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

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

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

(OP)
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.

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

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

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


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

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. winky smile

Chris
SolidWorks 11
ctopher's home
SolidWorks Legion

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

The Indent tool could also work for you.

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

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
www.engtran.com  www.niswug.org
www.linkedin.com/in/engineeringtransport
Phenom IIx6 1100T = 8GB = FX1400 = XP64SP2 = SW2009SP3
"Node news is good news."

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

(OP)
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.

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

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
www.engtran.com  www.niswug.org
www.linkedin.com/in/engineeringtransport
Phenom IIx6 1100T = 8GB = FX1400 = XP64SP2 = SW2009SP3
"Node news is good news."

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

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

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