Unfold Complex Surface

[Jtmea]

Attached is a part file of a complex curve, "quilt". The part was created by projecting a square onto a sphere and then thickening the surface to ensure all edges are perpendicular. This is a simplified mock-up of an actual design problem I am running into. I need a flat pattern of the shape. The problem is that all edges are compound curves and there are no stationary references. Even if we split the part to create a symmetric stationary reference we are still left with a piece that curves in 2 different dimensions. What is the best way to go about to get a direct flat pattern or simplifying so I can achieve a similar pattern? Any help is appreciated.

[CCarreiras]

Hi!

What's the manufacturing process? Die Forming?

[Jtmea]

Typically a piece like this would be manually formed onto an existing fabricated duct, because of the thickness (5/8") we may send this out to be roll formed. Either way this is typically a single time manufacturing and not a mass manufactured piece.

[mcgyvr]

part didn't attach (try a different browser)..

But in general Inventor can only flatten parts made in a press brake or roll forming machine..

So even if you were able to post your part from the description it sounds like something that Inventor cannot unfold..

Maybe get a demo of the new version of Solidworks to see if you can get a flat.. They are ahead of Autodesk on what they can/cannot unfold with their latest release..

There is also some addin software that works with Inventor files that will do it or there are some "online unfolding" websites now that may handle your part too.. (for a fee)

[Jtmea]

Because of the size and use of this plate the geometric tolerance of this piece is very broad. maybe about a 1/4" deviation in all directions. So I am open to any simplification work arounds.

[CCarreiras]

...and that's why inventor can't perform a flat pattern to a part like that, it's because is not a bending, but a plastic deformation. Inventor doesnt compute plastic deformations.

Nevertheless, place the part and we will see what we can do.

[Jtmea]

Here is the part again.

[Jtmea]

I have attached the file again, hopefully it works this time.

We currently do not have any access to Solid Works, we tried in Solidedge as well but we ran into similar problems. If there is a simple way to modify the part to create something similar that can be unfolded.

[Jtmea]

Here is the part again. Thank you

[CCarreiras · Accepted solution]

I believe this will be a good approach for your issue.

Check the file.

[CCarreiras]

Also, you can have the folded part to place in a assembly, and the flat pattern part in different files linked by the "derived tool". This way you can have the folded part to place in a assembly, and the flat pattern part to document.

I can do that for you.

[Jtmea]

I reviewed your approach and I can see you are manually collecting the cross sectional information across three different planes and using that information to constrain a projected flat pattern. This is exactly the kind of work around I was looking for. I will be able to adapt this method to my specific project. Thank you.

[Jtmea]

The derived method is exactly what I was going to use. Thank you for mentioning it for others to see.

[CCarreiras]

The third plane was only to check if it was a square. You can use only 2 planes to represent all cases.
Don't forget to take the arc lengths in the middle thickness.

[johnteng00]

solid3dtech.com has the tool to unfold such complex surface. There are many samples in Youtube.