How to "vacuum form" an existing part to make a form-fit accessory 3

[CheckThePlug]

Hi,

I saw this controller add-on online this weekend while doing my normal web browsing (post was about bad PR from the company, but that's beside the point), and I was wondering about the technique used to "vacuum form" the part. It doesn't appear that they used a traditional vacuum form, but rather had a CAD model (or 3D scan) of a controller and was able to make the neatly contoured device with that. If I had a model or 3D scan of a part with complex geometry like the XBOX controller, how would I go about creating a contoured "indention" in another part/assembly in Solidworks so that it would have that nice glove-like fit?

Here's the link to the product I'm talking about:

http://www.avengercontroller.com/picture.php

Any tutorials or even the proper name for this technique would be appreciated.

Thanks.

 

[MadMango]

Look in Help under Cavity Tool, or Tutorials for Molds.


"Art without engineering is dreaming; Engineering without art is calculating."


Have you read faq731-376 to make the best use of these Forums?

 

[ctopher]

I agree with MM.
If you have a SW model. If not, the 3D scan is your option.
You could also do a surface offset of zero, then thicken to make the part.
Various ways to do things in SW. ;-)

Chris
SolidWorks 11
ctopher's home
SolidWorks Legion

 

[CorBlimeyLimey]

The Indent tool could also work for you.

 

[kellnerp]

Cavity tool will only do part of the work. It will create a cavity that completely surrounds the object which is not how thermoforming works. Typically a thermoformed package does not wrap around the part.

Basically you would have to create the top surface of the controller, use the dome feature to build a bubble around the buttons and a sweep to build a bubble around the arms. From the top surface edges extrude down to the backing. Then add necessary draft as a last step.

TOP
CSWP, BSSE

http://www.engtran.com

http://www.niswug.org

http://www.linkedin.com/in/engineeringtransport

Phenom IIx6 1100T = 8GB = FX1400 = XP64SP2 = SW2009SP3
"Node news is good news."

 

[CheckThePlug]

Thanks guys, good answers!

The cavity tool will work for the things I want to do with it. I was aware of it before, but it was always presented as if it was only useful if you were actually making a full injection mold rather than just trying to get a negative of the part.

 

[kellnerp]

SW creates geometry. It doesn't know what the end use of the geometry is per se.

The cavity tool doesn't require making a full cavity either.

You could also use the dimple tool in sheet metal although I've never used it on something that complex.

TOP
CSWP, BSSE

http://www.engtran.com

http://www.niswug.org

http://www.linkedin.com/in/engineeringtransport

Phenom IIx6 1100T = 8GB = FX1400 = XP64SP2 = SW2009SP3
"Node news is good news."

 

[hendersdc]

If you have multiple bodies in a part, i.e. the filled in exterior of your accessory and the part you want it to fit aroud, you can use the combine feature and select subtract. It is under Insert->Features->Combine...

Doug