Hello everyone,


The picture in the attachment will explain my question.

(I have a Solidworks standard license)


I want to make complex figures (extrude cut) in standard extrusion profiles (steel or stainless steel) all around the tube.

With round tubes it's quite easy, then you can use the 'wrap' function and design the shapes in a 2D sketch, us Wrap function and then apply Deboss.


But with box sections (square tube, rectangular tube) it's more difficult.


This is how far I came:

1) Place a standard profiel (in this example ISO 80x80x5 mm)

2) Make a small gap over the full length (1mm)

3) Convert it to sheet metal + Unfold

4)  Sketch the (complex) shapes and do Extrude Cut

5) Refold

6) Fill the 1mm gap with a simple extrusion and make sure the 'Merge result' is on


Then I save the model as a STEP file, and this is the format the Tube Laser machine can recognize. (If I don't use the 'merge result' function, the program will recognize it as a bend piece of sheet metal instead of a tube). (Here an example of a Laser Tube cutting machine: Laser tube cutting machines | BLM GROUP - YouTube   )


BUT... the problem is step 6. Fill the gap with a 1mm extrusion can only be done when ever I can make a full length (vertically) extrusion. But I want to go further in my designs so that there is no place for a vertical extrusion over the full length (see example picture at the end). How can I do this? I have no idea


And, I think this method is a little complex. So I hope you can give me tips or help me to show how I can design this in a different way.

Thanks in advance.







Laser cut tube.png

Categories: Modeling and Assemblies, Weldments

Last comment By: Alex Furniture   Fri, 23 Mar 2018 17:28:26 GMT
Re: How to make complex shapes for tube lasering

Hi Lennart,


Just model your component as a solid. You will need a gap if you need to model your cuts in the flatten stage. No way around it.

You can add simple cut features in the formed position without it being a sheetmetal and model the "normal cut" feature into it after the fact. With merge body unchecked. First offset the inside surface to the outside at given thickness. Then offset the outside surface to the inside a given thickness.  Combine the bodies and select common. Now you can slot it and convert it to sheetmetal if you want.

You can als use wrap feature to wrap a flat layout around your tube and a combination of the three.

You can use multi body modeling. Create your cuts onto a sheetmetal slotted tube. Then transfer the contours onto your solid tube.

All in all you have quite a few options. Your contours will determine the best approach.



By: Elmar Klammer  Sun, 18 Mar 2018 14:42:19 GMT
Re: How to make complex shapes for tube lasering



Instead of a straight path, you'll to delevop a curved one.

See this related post for some insight on this:

Trouble flattening cylinder with holes passing over modified linear edge





By: Kevin Chandler  Sun, 18 Mar 2018 16:26:01 GMT
Re: How to make complex shapes for tube lasering

I am also looking for a solution on this mater. I will follow and if i have any update i will post it here.

By: Alex Furniture  Fri, 23 Mar 2018 17:28:26 GMT
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