Help show how to convert components to Sheet Metal then create Flat Pattern

[ianhughes7UFVF]

Hi

I have already posted this, but I really need someone to be really specific on how to convert components to Sheet Metal and then select Flat Pattern to allow me to create a flat DXF, all from a rolled surface.

I have attached a fusion file that has R2D2 skins. This is for a 1:1 scale project. The skins are eventually made in 1mm aluminium and rolled, but I need a flat version of the Outer and Inner Front and Back skins to give to a laser cutter.

It has already been suggested that the above way can do this, but I cannot find how to convert the skins to sheet metal or how to find flat pattern options. I can find flatten in sculpt but I don't think that is the right thing?

The original file was an iges and I don't think it was made that well, which I think doesn't help.

What I would really appreciate is a screencast of the method if anyone has time to do one for me to show me how to do this work.

I can provide the original iges if needed.

I really appreciate any help that may be forth coming.

Kind Regards

Ian

[TheCADWhisperer · Accepted solution]

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@ianhughes7UFVF wrote:

...create a flat DXF, all from a rolled surface.

...in 1mm aluminum  

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I think it would make good practice to model from scratch as Sheet Metal components and then get the DXF from flats (see attached).  I have never been a big fan of trying to use someone else's flawed work (I found issues with original geometry).

The original (at least for the single part that I picked out to Flatten) is actually .04in (1.016mm).

See Attached.  Is this typical of what you are after?

[Marco.Takx · Accepted solution]

Hi @ianhughes7UFVF,

It would be extremely useful if we could convert surfaces using the offset tool (Using the Thickness parameter) to Sheet Metal which we could then create a flat pattern.

See the Screencast for the workaround.

Hopefully, this helps you further.

If my post answers your question Please use  .Accept as Solution & Kudos This helps everyone find answers more quickly!

[ianhughes7UFVF]

Hi

This is exactly what I am after.

I realize I will probably have to do this for the other individual bits that are part of the skins, but the piece you created is a totally workable start to obtaining the dxfs.

How did you do it. I noticed there is another post with a method. Did you do it the same way or differently.

Kind Regards

Ian

[ianhughes7UFVF]

Hi

I would like to model from scratch, but no one shares the information on these skins.

They are open source, but only a few have exact measurements and they make them to sell. Information isn't shared to prevent competition.

I would to model from scratch but the hoarding of measurements prevents that. This is why I am trying to do it this way.

Kind Regards

Ian

[TheCADWhisperer]

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@ianhughes7UFVF wrote:

How did you do it. I noticed there is another post with a method. Did you do it the same way or differently.

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You should learn to read the Timeline as a "recipe" for how I did the Sheet Metal conversion and Flat Pattern.

You should note a couple of subtle differences between my technique and @Marco.Takx (no Combine and no cutting away extra material - I left a tiny tiny extra sliver, no Unfold/Refold).  But basically the same technique as shown in the video.

[ianhughes7UFVF]

Hi

For some reason the timeline won't move past the Flatten Pattern.

I will have a good look at the other post and see if I can replicate the process.

I really appreciate your help in this regards.

Kind Regards

Ian

[ianhughes7UFVF]

Hi

I can get the sheet metal option now with activating the timeline feature.

But I am having trouble with the rest.

Could I pester you Cadwhisperer for a screencast on how you did it.

Please, pretty please 🙂

Kind Regards

Ian

[TheCADWhisperer · Accepted solution]

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@ianhughes7UFVF wrote:

For some reason the timeline won't move past the Flatten Pattern.

To get back to the Timeline first Exit Flat Pattern.

Then you can see my steps in the Timeline.

1.  I created a Tangent Workplane (as shown in @Marco.Takx video).

2.  I created a sketch (as shown in @Marco.Takx video).  (Tip:  I made the sketch extra wide so that I could clearly see Step 3-5 and then after I was done with Step 5 - changed it to .01mm to save steps)

3. Then I created a Flange (as shown in @Marco.Takx video).  (but in different order to save steps)

4. Then I Thickened the surface (as shown in @Marco.Takx video). (but in different order to save steps)

5. Then I created Flat Pattern (as shown in @Marco.Takx video).

If you have any trouble with steps 1-4, Stop and Attach your file here and indicate the issue.  

[ianhughes7UFVF]

Hi

Success 🙂

This is the Front Inner Skin.

Now, probably the dumbest question from me, where do I go to save this flat plate as a dxf. I am selecting the browser lines and finding no spot to save the specific flat plate as the dxf?

I have added a timeline of my progress.

Kind Regards

Ian

[ianhughes7UFVF]

Hi

I worked that out. I projected the Flat Plate onto a sketch and then I could download the DXF.

Great.

The only thing I need to do now is build up the skin tops front and rear with all the individual pieces as the unroll process seems to only like doing one section.

But I am pleased with all your help.

Thank you.

Kind Regards

Ian

[simonjohnlacey]

I cant believe that the combine turn the whole thing into a functioning sheet metal. That's awesome!

[Jusdoo]

Please try my app:

it is developed to  convert 3D plate part to sheet metal part and create flat pattern for it and export the size for material list. Furthermore, another app Profiles Extractor can collect all the flat patterns, create views, show quantities, material, thickness, .....

iChords - Plate Formatter @ Autodesk App Store

Youtube:

iChords Plate Formatter - YouTube

[jhackney1972]

Your application, on the Autodesk App Store, is only listed to work with Autodesk Inventor.  If it functions with Fusion 360, you may get more users if you indicate this functionality.

[Jusdoo]

Thanks for your suggestion, John! I really need try fusion later.