe in the sheet metal industry).
3. Increased ease of use and speed.
4. Smart automated processes for repairing geometric errors and replacing missing surfaces that reduce the need for user intervention.
5. Conversion of design history and auto-recognition of model features.
6. All direct file formats for major CAD systems will be available in one simple product interface.
7. With the proliferation of high-end translation products, there will be fewer translation service bureaus.

In conclusion, while the problems are great, there are excellent solutions available today from companies who specialize in CAD translation products. These products create opportunities for innovative companies to reduce manufacturing costs and improve competitiveness.