After teaching 1000’s of students and writing about SOLIDWORKS and SOLIDWORKS Simulation, David Planchard, retired professor WPI, is exploring Design Study, Optimization Analysis and Generative Design. Through this lesson series, David helps educators and their students understand iterative processes through simple examples and industry practices.
In Lesson 6, we downloaded the Cantilever_Bracket-xDesign.3dxml part from Lesson 5. Then we started a SOLIDWORKS desktop session and imported the Cantilever_Bracket-xDesign.3dxml part into the SOLIDWORKS xDesign App from the MySession panel in the Task Pane.
We investigated the Load Case Manager in the Design Guidance tool. The Load Case Manager provides the ability to turn loads on/off, combine loads, as well as varying the load mass. We created a new Load Case, edited material removal, and added a new Load.
In Lesson 7, import a SOLIDWORKS Assembly Zip file into the SOLIDWORKS xDesign App from the MySession panel. Utilize the Design Guidance tool.
Define a Clamp restraint. Define two point load forces on the Pulley Assembly. Redesign the Bracket of the Pulley Assembly with 70% less mass.
Add ABS material for the Additive Manufacturing process. Create two Load Cases. Run a Design Guidance Study for each Load Case. Analyze the provided shape of the Bracket in the Pulley Assembly. Note: When creating the Pulley Assembly, the Mirror Component tool was utilized on the first Bracket. Designing for symmetry has its advantages.
Before you begin, you need to have a basic understanding of the 3DEXPERIENCE Platform and the SOLIDWORKS xDesign App.
The 3DEXPERIENCE Platform provides downloadable content (DLC) from a secure cloud location within your SOLIDWORKS session. The platform enables you to collaborate with students and teams through a browser.
Think of the 3DEXPERIENCE Platform simply as a SOLIDWORKS Add-In on your desktop. Experience a single modeling environment. Access the platform within the SOLIDWORKS Task Pane.
Start SOLIDWORKS and Download Pulley Assembly
Start a SOLIDWORKS session from your desktop. Note: You can also access the SOLIDWORKS xDesign App directly using the following link: solidworks.com/xdesign/student.
Double-click the SOLIDWORKS 2025 icon.
Connect to the 3DEXPERIENCE Platform. Enter the requested information.
The Welcome – SOLIDWORKS dialog box is displayed.
Close the Welcome dialog box.
Download the SOLIDWORKS Pulley Assembly Zip file to follow along with this lesson.
Click the 3DEXPERIENCE icon in the Task Pane. The MySession panel is displayed.
In this lesson, use your default Collaborative space on the 3DEXPERIENCE Platform. The 3DEXPERIENCE Platform is browser driven. Your existing cookies and cache determine what you will see on your computer desktop or during a SOLIDWORKS login.
Click the 3DEXPERIENCE icon from the Task Pane. The MySession panel is displayed.
Click the center of the Compass in the MySession panel. The Compass is a means of launching your Apps inside the 3DEXPERIENCE Platform and inside a SOLIDWORKS session.
View your available My Roles, My Cockpits, My Favorite Apps and My Apps. The display will vary depending on your licenses and roles. Drag the slider downward to view additional Widgets and Apps. A Widget is an extension of the App that allows you to use it in the Dashboard.
Start SOLIDWORKS xDesign and Import Assembly
Start an xDesign session.
Click the xDesign Widget.
Note: You can also access the SOLIDWORKS xDesign App directly using the following link: solidworks.com/xdesign/student.
Log into the 3DEXPERIENCE Platform.
The SOLIDWORKS / xDesign dialog box is displayed.
Scroll down-ward and view the available xDesign Tutorials.
Import the SOLIDWORKS Pulley Assembly Zip file into SOLIDWORKS xDesign.
Click Import.
The Import dialog box is displayed. You can import directly for your 3DDrive or from a File on your local hard drive. In this example, import the SOLIDWORKS Pulley Assembly Zip file from your local hard drive.
The Import dialog box is displayed.
Click the File on Disk.
Click the File Format drop-down arrow.
Select Assembly (*.zip).
Click the Choose File button.
Locate the SOLIDWORKS Pulley Assembly Zip file.
Click Import for the Import dialog box.
This may take 5 – 10 seconds depending on your internet connection. If it takes longer, you will see the below message.
The Pulley Assembly (Physical Product) is displayed in the xDesign Work Area.
View the Design Manager. Utilize the Design Guidance redesign tool to create a lighter, more organic Bracket for the Pulley Assembly.
Hide Bracket100 (Bracket100-1) from the Design Manager.
Right-click Bracket100 (Bracket100-1) from the Design Manager.
Click Hide from the Pop-up menu.
Hide Pin-4 (Pin-4-1) and Pin-4 (Pin-4-2) from the Design Manager.
Click Pin-4 (Pin-4-1) from the Design Manager.
Hold the Ctrl key down.
Click Pin-4 (Pin-4-2) from the Design Manager.
Release the Ctrl key. Click Hide from the Pop-up menu.
Redesign Bracket100 with Design Guidance Tool
The Design Guidance tool helps you design geometries taking into account loads, restraints, material, space, and contributing obstacles. Design Guidance works with new designs or a redesign of existing geometry.
Redesign Bracket100 with 70% less mass.
Open Bracket100.
Right-click Bracket100 (Bracket100-1) in the Design Manager.
Click Open from the Pop-up General menu.
The Close Component dialog box is displayed.
Click Save.
Bracket100 (Physical Product) Design Manager is displayed.
Add material (ABS) to the Bracket.
Click the Tools tab from the Action bar.
Click Material Browser.
The Material Browser dialog box is displayed.
Click the Search icon. Enter ABS.
Slide the inside selection arrow downward.
Right-click ABS Material as illustrated.
Click Apply from the Pop-up menu.
Bracket100 is selected by default.
Click OK from the Pop-up menu.
Close the Material Browser dialog box.
Material (ABS) is displayed in the Design Manager.
The current mass of Bracket100 is 85.3 g.
Click the Design Guidance tab in the Action bar.
Define a restraint. Click the drop-down arrow under Clamp. There are two options: Clamp and Fixture. A Clamp restrains the part from moving in all directions. A Fixture restrains the part from moving in one or more directions.
In this example, apply a Clamp restraint to the bottom face of Bracket100.
Select Clamp from the Pop-up menu.
The Clamp dialog box is displayed.
Click the bottom face of Bracket100 as illustrated. Face.1 is displayed in the Select faces box.
Click OK from the Clamp dialog box.
Clamp.1 is displayed in the Design Manager.
Define a point load force. A point load force applies a load in a single direction to a narrow proximity. Click the drop-down arrow under Force. There are three options: Torque, Pressure, and Force. Apply a point force pointing to the right, due to a belt load on the Pulley Assembly.
Select Force.
The Force dialog box is displayed.
Click Point for Force type.
Enter 600 N for Magnitude. Note: Average weight of an adult human.
Select the two inside half cylindrical faces for the Axle as illustrated.
Select Other direction. Note: A point load force applies a load in a single direction to a narrow proximity.
Click the bottom right side of the Bracket as illustrated.
Click the Flip direction icon. Note: The direction of the Force arrows (to the right).
Click OK from the Force dialog box.
Point Force.1 is created and is displayed in the Design Manager.
Create a new shape for the Bracket. Utilize the Redesign tool.
Click the drop-down arrow under New Design in the Action bar.
Click Redesign from the Pop-up menu.
The Design Guidance dialog box is displayed.
Click the Setting tab.
Select the front face of the Bracket as illustrated. Face.1 is displayed in the Select body box.
Set the Target Mass Reduction to 70%.
The Material is ABS.
Select Medium for Voxel Granularity. Note: Finer granularity provides a more refined shape but increases the time required to generate the shape.
Select the Volume tab.
Select Preserve regions. Select faces to preserve on the generated shape.
We want to preserve the base shape of the Bracket, the back face, the cylindrical faces for the two pins and Axle hole.
Select all of the base faces. Select the back face as illustrated.
Select the four inside half cylindrical faces of the two holes (for the pins) on the base as illustrated.
Select the two inside half cylindrical faces for the Axle.
Click the Generate button.
View Results
The Results button is highlighted when finished. View the Results Display options.
Click the Results Display drop-down arrow.
The new mass is 41 g. The original mass was 85.3 g. Note: Your mass may vary depending on the selected preserve faces.
Click OK from the Design Guidance dialog box.
View the Work area for the results.
The Design Guidance Study.1 is displayed.
Apply Second Point Load and Create Load Case
Add a second point load force. The second point load force will be pointing upward due to a different belt load on the Pulley Assembly.
Click the drop-down arrow under Force. There are three options: Torque, Pressure, and Force. Select Force.
The Force dialog box is displayed. Click Point for Force type. Enter 1350 N for Magnitude.
Select the inside top half cylindrical face for the Axle as illustrated. Select Other direction. Note: A point load force applies a load in a single direction to a narrow proximity.
Click the top face of the Bracket as illustrated. Click the Flip direction icon. The direction force arrow points upwards.
Click OK from the Force dialog box.
Point Force.2 is displayed in the Design Manager.
Apply Point Force 2 to create a new Design Guidance Study1.
Create Load Case.2.
Click Load Case Manager from the Action bar.
The Load Case Manager dialog box is displayed.
Click the Add icon.
Click the Check boxes as illustrated for Load Case.1. Load Case.1 is 600 N to the right.
Click the Check box as illustrated for Load Case.2. Load Case.2 is 1350 N upward.
Click OK from the Load Case Manager dialog box.
Load Case.1 and Load Case.2 are displayed in the Design Manager.
Double-click Design Guidance Study.1 in the Design Manager.
The Design Guidance dialog box is displayed.
Slide the selector arrow downward.
Click the Load Cases arrow.
Select Load Case.2.
Click the Generate button.
View the different design shape.
Click OK from the Design Guidance dialog box.
Display the new shape.
Right-click the front face of Bracket100 in the Work area.
Click Hide from the Pop-up menu.
View the Results from Load Case 2
View the result in the Work Area. This is a great start. AI can only go so far, you still need engineering intervention.
Save and Close the Brackt100 part from the Action bar.
Open the Pulley Assembly from My Recent Projects in the SOLIDWORKS / xDesign dialog box.
Show the Bracket in the Work Area.
Right-click Bracket100 (Bracket100-1) in the Design Manager.
Click Show from the Pop-up menu.
Repeat the above process for Pin-4 (Pin-4-1) and Pin-4 (Pin-4-2).
View the results.
Both brackets are changed. Designing with symmetry has its advantages in the original assembly (Physical Product).
I saved the Bracket100 component as an STL (*.stl) file. In SOLIDWORKS, I opened the Bracket100 STL file, applied the Convert to Mesh body tool, added material and viewed the Mass Properties. The mass is 41 g. The original mass was 85.3 g.
The lesson is finished.
The final files, including .STL are locating in Pulley Assembly (1)
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Design well, Marie
Marie Planchard
Categories: Education