CADfix: Advanced Solution for 3D Model Repair and Conversion Between CAD Systems

Discover how automatic geometric repair tools can transform your CAD conversion processes by filling gaps, correcting surfaces, and adjusting tolerances without excessive manual intervention. This article explores the key functionalities that guide users throughout the conversion process.

In modern manufacturing industry, challenges related to data exchange between different CAD systems represent a major obstacle to productivity. Each year, companies lose thousands of engineering hours due to defective or incompatible 3D models. This issue affects all industrial sectors, from aeronautics to automotive, mechanical engineering and energy.

CAD model repair has become a critical skill in an environment where multi-software collaboration is the norm rather than the exception. Given the diversity of proprietary formats and mathematical approaches used by different systems, having powerful diagnostic and geometric correction tools now represents a significant competitive advantage.

Table of contents

• The challenges of CAD interoperability
• Anatomy of geometric problems in CAD models
• CAD model repair methodologies
• CADfix DX: complete CAD repair and conversion solution
• Benefits of an effective CAD repair strategy
• Applications by industrial sector

The challenges of CAD interoperability

Interoperability between CAD systems represents one of the major technical challenges of modern industry. In an environment where collaboration between different stakeholders is essential, the ability to exchange 3D data without loss of information becomes crucial to maintain the efficiency of development processes.

The diversity of CAD systems: a technical obstacle

The CAD solution landscape is characterized by great heterogeneity. Systems such as CATIA, SolidWorks, NX, Creo or Inventor each use their own proprietary formats and mathematical approaches. This diversity creates incompatibilities that manifest when exchanging data between different systems.

• Incompatible proprietary formats
• Differences in mathematical representation of surfaces
• Variations in accepted geometric tolerances
• Distinct approaches to parametric modeling

These technical differences often transform a simple project into a logistical nightmare when partners using different systems need to collaborate on the same set of technical data.

The economic consequences of incompatibility

Beyond purely technical aspects, incompatibility between CAD systems generates significant costs for companies. Studies conducted with industrial companies reveal that interoperability problems represent up to 20% of the development costs for complex products.

Streamlining data exchange between CAD systems therefore represents a major strategic issue for any industrial company concerned with optimizing its development processes and reducing its operational costs.

Anatomy of geometric problems in CAD models

To effectively solve interoperability problems, it is essential to understand the nature of geometric defects that occur during data exchanges. These errors can take various forms and have varying impacts on the subsequent use of the models.

Typology of common geometric errors

Geometric defects in CAD models can be classified into several categories, each requiring specific repair approaches:

• Topological problems: missing faces, holes, unconnected edges
• Continuity defects: tangency breaks, discontinuities between surfaces
• Precision errors: tolerance deviations, numerical inaccuracies
• Problematic geometric entities: short edges, narrow faces, singular points

These errors mainly occur during conversion between different CAD formats, due to fundamental differences in how each system mathematically represents 3D objects.

Technical origins of problems

Understanding the root causes of interoperability problems allows for adopting more effective repair strategies. Here are the main sources of geometric defects:

These technical problems can be amplified by unsuitable modeling practices. A poorly constructed model originally will be all the more likely to present defects after conversion to another format.

Consequences on downstream processes

Geometric defects in CAD models are not simply isolated technical problems. They have concrete repercussions on the entire digital chain:

• Failures when generating machining programs
• Inability to create correct meshes for simulation
• Errors in finite element analysis calculations
• Manufacturing and assembly problems
• Difficulties in integrating virtual components

Early detection and effective repair of defective CAD models therefore represent a critical issue to ensure the continuity of digital flows and avoid costly rework.

CAD model repair methodologies

Faced with the challenges of CAD interoperability, various methodological approaches have been developed to optimize the repair of 3D models. These methodologies combine human expertise and automation to achieve the best results.

Manual vs automated approaches

CAD model repair can be approached according to different levels of automation, each approach presenting its advantages and limitations:

Modern solutions tend towards hybrid approaches, where automation is favored for simple cases, while human expertise is mobilized for complex situations requiring in-depth technical judgment.

Repair techniques by type of defect

Different techniques have been developed to effectively address each category of geometric defects:

• Surface stitching: Technique for connecting adjacent surfaces with small gaps to create a usable closed volume.
• Geometric healing: Correction of mathematical imperfections in the definition of curves and surfaces.
• Simplification (defeaturing): Removal of small, non-essential entities that unnecessarily complicate the model.
• Topology reconstruction: Recreation of relationships between geometric elements to ensure model consistency.
• Direct translation: High-level conversion preserving model intelligence between compatible systems.

These techniques can be combined in a complete repair process, adapted to the specificities of each model and the requirements of the target application.

Optimal repair process

An effective repair process generally follows a logical sequence that maximizes the chances of success while minimizing the time required:

1. Preliminary diagnosis: Automatic analysis of the model to identify all geometric defects.
2. Repair prioritization: Ranking of defects by order of importance and impact on model stability.
3. Automatic repair of standard problems: Application of correction algorithms for common defects.
4. Targeted intervention on complex cases: Manual or semi-automatic treatment of defects resistant to automation.
5. Geometric validation: Verification of model integrity after repair.
6. Functional validation: Testing the model in the target application to confirm its usability.

This methodical approach allows optimizing the balance between result quality, time spent and resources mobilized. It adapts to both one-off repair needs and industrial processes handling large volumes of data.

CADfix DX: complete CAD repair and conversion solution

In the landscape of CAD repair tools, CADfix DX stands out as a particularly comprehensive solution, combining advanced capabilities for diagnosis, repair and multi-format conversion.

Distinctive features

CADfix DX offers a set of technical features that address the most complex challenges of CAD interoperability:

• In-depth geometric diagnosis: Complete analysis of models with precise identification of all types of defects.
• Extended multi-format capabilities: Support for a wide range of native CAD formats and exchange standards.
• Advanced automatic repair tools: Sophisticated algorithms for correcting geometric and topological problems.
• Intuitive user interface: Clear visualization of defects and guided workflow for repair.
• Preservation of model intelligence: Maintenance of structures, hierarchies and attributes during conversions.

These technical capabilities are supported by decades of development and expertise in the field of CAD interoperability, which allows CADfix DX to effectively handle the most complex cases.

Optimized workflow for productivity

CADfix DX implements an optimized work process that guides the user through the different stages of repair:

1. Smart import: Reading and initial conversion of data with maximum preservation of information.
2. Automatic analysis: Comprehensive diagnosis of the model with classification of defects by category and severity.
3. Intuitive visualization: Clear graphic representation of detected problems to facilitate understanding.
4. Guided repair: Step-by-step process with automatic suggestions for each type of defect.
5. Dynamic validation: Real-time verification of repair effectiveness and updated diagnosis.
6. Targeted export: Conversion to the target format with specific optimization according to the destination application.

This structured workflow allows users of all levels of expertise to achieve optimal results, even when faced with models presenting complex defects.

Multi-format conversion capabilities

One of the major strengths of CADfix DX lies in its ability to serve as a universal interface between different CAD systems. The solution supports:

This versatility allows CADfix DX to integrate seamlessly into heterogeneous industrial environments where different CAD systems coexist, thus facilitating collaboration between departments and partners.

Benefits of an effective CAD repair strategy

The implementation of a structured approach to CAD model repair, supported by suitable tools such as CADfix DX, generates tangible benefits for industrial companies.

Impacts on development timeframes

An effective CAD model repair strategy significantly reduces development cycles:

• Elimination of bottlenecks related to interoperability problems
• Reduction of time spent on manual repair of defective models
• Smoother transitions between different development phases
• Acceleration of design iterations thanks to more reliable data exchanges

These time savings directly translate into faster time-to-market for products, conferring a significant competitive advantage.

Optimization of operational costs

The economic aspect constitutes a major argument in favor of a structured CAD repair strategy:

Return on investment analysis typically shows that advanced CAD repair solutions pay for themselves within a few months thanks to the savings made on industrial processes.

Improvement of product quality

Beyond temporal and financial aspects, the intrinsic quality of the developed products also benefits from better management of CAD interoperability:

• Reduction of design errors related to undetected geometric defects
• Improvement of accuracy in simulations and numerical analyses
• Better compliance between virtual models and manufactured products
• Greater consistency between different representations of the product

This qualitative improvement results in a decrease in non-conformities, returns and late modifications, contributing to the company's reputation for excellence.

Applications by industrial sector

CAD repair and conversion solutions like CADfix DX find specific applications in various industrial sectors, each presenting its own requirements and constraints.

Aerospace and defense

The aerospace sector is characterized by particularly high requirements in terms of geometric precision and traceability of modifications. Typical applications include:

• Data exchange between contractors and subcontractors using different CAD systems
• Model preparation for aerodynamic and structural analysis
• Migration of historical data to modern CAD systems
• Consolidation of digital mockups integrating components from various sources

In this sector, the ability to maintain geometric precision while ensuring compatibility between systems is paramount to guarantee the quality and safety of final products.

Automotive and suppliers

The automotive industry, characterized by complex supply chains and increasingly shorter development cycles, particularly benefits from advanced CAD repair tools:

The ability to quickly integrate components from multiple suppliers into a coherent digital mockup represents a major competitive advantage in this sector.

Heavy industries and energy

The energy and heavy industries sectors are distinguished by the size and complexity of installations, as well as the long lifespan of equipment:

• Preservation of data integrity over several decades
• Integration of existing systems into new installations
• Conversion of historical 2D diagrams into usable 3D models
• Model preparation for flow simulations and structural analyses

In these sectors, the ability to maintain the consistency of technical data throughout the lifecycle of installations, often measured in decades, constitutes a major strategic issue.

Architecture and construction

The construction sector is experiencing an accelerated digital transformation with the growing adoption of BIM (Building Information Modeling), creating new interoperability challenges:

• Conversion between mechanical CAD formats and BIM formats
• Integration of technical equipment into architectural models
• Model preparation for energy and thermal simulations
• Simplification of complex geometries for virtual reality applications

The convergence between the traditionally separate disciplines of mechanical design and architecture creates a growing need for tools capable of effectively translating data between these different technical worlds.

Cross-sectoral use cases

Some applications of CAD repair transcend sectoral boundaries and address common needs across various industries:

These cross-sectoral applications highlight the growing importance of interoperability in an industrial ecosystem where traditional boundaries between sectors tend to fade in the face of digital transformation challenges.