So here is the Sintra part I wanted to create, and as you can see the part has a couple bends that are not at 90degs.<\/p>\n\n\n\n And here is the profile from an end-view:<\/p>\n\n\n\n So, I did something that I hate\u00a0hate<\/em>\u00a0hate<\/strong>\u00a0to do. (No not brush my dogs teeth I mean I do hate that also), but I am talking about in-context design.\u00a0 I love the premise of the technique, and we can debate it all we want.<\/p>\n\n\n\n In-context design has been minimized for me, as I have started to fall in love with Multibody parts.\u00a0 I keep finding new ways to multibody parts, so modeling in-context has not been as critical as it used to be. \u00a0Plus I really hate in-context because it can be a pain to figure out what file is controlling what features, and what Gary\u2019s true design intent was. Do you remember Gary? Gary Daniel Smith? He was pink-slipped two weeks ago for being GDS (God Damn Stupid). Now all the files have shitty references that can\u2019t be undone without some LSD and a handful of quaaludes to help make sense of them.<\/p>\n\n\n\n The reason why I am designing in context today is because of one of the few limitations in Multibody parts. That limitation is that you can\u2019t have multiple gauge tables running in the same Multibody part file.<\/p>\n\n\n\n This was important as the main part is Sintra, and I used my custom Plastic Heat Bending Table. The jig I was making was going to be from E-Flute Corrugated. \u00a0Totally different materials with different bend properties.<\/p>\n\n\n\n I had to match the required shape pretty exactly, and I was doing this on the quick and dirty, AKA dangerously average.\u00a0 I knew I was running the risk that in two months, this jig would either be brilliant or all of my title blocks would go from T.P.H. to G.D.S.<\/p>\n\n\n\n But enough about Gary\u2026 What matters is the process<\/p>\n\n\n\n So, let us walk thru the key points for anyone reading who is starting to use SolidWorks for Corrugated design. I start off by taking the part I want to make the jig for and drop it into an assembly. Then I go all in-context and used the offset sketch tool to create .015in clearance for my template Jig. \u00a0This was all done in context so it kind of looked like this:<\/p>\n\n\n\n Yeah, there is a lot going on here.\u00a0 Basically, with corrugate, you design the parts like they are a fruit roll-up.\u00a0 The intent is to take a piece of flat stock, and keep bending up, and bending up, and bending up until it is all in place. \u00a0Here is an over-exaggerated sketch so you can see what I mean:<\/p>\n\n\n\n So when you are done, it ends up looking like this.\u00a0 \u00a0It is important to make sure that when you run the Base Flange feature none of the flanges intersect any part of the profile.\u00a0 \u00a0So keep using that magic 64th offset. I often will create a global variable of (Material Thickness + .015)<\/p>\n\n\n\n It gets explained later, but if you think you see \u201cExtra\u201d bends, then you are wrong, and those are not the bends you are looking for.<\/p>\n\n\n\n Now some things are a little more critical than others, but in general, if you flatten this out you are left with:<\/p>\n\n\n\n To keep this thing from un-rolling I will be using hot glue. I left some bends longer to use as Glue Tabs. The (5) glue joints are shown below, and I am now using the \u201cExtra Bends\u201d <\/p>\n\n\n\n With this being a heat bending jig, I was not too worried about how it looked, just if it worked, so I added some edge flanges to cap this profile in:<\/p>\n\n\n\n The outside shape is almost perfect, so we just need to add some small details to make sure the part I am bending can register righ up into the this jig. On the leading edge of the jig, I intentionally left a small gap between the two vertical walls. <\/p>\n\n\n\n What we are doing in this step is cutting a notch so the leading edge of the part gets locked into place before bending. This cut was made like this:<\/p>\n\n\n\n After this cut, go ahead and unfold the part, you will see the flat pattern looks like this:<\/p>\n\n\n\n So, you are left with a 2pc assembly.\u00a0 The Sintra part we are bending and the jig.\u00a0 Again we are using some in-context references to keep the profile of the Jig identical to the shape of the heat-bent cover<\/p>\n\n\n\n The Heat Bending was then pretty easy, Here is the Jig labeled for the shop guys on what bends are 1st, 2nd and 3rd<\/p>\n\n\n\n And finally a couple of images of the forming process, in well the forming process:<\/p>\n\n\n\n Blank right off of the CNC:<\/p>\n\n\n\n Heating up the bends:<\/p>\n\n\n\n Finally working the bends into the jig:<\/p>\n\n\n\n And bending back over the top:<\/p>\n\n\n\n Finally, it is not much of a glamour shot, but here you go, it is sitting perfectly around the bottom base:<\/p>\n\n\n\n So there you have it just another way that SolidWorks Sheetmetal has changed my life for the better. This approach may be dangerously average, but for only 30pcs, it worked perfectly!<\/p>\n","protected":false},"excerpt":{"rendered":" Okay so I have said it before, but SolidWorks Sheetmetal has changed my life. Today it is making my life quicker and easier. As you know, I have been using SolidWorks Sheetmetal for Corrugated (Cardboard) design. Today am going a little bit different direction. In this post, I will cover how I used SolidWorks Sheetmetal […]<\/p>\n","protected":false},"author":1,"featured_media":303,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[18,17,16,11,14],"class_list":{"0":"post-299","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-uncategorized","8":"tag-dangerously-average-approaches","9":"tag-solidworks-corrugate-design","10":"tag-solidworks-folding-carton","11":"tag-solidworks-sheetmetal","12":"tag-solidworks-sheetmetal-changed-my-life","13":"czr-hentry"},"aioseo_notices":[],"jetpack_featured_media_url":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/05\/P22-3-Full-End-Sketch.webp?fit=450%2C375&ssl=1","jetpack-related-posts":[{"id":211,"url":"https:\/\/trottingaround.com\/index.php\/2023\/04\/27\/solidworks-sheetmetal-changed-my-life-pt-1\/","url_meta":{"origin":299,"position":0},"title":"SolidWorks Sheetmetal Changed my Life: Pt.1 Custom Gauge Tables","author":"Trevor Hoffman","date":"April 27, 2023","format":false,"excerpt":"You read that right. SolidWorks Sheetmetal has changed my life. So much so, that I am starting a whole series of posts just to keep you up to date on how sweet SolidWorks Sheetmetal is, and how much it is actually making my life better. But before I show a\u2026","rel":"","context":"In \"Dangerously Average Approaches\"","block_context":{"text":"Dangerously Average Approaches","link":"https:\/\/trottingaround.com\/index.php\/tag\/dangerously-average-approaches\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/German-Eskimo4.jpg?fit=517%2C566&ssl=1&resize=350%2C200","width":350,"height":200},"classes":[]},{"id":238,"url":"https:\/\/trottingaround.com\/index.php\/2023\/04\/30\/solidworks-sheetmetal-changed-my-life-pt-2\/","url_meta":{"origin":299,"position":1},"title":"SolidWorks Sheetmetal Changed My Life: Pt.2 Take Home Food","author":"Trevor Hoffman","date":"April 30, 2023","format":false,"excerpt":"This post is just another place and time that SolidWorks Sheetmetal has changed my life for the better. Today it made the best part of my day even better. As you know nothing is better than lunch at some greasy spoon buffet with a couple of your co-workers. We have\u2026","rel":"","context":"In \"Dangerously Average Approaches\"","block_context":{"text":"Dangerously Average Approaches","link":"https:\/\/trottingaround.com\/index.php\/tag\/dangerously-average-approaches\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/TakeHomeBox_ISOPers1-1-edited.webp?fit=948%2C732&ssl=1&resize=350%2C200","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/TakeHomeBox_ISOPers1-1-edited.webp?fit=948%2C732&ssl=1&resize=350%2C200 1x, https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/TakeHomeBox_ISOPers1-1-edited.webp?fit=948%2C732&ssl=1&resize=700%2C400 2x"},"classes":[]},{"id":266,"url":"https:\/\/trottingaround.com\/index.php\/2023\/05\/02\/solidworks-sheetmetal-changed-my-life-p3-going-home\/","url_meta":{"origin":299,"position":2},"title":"Solidworks Sheetmetal Changed My Life: P3 Going Home!","author":"Trevor Hoffman","date":"May 2, 2023","format":false,"excerpt":"So this might just be my last post in this series. Why? Because this post is about those times when you feel\u00a0your\u00a0unofficial status as the greatest ever is challenged. \u00a0Specifically, that feeling that sits in your chest when you are sure that someone's mistake will be your official promotion to\u2026","rel":"","context":"In \"Dangerously Average Approaches\"","block_context":{"text":"Dangerously Average Approaches","link":"https:\/\/trottingaround.com\/index.php\/tag\/dangerously-average-approaches\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/05\/GreenCar.jpg?fit=834%2C317&ssl=1&resize=350%2C200","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/05\/GreenCar.jpg?fit=834%2C317&ssl=1&resize=350%2C200 1x, https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/05\/GreenCar.jpg?fit=834%2C317&ssl=1&resize=700%2C400 2x"},"classes":[]},{"id":11,"url":"https:\/\/trottingaround.com\/index.php\/2023\/04\/23\/best-wireless-mouse-for-solidworks\/","url_meta":{"origin":299,"position":3},"title":"Best Wireless Mouse for SolidWorks","author":"Trevor Hoffman","date":"April 23, 2023","format":false,"excerpt":"So I have started traveling more and more for work, and this year I should make Plantium Pro with American Airlines. This means I have to find time to run SolidWorks and CADD it on the go.\u00a0\u00a0Some trips are long, and some short.\u00a0 Hotels, Airports, Coffee Shops, Meetings with my\u2026","rel":"","context":"In \"Logitech Mouse\"","block_context":{"text":"Logitech Mouse","link":"https:\/\/trottingaround.com\/index.php\/tag\/logitech-mouse\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/m720-triathlon-mouse.png?fit=770%2C661&ssl=1&resize=350%2C200","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/m720-triathlon-mouse.png?fit=770%2C661&ssl=1&resize=350%2C200 1x, https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/m720-triathlon-mouse.png?fit=770%2C661&ssl=1&resize=700%2C400 2x"},"classes":[]},{"id":333,"url":"https:\/\/trottingaround.com\/index.php\/2023\/06\/30\/boox-nova-air-2-first-hand-review\/","url_meta":{"origin":299,"position":4},"title":"BOOX Nova Air 2 First-Hand Review","author":"Trevor Hoffman","date":"June 30, 2023","format":false,"excerpt":"Introduction: I do some writing in my spare time and also do some reading. Years ago, when I was traveling internationally for work a family member got me a NOOK. This device was a glorified tablet with low specs, but it did its job and got me into reading. I\u2026","rel":"","context":"In \"BOOX\"","block_context":{"text":"BOOX","link":"https:\/\/trottingaround.com\/index.php\/tag\/boox\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/06\/AAA-In-the-BOX-scaled.jpg?fit=1200%2C904&ssl=1&resize=350%2C200","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/06\/AAA-In-the-BOX-scaled.jpg?fit=1200%2C904&ssl=1&resize=350%2C200 1x, https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/06\/AAA-In-the-BOX-scaled.jpg?fit=1200%2C904&ssl=1&resize=700%2C400 2x, https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/06\/AAA-In-the-BOX-scaled.jpg?fit=1200%2C904&ssl=1&resize=1050%2C600 3x"},"classes":[]},{"id":175,"url":"https:\/\/trottingaround.com\/index.php\/2023\/04\/25\/unifi-dream-machine-review\/","url_meta":{"origin":299,"position":5},"title":"Unifi Dream Machine Review","author":"Trevor Hoffman","date":"April 25, 2023","format":false,"excerpt":"This post covers my Dangersouly Average experience with the Ubiquiti Unifi Dream Machine or Ubiquiti UDM. This device is an awesome way to bring big-boy equipment into your house with no extra hassle and an affordable price. During Covid, I was working from home a lot more. Well, not just\u2026","rel":"","context":"In \"Dream Machine\"","block_context":{"text":"Dream Machine","link":"https:\/\/trottingaround.com\/index.php\/tag\/dream-machine\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/04\/UDMv1.jpg?fit=570%2C545&ssl=1&resize=350%2C200","width":350,"height":200},"classes":[]}],"_links":{"self":[{"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/posts\/299","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/comments?post=299"}],"version-history":[{"count":5,"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/posts\/299\/revisions"}],"predecessor-version":[{"id":327,"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/posts\/299\/revisions\/327"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/media\/303"}],"wp:attachment":[{"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/media?parent=299"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/categories?post=299"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/trottingaround.com\/index.php\/wp-json\/wp\/v2\/tags?post=299"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}![\"\"](\"https:\/\/i0.wp.com\/trottingaround.com\/wp-content\/uploads\/2023\/05\/P22-1-CoverIso.webp?resize=450%2C375&ssl=1\")
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