Sheet metal Twist Spiral Auger shape to flat pattern

Sheet metal Twist Spiral Auger shape to flat pattern

TinWhisperer
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Message 1 of 14

Sheet metal Twist Spiral Auger shape to flat pattern

TinWhisperer
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Looking for some workflow to reliably produce flat patterns from twisted spiral auger shaped sheet metal components.

 

 twisted 4.pngtwisted sheet metal v2 3 .pngtwisted sheet metal v2 2.pngtwisted sheet metal v2.png

 

The yellow component is a four foot length of 2.5 schedule 40 pipe. The green component is a piece of 14 gauge steel 2 1/2 inches out from the pipe spiraling up to the top, rotating 90°.

 

Attached is an example of F3D of what I'm trying to do. Any guidance would be appreciated.

 

 

 

 

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Message 2 of 14

TinWhisperer
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I have been able to do a rough representation of the flat but this workflow is cumbersome. f3d attached.

I did this using triangulation instead.

 

twisted sheet metal for rough flat v1.png

twisted sheet metal for rough flat v1 2.png

twisted sheet metal v4 pattern.png

   

 I would like to come up with a workflow or a methodology to do this quicker and more accurately

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Message 3 of 14

Warmingup1953
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Not an answer as such but how close is this via an online Flight Calculator?

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Message 4 of 14

Warmingup1953
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..Or perhaps via Meshmixer?

 

Screenshot 2025-11-04 070201.png

Message 5 of 14

MichaelT_123
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Hi  Mr TinWhisperer,

 

Consider checking:

https://forums.autodesk.com/t5/fusion-design-validate-document/auger-flight-sections-into-flat-patte...

FlattenTheAuger_mono.png

 

Regards

MichaelT

MichaelT
Message 6 of 14

TinWhisperer
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@Warmingup1953  have used meshmixer before for projects like this. I'm not terribly keen on leaving the fusion environment and then bringing geometry back into the fusion environment. I do appreciate the idea though.

 

@MichaelT_123 @ this parameter based solution is interesting. It does seem complex. I wonder how it'll work on the face I'm looking at reproducing instead of the top face? In the example you provided it's aiming to get the pattern for the face in the top view where I am looking at getting a pattern for the side face. I am gonna dive into it a little bit more but I'm afraid it may be over my head.

 

If anyone does have a solution which is simple and stays inside the fusion program I would love to hear it.

 

 

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Message 7 of 14

TinWhisperer
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I made a scale model to test out my methodology.

 

It's posted here on makers world if you'd like to try it out

 

Tri Fin test model. Twisted Auger form by fourthstatecnc MakerWorld: Download Free 3D Models

 

IMG_20251119_080604_591.jpgIMG_20251119_080611_341.jpgIMG_20251119_082029_458.jpgIMG_20251119_082244_752.jpgIMG_20251119_082249_196.jpgIMG_20251119_082253_017.jpgIMG_20251119_082255_271.jpg

 

I also made a couple out of sheet metal for the sculpture we're working on I think it fits quite accurately

 

9bcf005c1c7a566a08878c69605cf4c621b9cf1b_2_562x1000.jpeg4d61d4c69556e85d28ccd58d7f668f2ec5a89bcf_2_562x1000.jpega499dd4fd512094d38cc7a6afbde4be618b8ad3d_2_562x1000.jpeg

 

still seeking A simpler methodology that stays with inside Autodesk fusion.  Please post if you have any ideas.

 

 

Message 8 of 14

TinWhisperer
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Good Morning @MichaelT_123  I read through this post more and downloaded your F3D you provided 

 

https://forums.autodesk.com/t5/fusion-design-validate-document/auger-flight-sections-into-flat-patte...

 

The differential geometry you presented it's a little above my pay grade. I did notice that the F3D you provided does not end in a sheet metal flat pattern. I did go through the timeline step by step to see your methodology. Do you have a version that ends in a flat pattern?

 

 

 

 

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Message 9 of 14

MichaelT_123
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Advisor

Hi Mr ThinWisperer,

I am on my mobile right now. I don't remember what macka geegee I have done there ... but look at parameters, There should be one controlling this thing.

Regards

MichaelT 

 

MichaelT
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Message 10 of 14

TrippyLighting
Consultant
Consultant

@TinWhisperer wrote:

lution for flating n 

still seeking A simpler methodology that stays with inside Autodesk fusion.  Please post if you have any ideas.

 


That does not exist!

 

Flattening non-developable surfaces is possible in Autodesk Inventor. The juicy bit is that the method used in Inventor came from Meshmixer, which is/was not originally software developed by Autodesk.

Since the developer of Meshmixer left Autodesk a few years ago, Autodesk has stopped developing Meshmixer.

 


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Message 11 of 14

TinWhisperer
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@TrippyLighting wrote:

@TinWhisperer wrote:

lution for flating n 

still seeking A simpler methodology that stays with inside Autodesk fusion.  Please post if you have any ideas.

 


That does not exist!

 

Flattening non-developable surfaces is possible in Autodesk Inventor. The juicy bit is that the method used in Inventor came from Meshmixer, which is/was not originally software developed by Autodesk.

Since the developer of Meshmixer left Autodesk a few years ago, Autodesk has stopped developing Meshmixer.

 


For this project we just did bring it into existence...

 

let's see if we can reduce the steps of this further.

 

Triangulated twist v1 Tessellation 2.png

Triangulated twist v1 Tessellation 1.png

  I've already built 2 real world examples of this, one in metal and one in 3D printed that worked out very well but now this new version of the methodology it is even simpler and more accurate. And all this stays with inside Fusion .

 

Attached is an F3D check out the process and see if we can take a few more steps out of it.

 

Message 12 of 14

TrippyLighting
Consultant
Consultant

You asked for a simpler method. In Inventor and other CAD systems, you can flatten such geometry with one feature.

I am happy that you were successful with the workflow you presented in the file you shared, but that definitely isn't "simpler" and also is much more limited than a general flatten workflow for non-developable surfaces.


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Message 13 of 14

TinWhisperer
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@TrippyLighting wrote:

You asked for a simpler method. In Inventor and other CAD systems, you can flatten such geometry with one feature.

I am happy that you were successful with the workflow you presented in the file you shared, but that definitely isn't "simpler" and also is much more limited than a general flatten workflow for non-developable surfaces.


Simpler in context of other methodologies that have already been presented here and refined and which stay inside Fusion. One of my criteria for the methodology was staying with inside the Fusion ecosystem.  There is many flattening programs out there meshmixer , rhino,  blender, etc but I'm not terribly interested in working outside of the Fusion ecosystem.

 

Reducing the steps to do this with in Fusion is the goal, while being repeatable and as accurate as possible.

 

My hope is fusion will just absorb inventor soon. I also wish Autodesk would just buy SheetCam and also absorb it into the fusion collective.

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Message 14 of 14

TrippyLighting
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Consultant

@TinWhisperer wrote:

.
..

 

 

My hope is fusion will just absorb inventor soon. I also wish Autodesk would just buy SheetCam and also absorb it into the fusion collective.


In June 2023, I re-posted a thread from this forum on the Fusion Slack channel, where Autodesk Expert Elites have direct access to the development team.
This was another thread where Mr. @MichaelT_123 showed his mathematical prowess to address this flattening problem. I was referred to functionality in Inventor and was informed that it was derived from Meshmixer. I suggested they get in contact with Michael to "compare notes".
There seemed to be no interest, which I find truly disappointing.

The Product managers responsible for this area of Fusion were invited to the thread but never responded.
The conversation died down.

In March this year, I asked again in that Slack thread and received zero feedback.
In September, I asked again in a new thread. Two of my fellow EEs showed interest, but I received zero feedback from the developers.

I would not hold my breath!

I'll see what I can do with your file! 

 


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