DEVELOP3D October 2008 by X3DMEDIA

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TECHNOLOGY FOR THE PRODUCT LIFECYCLE

OCTOBER 2008

Inside Astro Studios

How the team behind the Xbox 360 develops killer products

ND A T S A F THE S U IO R U F THE off id l e th k o o t M HOW KTracing with KISKA

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WELCOME EDITORIAL Editor Al Dean al@x3dmedia.com +44 (0)7525 701 541 Managing Editor Greg Corke greg@x3dmedia.com +44 (0)20 3355 7312 Consulting Editor Martyn Day martyn@x3dmedia.com +44 (0)7525 701 542 Editorial Assistant Stephen Holmes stephen@x3dmedia.com +44 (0)20 3355 7311 PRODUCTION/DESIGN Production Editor Penelope Rance Art Director Rob Biddulph ADVERTISING Advertising Manager Tony Baksh tony@x3dmedia.com +44 (0)20 3355 7313 Deputy Advertising Manager Steve King steve@x3dmedia.com +44 (0)20 3355 7314 SUBSCRIPTIONS Circulation Manager Alan Cleveland alan@x3dmedia.com +44 (0)20 3355 7311 DEVELOP3D is published monthly and is available FREE to qualifying individuals. To ensure you receive your regular copy please register online at www.develop3d.com/registration

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X3DMedia Ltd 93a Rivington Street London EC2A 3AY T. +44 (0)20 3355 7310 F. +44 (0)20 3355 7319 www.x3dmedia.com © 2008 X3DMedia Ltd All rights reserved. Reproduction in whole or part without prior permission from the publisher is prohibited. All trademarks acknowledged

o: the difficult fourth issue. Last month’s was a storming ride through many areas of product development, and I’ve never had such a warm reaction to a magazine – that’s what you get for putting Lego on the front cover. It made me think about the work that we do, that our readers do, and how it affects the world we live in. If you look at the products that are designed, engineered and manufactured on a daily basis, you realise the impact that we, as those engaged in product development, have on the world around us. What still amazes me is the level of innovation present in today’s marketplace, and the effort that goes into it. When you strip it back and look at it from a fresh perspective, try to understand everything that goes into the process of developing products that break the rules, and improve on what went before or change the game, it’s truly breathtaking. On my way to Barcelona for the SolidWorks press event, I managed to miss my flight, get rebooked through Zurich and arrive in time to meet some old friends in a wonderful city. It struck me that developing a product, whether a consumer product that people interact with every day, a lunatic vehicle for the petrol head, a fork-lift truck or the latest gaming workstation for HP (all of which feature in this issue) takes real passion. Design is not just a job – it’s a way of life. In Barcelona I spent time with many of the SolidWorks blogsquad, who are passionate about design and manufacturing. They spend their time discussing their use of SolidWorks in a public forum, for all to see and many to gain a better understanding of the tool – and I take my hat off to them. But SolidWorks is just that, a tool. Yes, tools make life easier for the designer or engineer – but the job is about much more than that. Something that, sometimes, the technology vendors miss entirely. The designer/engineer is salesperson, manager, project controller and influencer, both within the organisation they work for, and with suppliers, clients and the public at large. To get a product to market is a complex process and consumers often don’t realise that it’s about much more than shape, function and purpose. The ability to wrangle with suppliers, to deliver the goods, to sit and argue the case for a feature with peers, with management, with clients, takes true belief in what you’re doing. There are challenges that stand in the way of that desire to create a fantastic product, and part of our task is to find technology and present cases studies that show how to hurdle those barriers more quickly, more efficiently. In this issue we look at how BAE Systems formalised onto a single system and managed the translation of data onto a common platform. We examine the use of data management techniques to make simulation data more accessible, but still in a controlled environment. We reveal how two very different organisations are taking advantage of both rapid prototyping and traditional model making skills to achieve a solid end result. The last thing I want to do is to congratulate the organisational brains behind DEVELOP3D, Greg, and his new wife Helen on their recent marriage. Never were a couple better suited to spend their lives together. We just hope he makes it back from honeymooning in Kenya, because we aren’t entirely sure we can cope for another issue without him. In fact, I’m amazed you’re even reading this. Catch you next month,

Opinions expressed in articles are those of the author and not of X3DMedia. X3DMedia cannot accept responsibility for errors in articles or advertisements within the magazine DEVELOP3D is printed by Warners Midlands plc www.warners.co.uk

Al Dean Editor, DEVELOP3D Magazine al@develop3d.com DEVELOP3D OCTOBER 2008 3

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create – Build a digital model using Autodesk® Inventor™ software to define form, fit and function.

integrate – Add electrical

controls data to create a more complete digital prototype.

validate – Simulate

real-world performance before ever building a physical prototype.

HOW DIGITAL PROTOTYPING CAN DELIVER HIGH-SPEED MACHINING - BEFORE A SINGLE CUT IS MADE. autodesk.co.uk/digitalprototyping

Image courtesy of HanWha TechM, Inc.

Autodesk, Autodesk Inventor and Inventor are registered trademarks or trademarks of Autodesk, Inc., in the USA and/or other countries. All other brand names product names or trademarks belong to their respective holders. Autodesk reserves the right to alter product offerings and specifications at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. © 2008 Autodesk, Inc. All rights reserved.

contents

RP at Timberland P41

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OCTOBER 2008 ISSUE No.4

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NEWS Autodesk takes on SolidWorks over branding and DWG, SpaceClaim gets a new CEO, Dassault’s new green HQ for DS and V5 up revs to R19. While all that’s going on, Al Dean meets the Blogging community, Josh Mings goes all William Gibson over the future of 3D interaction and Evan Yares looks at how 3D design got to where it’s at

20 24 28 32 34 38 41 42 44 47 48

FEATURES Product Design Showcase COVER STORY Fast and Furious at KTM and Kiska How Astros Studios develop killer products Rendering tips and tricks for PhotoWorks Standardising CAD with BAE Systems and the Nimrod A breath of fresh air from Paragon Timberland and RP Meeting Siemens Visiting the SpaceMouse mothership What is OpenGL 3.0? Sogeti and Ansys

50 52 54 56

REVIEWS SolidWorks PhotoView 360 AcuSim 1.7 Ansys Engineering Knowledge Manager 1.1 Vero VISI Series

58 APPOINTMENTS Eight pages of the latest jobs in product development, design and engineering 66 THE LAST WORD Martyn Day on what the international economic crisis will mean for engineers PLUS

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86H: HIJ9N Kiska has rapid prototyping machines in-house, and a facility to build models. “We build clay models of all our vehicles and test them extensively. We scan them and create and modify the data as it is shared with our suppliers,” says Stassin. “The best feature of all these tools is the ability to evolve the vehicle using the results of the analysis we received from FEA, CFD and wind tunnel sessions.”

PUT TO THE TEST

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THE THE FAST FAST AND AND THE THE FURIOUS FURIOUS THE THE THE THE FAST FAST FAST FAST AND AND AND AND THE THE THE THE FURIOUS FURIOUS FURIOUS FURIOUS » Kiska has brought the power and exhilaration of a motorbike to four wheels with the new X-Bow. Frances Corbett talks to Austria’s largest design company about its work with motorcycle manufacturer KTM

or over 50 years, Austrian motorcycle manufacturer KTM has held a reputation for producing motorcycles that embody the company philosophy of ‘Ready to Race’. Recently, it has dipped a toe into the automotive market with the launch of the KTM X-Bow (pronounced ‘cross bow’), a high-performance racing car that recreates the exhilaration of riding a motorcycle on four wheels. With its aggressive styling, this two-seater sports car boasts a 177kW Audi TFSI turbo-charged engine that powers the 790kg lightweight to 100km/h in just 3.9 seconds. Stefan Pierer, KTM’s CEO, believes in the beneﬁts design can bring to the brand and has worked closely with Kiska, Austria’s largest design company with over 100 employees, for the past 15 years on the design of all its motorcycles as well as the company’s overall identity. “Stefan Pierer and I were sat having a beer back in summer 2005 and put one and one together,” remembers founder and MD Gerald Kiska. “Fewer and fewer young people were applying for a motorcycle licence, so it was a

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foregone conclusion that our customer base was shrinking. We thought about quad bikes, for which you don’t need a motorcycle licence, but the vehicle concept transpired to be unsuitable – not safe enough on asphalt. The next logical thought was what would work on the road and attract the attention of people with a driving licence for cars? A car, a racing car.”

RISK AND REWARD Kiska’s transportation designers were called upon to help KTM make this potentially risky transition, bringing its core values of performance, purity and adventure to a new market. But before pen was put to paper, Kiska carried out extensive research and analysis, dictated by its Integrated Design Development (IDD) process. During IDD all relevant aspects of the brand are taken into account: from analysis of the market and strategy development through to conceptual and product design. This is followed by marketing and communication strategies together with the design of the product environment (such as POS, shop and exhibition design). Kiska’s strategy, transportation design, product design,

� This is an unﬁltered driving experience. Lightweight, rapid acceleration and amazing driving dynamics

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communication design and environmental design departments complete the process under one roof. In the case of the X-Bow project, a thorough target group analysis was initially carried out to ensure that they were creating the best possible output for the target groups. From here, Sebastien Stassin, Kiska’s head of transportation design, and his team kicked off the design development process by sketching a few rough ideas on paper. Apart from specified legal mechanical and aerodynamic guidelines, the designers were given carte blanche. The intention was to create a street-homologated car with ‘transparent’ technology, in which every part fulfils a specific function, packaged in a simple, minimal design. “The aim was the simplicity and performance of a motorcycle, with exposed mechanics and no filter between occupants and experience,” says Stassin. “The car has no roof, no windshield and no heater. It has the acceleration of a motorcycle with the road holding of a race car.”

SUBSTANCE BEFORE STYLE But this was not merely an exercise in styling. To turn the X-Bow into a racing would require some advanced technologies. “This was and continues to be a dream project. The purity of the direction and the requirement for race car performance tests us to truly design the vehicle, not simply style it,” conﬁrms Stassin. In order to do this, Kiska and KTM discussed various materials and construction methods before deciding on

the best partners to assist in the design process. As they ambitiously wanted the X-Bow to feature a carbon fibre monocoque (reserved for Formula 1 cars) they called upon Italian racing and sports car expert Dallara. “Carbon fibre is extremely lightweight for its strength and does not fatigue over time,” says Stassin. “Dallara has over 20 years of experience in the field and has developed many proprietary finite element analysis tools for carbon structures.” As well as developing the monocoque, Dallara provided chassis, aerodynamics and suspension development. In May 2006, having secured an Audi engine and Dallara’s support, the designers sketched the chosen design direction into their Wacom tablets – a tool that allows them to immediately visualise their thoughts with a patented pen technology on a high-resolution LCD monitor. To achieve the unique overall shape, the design team then moved into Alias for advanced surface modelling, with further CAD work carried out in Pro/Engineer. The X-Bow design is a construct of various technical components – a direct influence from KTM motorcycles – chosen for their functionality and performance. “We interlinked the technical components with ‘floating panels’. These ensure perfect aerodynamics and road holding, and can be further developed individually,” explains Stassin. These four simple body panels, in KTM’s corporate orange, also serve an aesthetic purpose, complementing the simple headlamps, embedded indicators, which are flush with the car’s contours, and round lights at the rear. 9:K:ADE(9 D8ID7:G '%%- '*

While the KTM development team covered more than 100,000km with the test vehicle and early X-Bow prototypes, ( Dallara carried out over 200 tests in the wind tunnel – the equivalent of 100 testing hours and 29 complete car CFD runs. Tests on bodywork in the wind tunnel were conducted at speeds of around 130km/h, to ensure efficient aerodynamic performance. According to Gerald Kiska, a high point of the project was the success experienced in the aerodynamic development of the car. “Generally aerodynamic specialists are not prepared to make any compromises; usually the design of the car is inferior to aerodynamics. As a certain level of performance is expected from the X-Bow, the aerodynamics were given top priority. We then proceeded to further enhance the aerodynamic specification with our ideas and designs in many tests, sometimes to the amazement of aerodynamic experts at Dallara.” To complement its own in-house design team, which grew from two designers to five during the project, there were over 30 specialists from the fields of model construction, engineering, aerodynamics, mechanics and testing involved in the development of the X-Bow. “KTM did ) not have an automotive division to collaborate with. All of the expertise was derived from our work group including the production model, so it was surprising in 2008 to see Kiska, Dallara, Audi and IAV [a provider of engineering that our production model was almost identical to the show services to the automotive industry],” says Stassin. “The car,” says Kiska. “In 2007, people thought we would not be project was exhilarating, and a great opportunity for mad enough to actually build the car, but that is exactly everyone involved.” what we did.” KTM formed a new company in Graz, Austria, to produce the X-Bow – KTM-Sportcar Productions GmbH. In June BEST IN SHOW 2008, the first X-Bows were produced in this new, purposeAfter an 18-month design and development phase, the built plant, and delivery to customers started in August. prototype was unveiled at the 2007 Geneva Motor Show on From 2009, the plant will produce from 1,500 to 2,000 a stand created by Kiska’s environmental designers. The aim was to test public opinion to this aggressively designed X-Bows per year. As part of its IDD process, Kiska carried out design work sports car. “At first, we said that we would present a model relating to the X-Bow’s product environment from the of our car at the motor show and see how it went,” says printed promotional materials, trade show presentation Gerald Kiska. “We had prepared some pro forma sales contracts which only said ‘I undertake to buy a car at a price and exhibition stand design, through to photo shoots and the making of an action movie. “Everything relating to to be notified at a later stage’. The car stood there and we the X-Bow project was originated from us since the idea sold 70 units within the first three or four hours.” Following this success, they realised that they would have first saw the light of day,” says Kiska. “From the market analysis to the strategy. From the product itself to the to commit to building more than just the limited edition product environment right up to the communication and 100 originally planned. So, after more development and presentation of the car. From classic advertising to the testing, Kiska and KTM were back at the 2008 Geneva branding of the truck on which the X-Bow travels, and the Motor Show to present the production-ready X-Bow. “Normally, a show car does not have much in common with t-shirt worn by the mechanics – Kiska designed it all. The upshot of this is a consistent appearance, a unique identity of which we’re proud.” * The car has received fantastic coverage and sales have exceeded KTM’s expectations, attracting a whole new market to the KTM brand. But the key question is, what is it like to drive? Stassin, a petrol head who regularly rides KTM motorcycles, says: “This is an unfiltered driving experience. Lightweight, rapid acceleration and amazing driving dynamics. The ride is not harsh and can be enjoyed for extended drives. The KTM X-Bow is the only car that motorcyclists wave at with approval.”

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NEWS

PRODUCT DEVELOPMENT NEWS

Autodesk sues solidworks Âť Autodesk risks looking like Goliath picking on David as it tries to prevent Solidworks from suppling free DWG tools and products to the market leader's own customers

or a long time now, Autodesk and SolidWorks have admitted that they are in a knife fight over the emerging and lucrative 2D to 3D, mid-priced, mechanical market. It appears that Autodesk has recently raised the stakes and set loose its legal attack dogs. Autodesk has had a bee in its bonnet about misuse of DWG by competitors since Carl Bass took over the CEO helm at the company. It seems 25 years after coming up with the .DWG suffix for its drawing file format, the company wants to retrospectively trademark it and stop the competition from 'abusing' its use. Autodesk recently went after the Open Design Alliance (ODA), which is a company set up by competitors to pool their reverse engineering knowledge and coding efforts for reverse-engineered access to DWG files. Autodesk has been picking off the members, cutting individual, reciprocal deals for its own DWG libraries with some (PTC, Bentley), and trying to stop the ODA's use of DWG while legally trying to gain rights to the term DWG in both America and Europe. To date, there seems to have been little progress in Autodesk winning the actual rights to the DWG trademark, but it continues to try to stop

companies like the ODA from using the DWG file extension in the meantime. Previously Autodesk altered the DWG format to include a copyrighted phrase, which acted as a watermark, so when AutoCAD loaded a DWG it could tell if it was an 'official' Autodesk DWG or a reverse engineered one. DWGs that didn't have the phrase would result in AutoCAD warning the user that the file was not an Autodesk one. The ODA shipped libraries that reproduce this watermark to bypass detection and Autodesk sued again. At the time, Autodesk said that it was responding to increased calls from customers experiencing problems with DWGs which turned out to not originate from Autodesk products. The biggest remaining thorn in Autodesk's side is Dassault Systemes' SolidWorks, which has openly targeted Autodesk customers with a range of free DWG tools and products (based on ODA DWG technology). According to Ralph Grabowski's World CAD Access website, Autodesk has listed seven areas of legal contention: unfair competition; false designation of origin; false advertising; trademark infringement; trade dress infringement; unfair and unlawful business practices; and misleading advertising. It covers Autodesk brand terms on the

SolidWorks website, the naming of products with DWG, an orange rectangle resembling the Autodesk Inventor graphic, false claims of compatibility and much more. While Autodesk believes it is protecting its interests and trademarks and wants fair competition, there is a danger that the company will still not be granted the rights to DWG, and litigation of this sort against a smaller competitor will look like a repeat of David and Goliath. SolidWorks has established a reputation as a community-based modelling tool developer, while Autodesk is the $2billion gorilla. In the past Autodesk has staged some desperate-looking marketing stunts to down play SolidWorks, from taking tabloid pages in the Wall Street Journal to staging events alongside SolidWorks customer events, and even placing posters in SolidWorks event airports, welcoming users to the home of the "second most popular 3D design tool". This lawsuit drags the Autodesk/SolidWorks competition down to a totally new level of animosity, with the knife fight turning into a broader war between Autodesk and Dassault as the two companies lock horns in a range of product and market segments. www.autodesk.com www.solidworks.com

Head to head: Jeff Ray, left, CEO of SolidWorks, will have to fight off the copyright claims of Carl Bass and Autodesk

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Quadrispace looks to grab the tech pubs market

Dassault releases Version 5 Release 19

Âť Limited offer to upgrade to Document 3D Personal Edition and take advantage of new data and email tools

D communication and documentation software specialist QuadriSpace has launched a free version of its Document3D Suite. The Document3D Personal Edition is a new version of the company's flagship product, which allows you to take existing 3D product development data and repurpose it for the creation of technical publications. While it's not the full version of the software (as you'd expect), it does have some interesting features, including the ability to read a number of different file formats (such as SolidWorks and Inventor),

use that data as the basis for illustrations, then use the built-in tools to create additional information, whether through manual entry or by extracting information from the 3D data (such as BOMs and part lists). You can also send email with 3D attachments using email tools that are integrated with Microsoft Outlook. There is a limited offer to upgrade to the full version for $95 that will add 3D PDF output, interactive buttons, the ability to create interactive step-by-step procedures, clickable bill-of-materials, large model tools and document update utilities. It's currently available from: www.quadrispace.com

QuadriSpace's Document3D allows you to import CAD data from a variety of sources and create illustrations

hile there's been much talk about the future of products at Dassault Systemes with the unveiling of V6, it's clear that the V5 juggernaut is continuing unhindered. This month sees a major release for all of the component brands and application sets, including Catia, Delmia, Simulia, Enovia and 3DVIA. According to DS's press release, V5R19 offers "increased engineering excellence, expanding PLM deeper into production cycles, accelerating PLM adoption for mid-size companies, broadening IP lifecycle management and further integrating within the enterprise ecosystem". All this marketing speak means a cross brand release to sink your teeth into, with highlights including new auto-filleting functions and wall thickness analysis in Catia for plastic part design. Alongside this are new tools to assist with the design of large composite components which allow the composite engineer to design around sub-structures such as spars, as well as being able to define composite plies in smaller components which have been repurposed from being manufactured in metals, to composite-based manufacture. There's also greater integration between Delmia's shop floor capabilities and Composer for work instructions. Elsewhere SmarTeam gets BOM navigation and collaboration powered by the ever impressive 3DLive interface for PLM data as well as better Multi-CAD collaboration. "This release shows our continuous commitment to further developing V5," enthuses Dominique Florack, senior executive vice president, Products, R&D, Dassault Systemes. "It includes massive technology enhancements across the full spectrum of our solutions." www.3ds.com

Stratasys' thermoplastic materials

tratasys has developed two new thermoplastic materials for its rapid prototyping and manufacturing machines. The new selections give users stronger, more flexible, higher temperature materials with which they can more closely match prototype parts with production intent materials and get better performance from end use parts. "From conceptual prototyping through to direct digital manufacturing, we're committed to providing manufacturers with solutions to build accurate parts for testing or end-use," says product marketing

manager Fred Fischer. "The new materials give FDM users new options to help them expand their rapid prototyping and production operations." For the FDM 360mc, both PC and PC-ABS are now available, and for the FDM 400mc ABSi and PC-ISO are new options. The ABSi is interesting because it's one of the few FDM materials available that's translucent to any degree, so it's perfect for those working with automotive lighting (the reason that it's also available in red or amber as well as clear), or applications that require monitoring of liquid or particle flow. www.stratasys.com

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NEWS

rounD uP

Dassault will practice what it preaches with new hQ

ith being green the hot topic on every organisation's charter these days, but very few actually practicing what they preach (yes, car companies are talking green – its laughable), Dassault Systemes has just opened its custom built 'green' global headquarters, adjacent to meudon Forest. the facility has earned the French hQe1 (high Quality environment) label and is positioned to earn the first hQe exploitation label once available. Beginning next year, the HQE Exploitation label will help French businesses manage their facilities based on "strict sustainable development and environmental requirements". Currently only the facility designers and constructors are required to

Creaform shifts to 4D with the VIuscan 3D Colour Scanner

follow HQE standards but DS has earned an HQE High Performance score in five environmental target areas. Dassault Systemes surpassed requirements to include facility management standards for the upcoming HQE Exploitation certification. Key focuses include efficient lighting, energy efficiency (including reusing the heat generated by its servers to warm 70 per cent of the facility's air on the coldest of Parisienne days). While it's all fantastic for the environment, we're somewhat disappointed there's no mention of monorails or shark infested waters under trap doors. www.3ds.com

The new Dassault Systemes HQ scores highly in five green target areas – only three are needed to meet HQE standards

resolution and automatic 100 per cent accurate texture mapping. Having been fans of the original HandyScan products, DEVELOP3D is really excited about this new product, and when you consider the licensing agreement with Z Corp. to work with that company's colour 3D printers, the whole thing is looking very interesting indeed. www.creaform3d.com

eveloper and manufacturer of the handyscan 3D line-up of handheld and self-positioning laser scanners, Creaform, is about the introduce its newest and most innovative product: the VIuscan, a self-positioning handheld and high resolution portable 3D colour scanner. The VIUscan color laser scanner can achieve 'hyperrealistic' results thanks to features such as simultaneous texture and geometry acquisition, real-time rendering, true colour acquisition through a built-in lighting system, adjustable uniform texture

Version 11 of Alibre Design has been released. Following the largest Beta testing program in the company’s history, V11 sees the system migrate to the .NET platform with functional updates, including doubling of the size of assemblies that can be handled. www.alibre.com

Algor has received 32and 64-bit Certified Application for Autodesk Inventor 2009 for its finite element analysis (FEA) software. The designation identifies “high-quality, robust products that provide the highest level of interoperability with Autodesk Inventor”. www.algor.com

ESI Group released PAMSTAMP 2G v2008 and PAM-TUBE 2G v2008. The former extends stamping simulation from a simple formability evaluation to a streamlined scalable solution. PAM-TUBE 2G is for stamping simulation focused on tube bending and hydroforming. www.esi-group.com

Autodesk redesigns its Community website utodesk has redesigned its Student engineering and Design Community website to resemble popular social networking sites to improve ease of use for students. the enhanced Student Community oﬀers a number of free new features and benefits to more than 350,000 students and educators. The redesign introduces profile sharing, social networking, blogging and news feeds. There's also a Career Center that

DriveWorks 6 users can now take advantage of the productivity enhancements in SolidWorks 2009. Although SolidWorks 2009 was only released mid September, the DriveWorks Development and QA Teams have been able to quickly deliver support for the latest release. www.driveworks.co.uk

includes job search technology, employer profiles and advice, together with a feature to allow students to showcase their work using links to YouTube. Since September 2006, the Student Engineering and Design Community has attracted members from more than 16,600 schools in 137 countries. Over 350,000 members have downloaded approximately 650,000 copies of Autodesk's 3D design software solutions. www.students.autodesk.com

Zweave launches version 2.0 of its PLM solution for footwear and apparel. The system is available as an on-demand, hosted application. The company has added significant functionality across the entire lifecycle of product design and upgraded the user interfaces. www.zweave.com

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NEWS

all change at spaceclaim as randles takes the helm Âť Newly appointed CEO of direct modelling firm SpaceClaim Chris Randles must see the company through the credit crunch

hris Randles has replaced Mike Payne as president and CEO at SpaceClaim, developers of the innovative direct modeling tool. Payne, one of the fathers of parametric modelling at PTC and SolidWorks, continues as chairman of the board. Randles was formerly entrepreneur-in-residence at Borealis Ventures (one of the initial investors in SpaceClaim) and prior to that led the management buyout of Mathsoft, serving as chairman, president and CEO until the company was acquired by PTC (Parametric Technology Corporation). SpaceClaim Professional was probably the most recent 'new' design and conceptual modeling tool to be released on the market. Ease of use and low cost are it's two key benefits, together with an ability to edit most dumb geometry in an intelligent way. The technology has been compared to CoCreate's OneSpace and Siemens PLM Solutions' Synchronus Technologies. Since it's launch, the marketing, pricing and route to market have appeared confusing, considering the maturity of the 3D CAD market. Randles hopes to solidify these areas and sell 3D to new users and areas like CAE model preparation. SpaceClaim has recently tied up some impressive partnerships, announcing a partnership with Bunkspeed, a cool developer of 3D rendering visualisation software, to enable users to create photographic renderings of 3D designs directly from SpaceClaim. This is in addition to ALGOR (Ansys) and Robert McNeel & Associates (Rhino), which included both an API exchange and access to McNeel's resellers. Jesse Devitte, managing director of Borealis Ventures, an investor in SpaceClaim, told DEVELOP3D, "SpaceClaim now has the type of leadership that can thrive during interesting times by identifying the opportunities that are seemingly always nested in, around, up and downstream from the existing solutions in the market." It appears that SpaceClaim is keeping clear of the traditional CAD markets and focusing on where its technology found the most appreciation during the first year of sales. Payne's departure as CEO happened quietly, earlier in the year. His tenure ensured a robust and fast-paced development of the technology together with some premature sabre rattling for existing modelling developers, namely PTC, SolidWorks and Autodesk, who decided SpaceClaim was Foe not Friend. This made developing a channel of any quality difficult, and from an outside perspective, many other aspects of the business model lacked focus. One assumes

Randles is a safe pair of hands to provide stability for the company's investors. On the subject of stability, considering the financial market's lack of it, and the doom in the news, we took the opportunity to ask Devitte what he thought of the climate for investing in CAD firms and technologies. "One thing I do have confidence in is application software which I believe as a category generally has a better chance of rolling through tough times because people are relying on it to do their professional jobs," he said. "To me, the companies with a broadly diversified portfolio of products that are priced for the mainstream and have consistent success throughout world markets along with a lower internal company cost structure have the best platform for continued success during challenging economic times." [Read: Autodesk]. Devitte concluded, "To use a racing analogy, I like racing under the 'yellow' so I am absolutely still investing â&#x20AC;&#x201C; this is the best time to start companies. We don't try to calculate exact risk reward scenarios too precisely too early, as that would kill too many good ideas since so little is known when companies or products are early in their gestation period. "We try to think out five to ten years and as a venture capitalist that is our return period as well as our perspective. I would just add that our investment decisions are about much more then technology: equally important to us are the team and the market." www.spaceclaim.com

Randles represents a safe pair of hands to guide SpaceClaim through troubled economic times

Autodesk will fill missing link in Electrical Design

n August, Autodesk announced that it intends to acquire the EleckroCAD-Software, an Electrical CAD software developer, and its ECSCAD line of products, which are all part of the Mensch und Maschine group. This is all part of Autodesk's drive to fill out its Digital Prototyping concept. It's thought that this acquisition is intended to complete the AutoCAD electrical product and provide users with more tools for control design. "Autodesk can better serve electrical controls designers in Europe by offering the best solution for even the largestscale projects," confirms Robert 'Buzz' Kross, Autodesk Manufacturing Solutions senior vice president. "The addition of ECS technologies enhances the Autodesk solution for Digital Prototyping and helps a larger audience to create complete digital prototypes that integrate both mechanical and electrical designs." www.autodesk.com

NEI Software launch NEi Fusion V1.4

astran FEA developer, NEi Software has launched NEi Fusion V1.4, an engineering simulation system that combines 3D parametric solid modeling with Nastran FEA solvers. The latest release adds 64-bit support along with enhancements to meshing, material, boundary conditions and post processing. NEi CEO Dave Weinberg says, "Everyone recognises the need for design to be faster, more innovative and lower cost. For product development managers, NEi Fusion helps accomplish that. NEi Fusion with Nastran replaces the guesswork and make or break methodology that consumes so much time and money in prototypes, testing, and redesign with a simulation solution that is affordable and professional." www.nenastran.com

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How do you choose the best value from today’s expansive range of CAE solutions? It’s the one that provides your company maximum flexibility — no matter your industry, business goals, financial pressures, customer demands or market objectives. But no single solution meets all needs. So ANSYS is committed to addressing your changing requirements through flexible, scalable, integrated and unparalleled simulation solutions that span the design continuum and enable collaboration across your enterprise. The company now includes both the ANSYS and Fluent families of products, offering tools with greater breadth, functionality and usability. The integration reaffirms and strengthens the ANSYS commitment to align software tools with the customer design and development process. We call this the Simulation Driven Product Development process, which can reduce a manufacturer’s development time and prototype testing, provide a faster time-to-market and accelerate the market acceptance of innovative new products. ANSYS offers: • A CAD-independent suite that lets you leverage your choice of design software for the most value • Integrated, best-in-class simulation multiphysics analysis tools — incorporating FEA, CFD and FSI —in a CAE framework that supports collaboration • Products that have influenced the global CAE community for more than 35 years, including ANSYS®, ANSYS CFX® and FLUENT®

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COMMENT

In this online, hyper-connected world, where do you go for the truth? What is the truth, and it is variable? Al Dean ponders the distribution of information in the online world and how to navigate a wealth of resources

feel slightly odd writing about this subject for a print magazine. After all, print is old school. It’s trees. It’s dead trees, chopped up, processed and stuffed through a very large printing press, packaged up, posted and delivered to your door/desk/in tray. It’s not very connected up is it? But it looks nice, it smells nice and it has a tactile response that a web site displayed on a 22” LCD screen simply doesn’t have. So what am I rambling about? Let’s talk about sources of information. When looking at any form of technology, almost all of us revert to the web to find out other people’s views, how our peers perceive the product we’re looking at. Amazon is a fantastic example. How often when buying something do you have a look at the reviews? There, laid bare, are the product’s functions, features and faults – and with the odd exception of the nut-job, it’s all pretty honest. The same goes for the web. When the Web 2.0 talk is made, it all comes down to one thing: connecting people and connecting content. I say something – you can feed back, instantly. But while this works perfectly for consumer electronics, music and books, the same is not necessarily so of technology for product development and manufacturing – or so I got to thinking at a SolidWorks press event recently. Look at the attendees of that event: it was split into three groups, the Press, the Analysts, and the newest bunch to join the throng, Bloggers. The Press is what many of us are used to: magazine sent out, typically for free, supported by advertising so you don’t have to pay for it. Then there’s the Analysts, who conduct work behind closed doors, with little making it to public airing, funded by the vendors or a user organisation. And there’s the Bloggers: the enthusiasts that spend spare time – free time – to create web-based resources that talk about their subject of choice (in this case, SolidWorks). One

 thing that came up prior to, during and after this event was the question of who has the most authoritative view on what goes on during that press event. The Bloggers make the most noise, reporting directly from the site, to those that read their websites/blogs. The Press, used to a monthly magazine cycle, delay things, tend to make less noise, but do so to a typically large circulation. The Analysts? I’m not too sure what they get out of it. But who has the better idea of what’s going on? Where does the value in reading this information lie, and what should you bear in mind when doing so? Bloggers. I love them. Well, most of them. These are a bunch of users that feel so impassioned about the tool that they use day in day out that they spend their spare time creating some pretty amazing content. I like them so much that we’ve got two of them writing in this issue. In addition to our regular columnist, legend Josh Mings (solidsmack.com), we also have Rob Rodriguez (robrodriguez.com). There are others within the SolidWorks community that I’d recommend: Gabi Jack (designsmarter.typepad.com/gabijack), Mike Puckett (mikescadblog.com), Ben (solidmentor.com) and Alex Ruiz (theswgeek. com), Jason (rocksolidperspective.com) and Brian (cadfanatic.com). These guys do an outstanding job of keeping SolidWorks users up to speed with what’s going on, and the plan is that you’ll see more of them in these pages in the future.

It all comes down to one thing: connecting people and connecting content. I say something – you can feed back, instantly



But should these sources be relied upon as an unbiased source of information? There’s an argument that peer created information is going to be more accurate and more honest than that provided by the traditional press – bloggers have no concerns about advertiser relationships, and no need to pull their punches. Or do they? Take one of the most vocal bloggers in the SolidWorks community, Matt Lombard. Makes a lot of noise, kicks up a stink (in some cases, rightfully so) and claims to be independent. But he’s also the author of the SolidWorks Bible – is there a connection? More noise means more book sales… Maybe. What’s clear is that just because someone is an end user doesn’t necessarily mean that their opinion counts for more or less than someone who is percieved as disconnected from the software. The good news is that its now possible to find out pretty much exactly what you want about a product, in the way that you want, how and when you want. What needs to be considered is how you interpret that information. I’m tired of the ‘Bloggers vs Press’ argument – what I’m interested in whether it’s good content or bad content, because in this day and age, the delivery medium doesn’t really matter. Al Dean has become all that he hates: a disorganised traveller who can’t read the departure time on a ticket and wanders around airports, dazed, wondering why, in the name of Christ, he’s in Zurich at 7pm on a Saturday.

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Siemens PLM Software Succeeding with Teamcenter EXPRESS, A VELOCITY SERIES SOLUTION

Making time fly Wristwatches from IWC Schaffhausen do more than tell the time. These handcrafted, technically sophisticated luxury timepieces are collector’s items. IWC’s challenge was to increase the pace of new product development to meet rising market demand, while maintaining product quality and design re-use. “Our vision is to have an integrated product lifecycle management (PLM) system across the entire company – including design, product management, marketing, development, quality and our supply chain,” says Antonio Palmisano, process manager, IWC. IWC chose Teamcenter® Express digital lifecycle management technology from Siemens PLM Software so that everyone works from a single, shared source of product data and follows consistent work processes. IWC is a long-time user of Solid Edge® software as its 3-D CAD solution. With the addition of Teamcenter Express, IWC now has integrated CAD and data management tools. Teamcenter Express is a complete, easy-touse and easy-to-deploy collaborative product data management (cPDM) solution that delivers a preconfigured, yet extensible environment, and is the core PDM component of the Velocity Series™ portfolio. Velocity Series allows companies to implement PLM using software designed specifically for rapid, easy deployment on Windows®, at a low total cost of ownership.

Learn more today. Visit www.siemens.co.uk/plm

© 2007 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. UGS Velocity Series, Solid Edge and the Signs of Innovation trade dress are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. SolidWorks is a trademark or registered trademark of SolidWorks Corporation. Windows is a registered trademark of Microsoft Corporation. Autodesk Inventor is a trademark or registered trademark of Autodesk, Inc. All other logos, trademarks or service marks used herein are the property of their respective owners.

COMMENT

Teetering on the edge of space, Josh Mings explores the role of multi-touch in the future of 3D interaction in product development

ou touch your screen to turn it on. It flashes up instantly. You touch a sphere that opens to reveal 3-dimensional representations of your designs. You select two with your fingertips and flick them toward one edge of an 8-sided screen that immediately displays the content and structure of the 3D model... That was five years ago. Now we’ve come to a threshold in what is possible with multi-touch technology. It’s not touch anymore, it’s reaching in and pulling out the syntonicly calibrated beating heart of the most adaptive design environment known to humans.

Where we’ve come from I’m sitting in the back row of a small jet teetering on the edge of an Earthen atmosphere and a void of dark space. On the edge of floating and falling – the perfect place to write about the future of 3D interaction within the field of engineering and design, and the role our ability to manipulate areas of space with our touch is going to play. Multiple ways to touch, multiple ways to interact with ribbons of our lives in timelines of playful video and digitised images: a technological revolution that linked our minds and our machines in one co-ordinated effort. We learned to create with our hands again, and multi-touch gave way to the mainstream influx of 3D as the only criteria for moving a design from engineering to production, making 2D redundant. All ideas of what CAD was to become had been dissolved with the simple idea of multi-touch. But it wasn’t ‘multi-touch’ we longed for all those years ago. We wanted to reach the limits of controlling multi-dimensional space. The output previously determined the way in which we interacted with objects on

 But it wasn’t ‘multitouch’ we longed for all those years ago. We wanted to reach the limits of controlling multidimensional space



What will the future of 3D interaction look like? Who knows? But it’s going to look pretty damn cool when it does arrive. And shiny. Definitely Shiny

a display. We were strapped to a flattened digital landscape – a single point within that landscape; a single action within that point. Then multiple points of input changed our ideas about the limitations of that landscape. Multi-touch became a symbol of a desire to explore outside of it. Many people in digitally aided design companies thought the mainstream adoption of multi-touch technology would take a while. Developers had sensed it, but nobody realised the hardware and the software would act as one. It shook the world. The skeptical majority failed to recognise the expectations of generations already familiar with using multi-touch environments to create libraries of media, networks, interactive games and relations between programs and data. In the CAD industry, the shortsighted simply saw a multi-touch screen as a way to move items about and failed to see 3-dimensional space in the context of multi-selectable, dynamic 3D design. Now, (cue the Theremin*) we float on the edge of the unknown limit of multidimensional systems with the possibilities of larger, more adaptive environments residing outside the film of OLED displays and graphical processing power reaching into the terabytes. What started as a theory of physical movement across a screen, designed to work in a 2D world, is rapidly becoming something amazing that will ooze outside the display of every design engineering device.

and adjoining parts will adjust in real-time with materials and conditions. The road to consolidating all aspects of design will be revealed in the adaptive environment that combines the requirements of each. Beyond this, redefining the interface redefines how ideas and product are manufactured, putting designer, 3D modeller and engineer in the midst of the environment where the object will be used. Even in manufacturing, prototyping will stretch beyond the CNC operator moving multiple objects across the display. As a model is created, machine operators will use multitrajectory tool-pathing techniques to test and create machine operations. And multitouch technology will affect manufacturing methods even further. During the spread of multi-touch technology into manufacturing, the idea of rapid laser sintering technology was being developed to bring product design and manufacturing closer together. In the new multi-touch environments, there will be no gap between designer and manufacturer. Flash-atomising of material will give immediate results for each design iteration. Tied to the adaptive revisioning of parts, prototypes can be super-sintered instantly to redefine feel, function, weight and aesthetics. The processes that separated each phase of design and engineering have been brought together by the simple idea of being able to touch each aspect instantly.

The possibilities

The future

Multi-touch will be everywhere, but not the flat screen approach we envision. Multi-dimensional design corporations, 3-dimensional digitised media companies, and virtual world communities are leading the push in hardware and software development. The landscape is changing. The 3-dimensional design environments of the future will reside beyond the screen. We will control the movements of commands within a system that adapts to the processes we use to create 3-dimensional geometry. But constructing the geometry will not be the focus. Geometry will be the by-product of criteria entered onto multiple contact points in the surrounding environment of surfaces, lines and envelopes which relay adaptive design changes to the model. Real-time rendering, tolerance and element analysis pre-empted multi-touch technology, but not to the extent that it will be used within a fully adaptive environment. Just as the measures of a 3D model are composed, the sounds and resonance of surroundings

Ten fingers used to be the limitation. Now they are the most powerful input devices to deliver precise responses to an environment that is just as responsive. It’s not that ‘multitouch’ is making all of this possible. It’s the expanse in front of us that hasn’t been explored; the space that hasn’t been moved. Multiple points of interaction within that space will transform design and engineering. The boundary between the inside and the outside of the display will be blurred... and this is just the beginning. *A Theremin is the earliest known electronic musical instrument. The player controls frequency and volume in 3D space by disrupting magnetic fields with their hands to create sound. It was the first 3-dimensional multi-touch device. Josh Mings is a mechanical engineer in the aircraft interiors industry. He is also the brains behind solidsmack.com. He sidelines as both juggler and human beatbox, but not at the same time, on the streets of Barlcelona at 3am.

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COMMENT

Evan Yares highlights a productivity gap that CAD users have suffered from for the last two decades, exposes its source, and reviews the technology that will make it finally go away  or the last 20 years, parametric feature-based solid modelling has been the de facto standard for MCAD. Chances are that, if you read DEVELOP3D, you use (or have used) a CAD program that is based on parametric feature based modelling. And, if so, then you’ve experienced your share of frustrations with the technology. It’s always possible to point out weaknesses in particular products, or failures in the areas of training or best practices when using CAD. Yet even in cases where best in class software is coupled with excellent training and best practices for use, there is a persistent gap between the theoretical productivity benefits offered by parametric CAD and the productivity benefits users realise from it in actual practice. In short, there’s a problem, and it’s not your fault. To understand where the productivity gap comes from, we need to step back and look at the history of CAD.

The Dawn of Parametric Feature-Based Modelling The vast majority of significant MCAD programs in use today trace their conceptual origins back to 1998, to the release of Pro/ Engineer, the first commercially successful feature-based solid modelling system. Other companies were working on similar systems at the time, yet Pro/E was notable in that it used parametric feature-based solids and NURBS surface mathematics. It also had a common data structure for all modules, including basic sketching, feature-

based modelling, assembly modelling, drawing generation surface geometry and data management. Pro/E introduced the common work process for solid modelling: draw a 2D sketch, add geometric constraints to it, and then convert it into a solid geometric feature using one of several basic operations. Subsequent sketches could be used to add or subtract additional features to the base model. Pro/E would record all operations, including sketches, constraints and feature creation, in a ‘history tree’. Sam Geisberg, the founder of PTC, said of Pro/E, “The goal is to create a system that would be flexible enough to encourage the engineer to easily consider a variety of designs. And the cost of making design changes ought to be as close to zero as possible. In addition, the traditional CAD/CAM software of the time unrealistically restricted low-cost changes to only the very front end of the design-engineering process.” Like most new technologies, Pro/E had some flaws out of the chute. Yet the product was impressive enough that it forced competitors, such as SDRC, Unigraphics, ComputerVision and Dassault, to deliver similar capabilities. And it became a prototype for new generation lower-cost CAD products, such as SolidWorks, Solid Edge and Inventor. Ten years after the introduction of Pro/E, its competitors were all conceptually more similar to Pro/E than different.

User Frustrations New technologies often take a while to mature. CAD, complicated as it is, has taken a very long time. Consider that in 2007, 20

It’s always possible to point out weaknesses in particular products, or failures in the areas of training or best practices when using CAD

years after it first developed Pro/E, PTC still spent over $100 million on R&D on the product. Competitors spent commensurate amounts on their products. Yet even with this investment, there are two common frustrations repeated by users of almost all parametric feature-based modellers. You must be an expert to modify an existing model, and models are inflexible, and as they become complex, they fail too easily after changes. And, while there are things that can be done to reduce the occurrence of these frustrations, there are no universal solutions – if only because these are symptoms of a deeper problem.

The Nature of the Problem

It’s possible to understand the deeper problem with parametric feature-based modelling by considering two fundamental concepts. A process is ‘imperative’ if it describes a sequence of steps to reach an end state (the term ‘procedural’ is also used for this). A process is ‘declarative’ if it describes what the end state is. Parametric feature-based modelling is, by its very nature, imperative. That is, it is based on a sequence of commands (the history tree) that change the state of the model. Little known to most users is that it’s typical for parametric feature-based modellers to use a LISP interpreter, buried in the program, to evaluate the history tree. The process of engineering, as practiced by humans, is primarily declarative, in that it describes what something ‘is’, and is secondarily imperative, in that the process of actually making something often requires a sequence of steps. 1 CoCreate. A mature ● While this distinction between imperative non-history based and declarative may seem a little esoteric, CAD system that has what it does show is where parametric gained inference capabilities over time feature-based modelling works well (with the portion of the engineering process that is 2 KeyCreator. Has imperative), and where it does not work well ● strong support for (with the portion of the engineering process STEP, model repair, that is declarative). model validation, with Because the terms procedural and inference of common declarative also relate to forms of human feature types. No memory, this distinction also provides an history support



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COMMENT

4 explanation of why some people are able to easily learn to use parametric feature-based CAD systems – it is because they have strong functioning procedural memory.

5 Wizards. These are canned procedures, which create a particular class of declarative object

Knowledge Management Languages. These are essentially powerful imperative languages, which run inside a CAD program, and which can be used to build canned programs representing declarative objects

Typical solutions to the problem It is ultimately the difference between the imperative nature of parametric featurebased CAD, and the declarative needs of the engineering process, that leads to the gap in practice between the theoretical productivity of the software and its actual productivity. The only practical solution to closing this gap lies in adding declarative design capabilities to CAD software. Of course, it’s easier said than done. Here are some of the more common techniques: Kludges. These are special commands that let users get around limitations that would otherwise prevent them from getting their work done

Special Modules. Extra-cost add-ons (often expensive), to support a particular type of declarative object

complexity is not really that good a thing in the long run. The cleanest solution to the parametric productivity gap is to add declarative modelling/editing capabilities to a program. But clean does not mean easy. A number of CAD vendors have been working on this for several years. Interestingly, their solutions are, in essence, very similar: a combination of direct geometry editing (without reference to history), and local feature inference.

Application Programming Interfaces. Software interfaces that let you use an external program (eg Excel, or a thirdparty program).

Towards a real solution The problem with the typical solutions to the parametric productivity gap is that they most often just make the software more complicated. In a situation where all users are CAD specialists, that’s probably not a major problem. Yet, in a situation where a company would benefit from making it possible for smart engineers and designers to be productive with CAD software without needing to be specialists, extraneous CAD

3 IronCAD. Supports ● drag-and-drop features, with limited inference on dumb models. Supports both history and non-history based modelling 4 SpaceClaim. A ● clean-sheet program, supporting direct editing of dumb files, inference of most features, drag and drop editing, and a modern Vista-style interface. No history support 5 Solid Edge/NX ●

with Synchronous Technology. Probably the most extensive implementation of history/nonhistory, imperative/ declarative modelling in mainstream CAD applications. Supporting persistent non-history based constraints – a first

Towards the Future For 20 years, CAD users benefited from the capabilities of parametric feature-based modelling, but were often frustrated by its limitations. A new class of capabilities, whether called direct, explicit, history free, synchronous or declarative, promises to change CAD from a tool for specialists to a tool that’s actually useful for normal (smart) people. Though the elements of the technology have been around in some form for a number of years, it is only in this year that companies such as PTC and Siemens, in delivering them in a mainstream guise, have raised their profile. Siemens, in particular, has raised the bar by adding support for constraints (including parametric dimensions) without requiring history. Evan Yares is a writer, consultant, analyst and user advocate, focusing on engineering software. His blog is found at www.evanyares. com. He gives Al Dean a run for the scariest man in CAD – and wins every time. His thanks go to David Weisberg, author of The Engineering Design Revolution, The People, Companies and Computer Systems That Changed Forever the Practice of Engineering, available online at www.cadhistory.net, for providing a reliable historical reference to the CAD industry.

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No design challenge too big. No company too small.

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12/24/2007 12:34:16 PM 8/10/08 13:03:24

PROFILE

PRODUCT DESIGN S Â» Stephen Holmes takes a look at some motorised heavyweights, and the design technologies that drove them into production

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N SHOWCASE

Rocking all over the world

Terex Pegson is the world’s leading manufacturer of mobile crushing plant equipment and it sells more tracked crushers in its size range than any other manufacturer

ock crushers have never been the most glamorous of heavy industrial machinery, but this doesn’t stop them from being inanely practical work horses that do exactly what the name says: crush rock. At its heart the Terex Pegson Maxtrak 1000 has an Automax cone crusher complete with hydraulic settings, unblocking system and, curiously, a ‘tramp release’. Its crushing action produces high quality aggregate and sub-base materials, and in doing so has a lot of components under stress. Pro/Engineer is the software behind the design “We have a lot of parts in the assemblies and a lot of complex geometry, it’s ideal for that sort of thing,” says Carl Adams of Terex Pegson. “We’ve got a number of large assemblies and parts that it’s good for handling from the top level down. “We use the integrated Pro/Mechanica quite a lot as part of Pro/Engineer. We take models back and forward from Pro/Mechanica and manipulate them doing runs, and for static analysis. That’s another function that we’re particularly interested in. We look at it from the general form of stress analysis and displacements.” All understandable, considering the vast loads and differing variables of rocks being fed into it and spat out the other side.

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PROFILE

Pulling power

‘‘ By virtue of industrial design having the right tools, the vehicle’s original styling intent was maintained throughout the development process

’’

The 7000 series Fastracs form a new generation of advanced and highly-productive power units for farmers and contractors wanting the ultimate in productivity, comfort and safety

ncountering an oncoming tractor down a country lane is the stuff of nightmares for most motorists, and the slick silhouette and aggressive lines of this monster concept would only heighten that fear. As a study in digital design, the JCB 7000 series Fastrac is a polished example of seamless concept realisation. Built up from original sketchwork from JCB’s in-house design team, it was swiftly drawn up into 3D using Alias. Giving them control over exterior and interior surfacing from the first pass through to production, the software not only proved the engineering team’s claims of space distribution, but also allowed for renderings for design review. For full sign-off, the model was taken into Showcase to create photo realistic fly-by animations. On achieving design approval, the data set was used to cut pre-production tools for prototype components such as the roof mouldings. Testing allowed modifications to be quickly built back into the Alias model, and the process moved into Unigraphics to build the fully parameterised master model with the raw sheet data. Nigel Chell from JC Bamford, says, “By virtue of industrial design having the right tools, the vehicle’s original styling intent was maintained throughout the development process from initial artwork to product launch.”

Red devil

n the red corner, weighing in at eight tons, it’s ‘The Mover from Munich’, the Linde 396 series forklift. Showcasing a series of significant design improvements, increasing the view through the mast by nearly 20 per cent, and introducing a variable suspension system that reduces body vibrations, the new design has improved the comfort and safety of the operator greatly. Mark Stent, project manager at the UK arm of Linde Material Handlings is proud that the design team makes full use of the technologies they have to hand. “In today’s fast design and manufacturing world it would be virtually impossible to produce the designs that we do, to the timescales required, without the aid of a 3D modeling package,” he says. His team rely on Siemens NX5. “You can then manipulate your view of the truck from any angle or position; thus allowing you to hide parts, make parts transparent and move parts around. All this is essential in order for us to properly design position and check clearances between components,” Stent continues, adding that they benefit greatly from the ability to produce renderings, conduct FEA’s and take parts straight to CAM from their software.

DEVELOP3D OCTOBER 2008 23

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case study

THE THE THE THEFAST FAST FAST FASTAND AND AND ANDTH TH TT » Kiska has brought the power and exhilaration of a motorbike to four wheels with the new X-Bow. Frances Corbett talks to Austria’s largest design company about its work with motorcycle manufacturer KTM

or over 50 years, Austrian motorcycle manufacturer KTM has held a reputation for producing motorcycles that embody the company philosophy of ‘Ready to Race’. Recently, it has dipped a toe into the automotive market with the launch of the KTM X-Bow (pronounced ‘cross bow’), a high-performance racing car that recreates the exhilaration of riding a motorcycle on four wheels. With its aggressive styling, this two-seater sports car boasts a 177kW Audi TFSI turbo-charged engine that powers the 790kg lightweight to 100km/h in just 3.9 seconds. Stefan Pierer, KTM’s CEO, believes in the benefits design can bring to the brand and has worked closely with Kiska, Austria’s largest design company with over 100 employees, for the past 15 years on the design of all its motorcycles as well as the company’s overall identity. “Stefan Pierer and I were sat having a beer back in summer 2005 and put one and one together,” remembers founder and MD Gerald Kiska. “Fewer and fewer young people were applying for a motorcycle licence, so it was a

Risk and reward Kiska’s transportation designers were called upon to help KTM make this potentially risky transition, bringing its core values of performance, purity and adventure to a new market. But before pen was put to paper, Kiska carried out extensive research and analysis, dictated by its Integrated Design Development (IDD) process. During IDD all relevant aspects of the brand are taken into account: from analysis of the market and strategy development through to conceptual and product design. This is followed by marketing and communication strategies together with the design of the product environment (such as POS, shop and exhibition design). Kiska’s strategy, transportation design, product design,

The KTM X-Bow boasts a 177kW Audi TFSI turbo charged engine in a vehicle weighing just 790kg

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DTHE THE THE THEFURIOUS FURIOUS FURIOUS FURIOUS  This is an unfiltered driving experience. Lightweight, rapid acceleration and amazing driving dynamics



communication design and environmental design departments complete the process under one roof. In the case of the X-Bow project, a thorough target group analysis was initially carried out to ensure that they were creating the best possible output for the target groups. From here, Sebastien Stassin, Kiska’s head of transportation design, and his team kicked off the design development process by sketching a few rough ideas on paper. Apart from specified legal mechanical and aerodynamic guidelines, the designers were given carte blanche. The intention was to create a street-homologated car with ‘transparent’ technology, in which every part fulfils a specific function, packaged in a simple, minimal design. “The aim was the simplicity and performance of a motorcycle, with exposed mechanics and no filter between occupants and experience,” says Stassin. “The car has no roof, no windshield and no heater. It has the acceleration of a motorcycle with the road holding of a race car.”

Substance before style But this was not merely an exercise in styling. To turn the X-Bow into a racing would require some advanced technologies. “This was and continues to be a dream project. The purity of the direction and the requirement for race car performance tests us to truly design the vehicle, not simply style it,” confirms Stassin. In order to do this, Kiska and KTM discussed various materials and construction methods before deciding on

the best partners to assist in the design process. As they ambitiously wanted the X-Bow to feature a carbon fibre monocoque (reserved for Formula 1 cars) they called upon Italian racing and sports car expert Dallara. “Carbon fibre is extremely lightweight for its strength and does not fatigue over time,” says Stassin. “Dallara has over 20 years of experience in the field and has developed many proprietary finite element analysis tools for carbon structures.” As well as developing the monocoque, Dallara provided chassis, aerodynamics and suspension development. In May 2006, having secured an Audi engine and Dallara’s support, the designers sketched the chosen design direction into their Wacom tablets – a tool that allows them to immediately visualise their thoughts with a patented pen technology on a high-resolution LCD monitor. To achieve the unique overall shape, the design team then moved into Alias for advanced surface modelling, with further CAD work carried out in Pro/Engineer. The X-Bow design is a construct of various technical components – a direct influence from KTM motorcycles – chosen for their functionality and performance. “We interlinked the technical components with ‘floating panels’. These ensure perfect aerodynamics and road holding, and can be further developed individually,” explains Stassin. These four simple body panels, in KTM’s corporate orange, also serve an aesthetic purpose, complementing the simple headlamps, embedded indicators, which are flush with the car’s contours, and round lights at the rear. DEVELOP3D OCTOBER 2008 25

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From:

Jill Crawford

To:

Jill Crawford;

CC: Subject: Date: Attachments:

FW: Paragon Advert Thursday, September 11, 2008 4:24:59 PM Paragon-2.jpg

p26_D3D_OCT08_PARAGON_LASERLINES.indd 1

7/10/08 12:53:33

CASE STUDY Kiska has rapid prototyping machines in-house, and a facility to build models. “We build clay models of all our vehicles and test them extensively. We scan them and create and modify the data as it is shared with our suppliers,” says Stassin. “The best feature of all these tools is the ability to evolve the vehicle using the results of the analysis we received from FEA, CFD and wind tunnel sessions.”

Put to the test While the KTM development team covered more than 100,000km with the test vehicle and early X-Bow prototypes, Dallara carried out over 200 tests in the wind tunnel – the equivalent of 100 testing hours and 29 complete car CFD runs. Tests on bodywork in the wind tunnel were conducted at speeds of around 130km/h, to ensure efficient aerodynamic performance. According to Gerald Kiska, a high point of the project was the success experienced in the aerodynamic development of the car. “Generally aerodynamic specialists are not prepared to make any compromises; usually the design of the car is inferior to aerodynamics. As a certain level of performance is expected from the X-Bow, the aerodynamics were given top priority. We then proceeded to further enhance the aerodynamic specification with our ideas and designs in many tests, sometimes to the amazement of aerodynamic experts at Dallara.” To complement its own in-house design team, which grew from two designers to five during the project, there were over 30 specialists from the fields of model construction, engineering, aerodynamics, mechanics and testing involved in the development of the X-Bow. “KTM did not have an automotive division to collaborate with. All of the expertise was derived from our work group including Kiska, Dallara, Audi and IAV [a provider of engineering services to the automotive industry],” says Stassin. “The project was exhilarating, and a great opportunity for everyone involved.”

Best in show After an 18-month design and development phase, the prototype was unveiled at the 2007 Geneva Motor Show on a stand created by Kiska’s environmental designers. The aim was to test public opinion to this aggressively designed sports car. “At first, we said that we would present a model of our car at the motor show and see how it went,” says Gerald Kiska. “We had prepared some pro forma sales contracts which only said ‘I undertake to buy a car at a price to be notified at a later stage’. The car stood there and we sold 70 units within the first three or four hours.” Following this success, they realised that they would have to commit to building more than just the limited edition 100 originally planned. So, after more development and testing, Kiska and KTM were back at the 2008 Geneva Motor Show to present the production-ready X-Bow. “Normally, a show car does not have much in common with

2 the production model, so it was surprising in 2008 to see that our production model was almost identical to the show car,” says Kiska. “In 2007, people thought we would not be mad enough to actually build the car, but that is exactly what we did.” KTM formed a new company in Graz, Austria, to produce the X-Bow – KTM-Sportcar Productions GmbH. In June 2008, the first X-Bows were produced in this new, purposebuilt plant, and delivery to customers started in August. From 2009, the plant will produce from 1,500 to 2,000 X-Bows per year. As part of its IDD process, Kiska carried out design work relating to the X-Bow’s product environment from the printed promotional materials, trade show presentation and exhibition stand design, through to photo shoots and the making of an action movie. “Everything relating to the X-Bow project was originated from us since the idea first saw the light of day,” says Kiska. “From the market analysis to the strategy. From the product itself to the product environment right up to the communication and presentation of the car. From classic advertising to the branding of the truck on which the X-Bow travels, and the t-shirt worn by the mechanics – Kiska designed it all. The upshot of this is a consistent appearance, a unique identity of which we’re proud.” The car has received fantastic coverage and sales have exceeded KTM’s expectations, attracting a whole new market to the KTM brand. But the key question is, what is it like to drive? Stassin, a petrol head who regularly rides KTM motorcycles, says: “This is an unfiltered driving experience. Lightweight, rapid acceleration and amazing driving dynamics. The ride is not harsh and can be enjoyed for extended drives. The KTM X-Bow is the only car that motorcyclists wave at with approval.” www.kiskadesign.com, www.ktm-x-bow.com

1 Traditional ●

sketching skills were used alongside digital media for concepts

2 Clay prototypes ●

were used to refine the forms

3 Photoshop and ●

Wacom CIntiq tablets were used produce concepts and design themes

TECHNICAL DATA Weight

790kg Length

3738mm Width

1900mm Height

1205mm Acceleration

3.9 seconds to 100 km/h 8.9 seconds to 160 km/h Max lateral acceleration

1.5g

Max speed

220km/h

DEVELOP3D OCTOBER 2008 27

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‘‘

Area51 [Microsoft] were really CASE STUDY excited by our range of Alienware desktop computers and how that had revolutionised an entire industry

‘‘

Nike Triax Watch That was from scratch; they came to us and wanted to get into the consumer electronics area. They wanted to start with a running watch for people who run on the track and in marathons and we developed a series of concepts

GAME I GEAR » Stephen Holmes questions Astro Studios about its design process, how technology fits into its workflow and creating the next killer product

t must be exciting, waking in the morning knowing that after skipping to work along the sun-kissed sidewalks of San Francisco, you’re going to design something that is both achingly cool and soon to be the most sought after item on the planet. The team at Astro Studios have secured these perks through a reputation for creative forms, hard work and desirable products that consumers itch to get their hands on. Their highest profile design to date has been Microsoft’s domineering Xbox 360, a gaming console described as a ‘portal’ into the new world of live gaming. Released in late 2005, it became a global phenomenon and has since ranked in the top echelons of gaming hardware, putting an Astro Studios design into over 19 million homes worldwide. The company caters for much more than the gaming hardware sector that has boosted its profile on a global scale. Designing products for sports giant Nike has also gained it critical acclaim. Concepts such as wristwatches for joggers, sunglasses for sprinters and even a set of gravitymanipulating golf irons have all made it into production as a result of the design crew’s innovative take on what the consumer is looking for. Creativity abounds in a studio that aims to offer the whole shebang: product innovation, design, identity, path to production, brand strategy and even packaging design. Customers choose which services they wish to take up, with some turning up just to quiz the group for a particular innovative solution or answer to a query. “Sometimes a client will arrive with binders and binders full of research and development that they’ve done, sometimes they show up with a simple one-sheet project brief; some clients look to us to figure it all out for them,” says studio manager

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in s

‘‘

HP Blackbird The stunning HP Blackbird desktop opened a lot of doors for Astro Studios and led to the formation of Astro Gaming: a side project that designs and takes high-end gaming accessories to market

John Moreira. “Usually that’s more with the start-ups, but we have experienced it with the larger companies who are looking to us for the next step and to see what we think. They push us to figure out what’s next for them.”

back to The drawing board Being such an innovative bunch, sketching and outline hand drawing forms a large part of the design process. Moreira admits that the process varies dramatically with the needs of each customer. “We’re similar to many other studios in that we have a lot of front-end sketching, then once we get to a point where we’re comfortable in terms of the direction that we have forming, we basically post it up on the wall on our CAD board and move it around into different things.” The main tool that the designers work with is Alias Studio, a base for them to expand their concept into all the different fields required by the customer. “Alias is one of the tools that we use to start modelling and visualising in 3D, and then from there the process can take different paths depending on the project,” says Moreira. This can take a project anywhere, from visualising to photorealistic rendering or physical models. In-house, the studio uses an Objet 3D printer, although the team will often commission professional model makers for volume models to give the overall form and volume of the product, a particular part or even a prototype model. “In terms of 3D software our designers are mainly using Alias, but if we need to go to engineering level for development or analysis, we use Pro/Engineer which offers us the dominant package that works pretty seamlessly with the work that we do and adding our 3D work to that. We work with particular Pro/Engineer modellers pretty regularly so we’ve got a good system in place.”

‘‘

Xbox 360 That was an unusual one because they wanted a radically different approach from what was on the market. Microsoft wanted to see different perspectives from different studios and what the next generation Xbox could be

Moreira says the designers keep away from the product contents. “We’re a pure product development group. We don’t have any mechanical or electrical engineers on staff. We partner with local groups and have a pretty extensive network when it comes to the engineering partners,” he explains. “Most clients have their own internal teams; if they have something in mind we usually work with them to find a way around a challenge or see if there’s maybe another way to think about it.” As a company, the design flow begins at the top and is delegated down from the company’s two vice presidents, one of whom deals with design, the other business development. Even the CEO handles a lot of the business development by bringing in the work. “Once a project has been accepted, we automatically assign a creative director who then takes ownership of the project. Then usually the team for the project will consist of one creative director, one to two leads and anywhere from two to four designers, and then depending on drafting and branding needs we also assign teams there as well.”

Team players It’s a team effort as much as it can be, but the process has changed recently as Astro’s clients look to make the most of its expertise. “A lot of clients are coming to us and we’re almost, in a sense, doing a lot of their marketing for them; helping them pitch their projects to decision makers. So there’s more storyboarding and video development: not only do we create the product and the concept, but we also get into pitching how it’ll be used.” All of this continues from the existing concepts put together using Alias. As for the end deliverable, it varies from client to client, but Astro is strictly design. “We don’t deliver databases ourselves to go to manufacture. We’re more ‘design intent’ DEVELOP3D OCTOBER 2008 29

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CASE STUDY

 and will work sometimes directly with the manufacturers, although more often we work with mechanical engineers to develop the final database to try to make sure our design intent makes it as much as possible to the end product.” With a concept such as the Nike Triax wristwatch, one of the company’s earlier projects, Astro was given a lot of freedom to work with. “That was from scratch; they came to us and wanted to get into the consumer electronics area. They wanted to start with a running watch for people who run on the track and in marathons and we developed a series of concepts.” Norio Fujikawa, a lead designer at Astro Studios, describes the end design as revolutionising the sports watch industry. “The standard and the way digital watches were made hadn’t changed in many years: the way they were manufactured, the display, the angle of the watch – none of it had changed,” he says. “The Astro team looked at what the watch needed to be, the needs of the runners when running, everything from them having to turn their arm and wrist to see the display, to the display being too small for them to see it, so a lot of things went into the design.” Their most notable design to date gave them less freedom to work with, but was a chance to create something that would revolutionise the way gaming fitted into a normal household. “Microsoft had already found its footing in the video gaming console world and had to follow-up with the next generation console,” explains Fujikawa. “Several design firms were initially involved to pitch different directions and Astro was one of them. The concept that we presented was one of those that were best received. So along with a group in Japan we worked collaboratively with Microsoft to develop the Xbox 360. “Most projects we get directly; that was an unusual one because they really wanted a radically different approach from what they already had on the market. Microsoft wanted to see different perspectives from different studios and what the next generation Xbox could be. On the business side of things they were really excited by our range of Alienware desktop computers and how that had revolutionised an entire industry.”

Creativity abounds in a studio that aims to offer the whole shebang: product innovation, design, identity, its path to production, brand strategy and even packaging design

1 2



1 Astro A40 crystal ●

clear dolby audio with voice comms 2 When combined ●

with the A40 mixamp - it gets you rockin’

3 Concept sketches ●

for Alienware PCs

4 ●

Alias surfaces for Xbox 360 console

5 Alias Surfaces for ●

Nike Triax watch

6 Exploded view of ●

HP Blackbird Desktop

The slick lines of the console, interchangeable fascias and glowing lights made the end product the most desirable in the world, appealing not only to the young bedroombound teenagers usually associated with gaming, but older professionals choosing a console on its aesthetics as well as its performance as an entertainment system. “With the combination of the desktop computers and the Microsoft Xbox 360, we saw an opening in the market for high-end accessories in gaming,” says Moreira. The team continued to work among gaming desktops with the stunning HP Blackbird desktop, admitting that this combined work for the gaming sector “opened a lot of doors” for Astro Studios. This led to the formation of Astro Gaming, designing high-end gaming accessories such as the A40 headset and audio mixer. “With the A40 headset and the mixers we won awards for the packaging. With more and more of the products we’ve worked on the branding has exploded, and we’ve received a lot more jobs that go along with the product work,” says Fujikawa. “As far as Astro Gaming is concerned, we’re developing those projects into what will turn into another six or seven products within the next six months. We’re really excited about a bunch of stuff we’re releasing next year.” Chances are that the majority of the world will be equally excited to see what comes out of Astro Studios. DEVELOP3D OCTOBER 2008 31

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TIPS

reating photographic quality images of your SolidWorks models can be challenging, but there are some simple things that can make the difference between a good and a great image. While the release of PhotoView 360 is going to allow the majority of users to take advantage of rendering technology with little hassle, many are going to have PhotoWorks around for some time. So here are ten ways to make the most of it.

Use cameras: it will put things in perspective

Give your image depth by using a camera for your rendering view. The human eye sees objects is perspective – they have a vanishing point which gives a perception of depth. The standard SolidWorks camera doesn’t see your model in perspective, but fortunately for PhotoWorks users SolidWorks has a camera tool. In the ‘lights, cameras and scene’ folder, choose the ‘add camera’ option. From there, setting up your new camera is pretty straightforward. Set the target point, adjust the camera position, choose a pre-defined lens or create one of your own. To add a nice special effect, check the ‘depth of field’ box at the bottom of the property manager and choose which areas of your image are in and out of focus.

Image Quality: smooth those edges

More for the novice PhotoWorks user, this simple tip ensures your swoopy shapes appear that way in your rendering. Go to TOOLS/OPTIONS/DOCUMENT PROPERTIES/IMAGE QUALITY and be sure the adjustment slider is shifted to the far right, just shy of the red zone. If you’re working with an assembly file, be sure the ‘apply to all referenced part documents’ box is checked.

Appearances: apply them wisely

PhotoWorks 2008 changed the appearance hierarchy rules to be consistent with SolidWorks colours. Knowing the rules can make initial appearance application faster and save time when the

inevitable changes come near the tail end of your project. You need to decide if your appearance is applied at the part or assembly level. I prefer to apply my appearances at the part level, but assembly level appearances do have their benefits. You’ll have to decide which is best for your particular rendering, and understanding the appearance hierarchy will make it easier.

TRICKS OF THE TRADE » Rob Rodriguez, co-author of the PhotoWorks Step By Step Guide, gives us his top tips for achieving rendering perfection using PhotoWorks within SolidWorks

Lighting: it’s all about the image

Image based lighting is the fastest, easiest way to light your scene and produce high quality images. Set up is a snap and simply changing the image can change the entire look of your rendering. PhotoWorks includes many default image based lighting set-ups, or you’re free to browse your own collection of images. HDR or HDRI images give the best results, but LDR image formats (jpg, tif, bmp) can be used as well with good results.

Reflection/ refraction: it’s all about the bounce

Transparent and reflective appearances look great when these settings are correct. Go to PHOTOWORKS OPTIONS/ DOCUMENT PROPERTIES/ RAY TRACING. The ‘reflection’ setting is set to 1 by default and controls how many times your reflection will bounce. If you have objects with adjacent reflective appearances, increasing the ‘reflection’ setting will cause your reflection to bounce more times. You see reflections of reflections in your objects and this increases the realism of your image. The ‘refraction’ setting determines how many

transparent layers light will bounce through. For example, if you had a hollow cube with a glass appearance applied, you’d have to look though four transparent layers to see what was behind the cube if viewing straight from the front to the rear. Each wall of the cube has a front and a back, meaning each wall has two transparent layers. Add a glass center divider to the cube and you have six transparent layers to view through. Since the default ‘refraction’ setting is 4, your cube with a center divider rendering would be grey in the center. To have a clear view through the cube, you’d need to adjust the refraction setting to 6. Use caution when adjusting: too little and your rendering won’t live up to expectations. Too much and your image processing time will increase dramatically.

Decals: they just fade away

Appearances that fade from one colour or one appearance to another don’t exist in PhotoWorks, but you can still create the effect using

decals – the secret is in the mask. When you create a PhotoWorks decal you have the option to use a mask. Decal masks work on a grayscale rule: any portion of your mask that’s pure black will be masked out; pure white will be transparent. The grayscale values between pure black and pure white give you degrees of transparency. A black to white gradient mask will create the ‘fade’ effect.

Backgrounds: using pictures for product placement

Placing your product in a realistic setting is an easy way to increase your rendering effectiveness. Problem is, who has time to create solid models of the many different studios you may require? Luckily PhotoWorks has an easy way to solve this problem.

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TRICKS OF TRADE

Open the Scene Editor, select the BACK/FOREGROUND tab, choose ‘image’ and browse to your desired background. To be sure the image is viewable in the SolidWorks graphics area, go to TOOLS/OPTIONS/SYSTEM OPTIONS/COLOURS and be sure the ‘background appearance’ setting is set to ‘use document scene background’. Voilà, you have an instant studio for your product placement. To add one more layer of realism to your image, be sure to set your floor to the ‘shadow floor’ appearance and check the ‘visible’ box. This will cast a shadow from your model on the background image.

and someone else will be using your image to composite another image. You can make merging your images with others easy by utilising file output formats with alpha channels. The two formats I generally like to use the most which allow for this are .tif and .png.

Brightness, contrast, saturation: it’s easy to adjust the levels

You’ve created the perfect image but wish the entire rendering was a just a bit brighter, had a little more contrast or the colour saturation was different. In the past this meant adjusting the levels in an image editing program. In PhotoWorks 2008 this functionality has been added to the main product. Just render your image to the screen, go to PHOTOWORKS OPTIONS/ DOCUMENT PROPERTIES ‘image adjustment’ and adjust the sliders to create the desired Alpha channels: effect. The best part of this 8 merge your process is that your image will rendering Easily update in real time to the screen Many times you’re simply providing an image of your model while you make adjustments.

PhotoWorks Options: speed up the process

Test rendering is a vital part of the overall process of creating the perfect image. However, it can be very time consuming to be continuously rendering your image to screen while you’re making adjustments. To speed up this process, you can adjust some of the PhotoWorks Options settings. Specifically, set the ‘antialiasing’ setting, found in PHOTOWORKS/OPTIONS/ DOCUMENT PROPERTIES to ‘medium’. Also under the ILLUMINATION tab be sure that the ‘indirect illumination’, ‘caustics’ and the ‘global illumination’ settings are all set to ‘draft’ or ‘minimum’. Once you’ve finished test rendering, you should adjust these settings to higher levels to process your final image.

With due care and attention to detail, material texture use, lighting and camera angles, PhotoWorks can produce amazing results

Rob Rodriguez provides CAD services and SolidWorks consulting through his business Axis CAD Solutions LLC (www. axiscadsolutions. com). He is coauthor of the 2008 PhotoWorks Step By Step Guide and his website www. robrodriguez.com offers a monthly PhotoWorks rendering contest.

nd there you have it: ten tips to better PhotoWorks renderings. Of course, these tips only touch on ways to improve your images. For more in-depth information covering all of the PhotoWorks tools available, you should really check out the 2008 PhotoWorks Step By Step Guide. Consider that tip number 11. DEVELOP3D OCTOBER 2008 33

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CASE STUDY

If the audit data was to be created manually, it would require such significant manpower that it would extend the time frame to completion beyond acceptable limits

BAE Systems considered that unifying the MRA4 project onto a single CAD system would be of huge beneďŹ t

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NOT LOST IN TRANSLATION Âť The world of aerospace design is highly complex, traditionally requiring multiple design systems. We look at how BAE Systems handled the migration of its CADDS data to Catia while maintaining critical information

erospace in the early 1980s, perhaps more than any other industry, required that best of breed be employed. The design system considered best suited to the product was used, resulting in aerospace companies running and maintaining multiple systems, particularly on largescale projects. As the technology has matured and the scale of installations increased, and as the projects have grown, many organisations are considering the benefits of unifying their CAD processes onto a single CAD system. These are the circumstances BAE Systems found itself in with the Nimrod MRA4 project. Originally CADDS had been selected for wing design and Catia was being used elsewhere on the airframe. BAE Systems considered that unifying the MRA4 project onto a single CAD system would be of huge benefit and the migration of CADDS data into Catia highly desirable if it could be done effectively and economically â&#x20AC;&#x201C; a step which created many challenges.

CADDS had been used effectively for wing design for years, and BAE had built up a database of designs comprising over 120,000 models and drawings, including stand-alone 2D drawings, 2D model data, 3D wire frame, 3D surface data, 3D solids and the various combinations. It soon became clear that while standards-based methods such as IGES or STEP would assist in the migration of elements of this data, they would not enable a full migration. Even a direct database CADDS to CATIA translator, although able to translate 2D and 3D model files, was not able to offer a solution for the whole 2D data set.

Checks and balances BAE Systems was aware that a migration project is more than a series of translations. There existed fully defined procedures for checking and validation of translations, and these needed to be applied to migrated data to ensure that model and drawing integrity had not been compromised. Also, the nature of the project meant that a detailed audit trail would need to be maintained and that every action taken in the process of the migration should be traceable. DEVELOP3D OCTOBER 2008 35

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CASE STUDY

 While the goal of the project was clear and the possible future apparent, the potential manual overhead needed to undertake the project would negate any benefits



This additional administrative overhead was so significant that it could have prevented the whole project from going ahead. If everything was to be checked manually, a large number of checkers would need to be employed for the project to be completed within a reasonable time frame. A similar issue was apparent in auditability. If the audit data were to be created manually, it would require such significant manpower that it would extend the time frame to completion beyond acceptable limits. Furthermore, the manual creation of an audit trail on such a large project would be error prone and therefore unable to satisfy one of the key project criteria of proving that the data was correct and consistent. The implications of these challenges were that while the goal of the project was clear and the possible future benefits in efficiency and expenditure reduction apparent, the potential manual overhead needed to undertake the project would negate any benefits. Nevertheless, BAE Systems began to evaluate the possibility of overcoming these challenges and asked Theorem Solutions to work with them to identify acceptable ways of doing so. The first task was to confirm that there was a workable solution to the translation of the whole data set from CADDS to Catia. Theorem’s standard CADDS to Catia CADverter (already in use on this project) would translate 3D models and 2D geometry, but not drawings. However, Theorem had already developed drawing translation capabilities on other migration projects and the enhancement of this module to meet BAE’s specific needs solved the problem. At an early stage in the process of identifying a solution, the requirement to translate the full data set was met.

Man versus machine A natural by-product of the process has been that detailed audit trails are also automatically produced

BAE Systems and Theorem then turned their attention to the challenge of automating the tasks that had previously been viewed as only manually achievable. It seemed logical that since in any given translation the Theorem translation process had full knowledge of the source CADDS data and

the destination CATIA data, and that it would ‘know’ of any problems, a comparison of the two data sets could take place at the time of translation. While this is theoretically true, it was decided to make comparisons after translation when the target CATIA file had been written to disc. A translation process was developed using Theorem’s CADverter to translate all CADDS geometry into CATIA format, and then carry out three comparison operations on the source data and the resulting destination data: n For every translation the mass properties were compared n T heorem’s shape comparison module would be applied n Every entity in the source CAD file would be compared with its equivalent in the destination CATIA file. It was shown that using these three different methods any discrepancy could be identified, but the question of how to enable a manual checker to confirm this remained. The data created by the three stage checking process produced detailed reports, and the prospect of manually trying to interpret such documents was not acceptable. The solution to this difficult problem was Theorem Process Manager (TPM), a product for the management and control of translation processes. TPM provides the ability to be able to ‘read’ all the detailed comparison logs and build summary and exception reports, including detail from other system messages, during the process. Not only this, but TPM has the ability to compare the data in the summarised results with user defined ‘range tables’, and was therefore able to pinpoint any translations that included values outside acceptable ranges. This meant that TPM was able to create not just manually readable summary information, but specific exception reports, directing manual checking to the translations that showed potential problems and avoiding the need to check the majority of translations ‘just in case’ there was an error. TPM has automated the checking process and removed one of the most labour intensive and significant cost overheads, and made the MRA4 migration project much more viable. A natural by-product of applying TPM to the checking process has been that detailed audit trails are also automatically produced. This removes the other potential stumbling block of having to create and validate an audit trail manually, and reinforces the effectiveness of the migration process to a point where the effort is readily justifiable and anticipated benefits can be achieved.

Mission accomplished This successful migration project calls for simple file selection and ‘drag and drop’ operation. It has automated control of a number of processes and incorporates knowledge and skill that previously remained within key personnel. It carries out the migration of MRA4 project CADDS data into Catia and enables significant, tangible savings, including system and manpower costs, that result from unifying the data set onto a single system. As the CAD world evolves into the PLM world of design and interoperability, many organisations may find that their reasons for installing different CAD systems in different departments or sub-divisions are no longer applicable. Changing business patterns, business mergers and other factors also drive the need for unification. Migrations may look difficult and the solutions complex, requiring not just translation technology but sophisticated process control as well, but BAE Systems has demonstrated that in selecting the right vendor and the right solutions, CAD migration is not just possible, but can also deliver tangible business benefits. www.theorem.co.uk

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stablished in 1963, Parker domnick hunter is the world-leading manufacturer of filtration and cold sterilisation systems for compressed air and gases. This position has been achieved by the pursuit of excellence throughout its operation – technological innovation and export achievement have been recognised by eight Queen’s Awards to Industry. Working closely with defence organisations, Parker domnick hunter research and development specialists ensure that every military product is developed fully for its intended use. Since its acquisition by Parker Hannifin in 2005, Parker domnick hunter has continued development of its filtration technologies under the Parker umbrella. It had previously produced a unique regenerative filtration system designed to protect personnel from chemical and biological (CW and BW) agents, plus other toxic materials developed from one of the company’s core technologies, the pressure swing adsorption system. Parker domnick hunter’s multi adsorbent system provides effective broad spectrum protection from CW and BW agents.

Providing protection Regenerative CBRN technology uses two identical beds of filter media: an on-line bed of adsorbent material to provide protection, while an off-line bed desorbs previously adsorbed chemicals and a purge system dispels them safely back into the externally contaminated environment.

The models produced for Parker domnick hunter combine old school model making and the latest prototyping technologies

 Although the system is still at a developmental stage, Parker domnick hunter was keen to demonstrate the technology and evaluate the reaction from interested parties

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A BREATH OF FRESH AIR

case study

Âť How Paragon Rapid Technologies used a wide range of prototyping techniques mixed with old school model making prowess to assist Parker domnick hunter, a division of Parker Hannifin, to bring the CBRN filtration system to market

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CASE STUDY The beds reverse operation on a predetermined cycle, and it is this ability to regenerate which maintains the safe integrity of the filter to provide continuous protection and safe breathing conditions for various NBC requirement platforms (vehicle, fixed building and shelter). Parker domnick hunter’s innovative development of the regenerative filter concept culminated in the integration of a pressure and temperature swing (PTSA) system onto BAE Systems’ ETS program. The Trojan and Titan armoured vehicles, based on the Challenger II hull, are the world’s first platforms to have a regenerative CBRN filter system. The capability of a fully regenerative CBRN filtration system has been successfully demonstrated over the past ten years, and the benefits of Parker domnick hunters’ regenerative CBRN filtration are well known: n Meets protection requirements for from all known CW agents and Toxic Industrial Chemicals (TICs) n Regenerative – hence offers continuous protection n Eliminates logistical support issues n Environmental benefits – no disposal of filters. Paragon has a broad range of skills and experience covering the regular RP processes as well as fabrication and machining, and almost all of these processes were The next generation of this technology is currently under implemented to provide the most cost effective solution for development and a new media is on trial. The molecular the overall project. sieve hollow fibre is a semi-porous capillary like tube of The manifolds and more complex components were adsorbent/polymer mix which is spun to form multi-layer fibres with different compositions of material in each layer. produced in epoxy resin as stereolithography models on Paragon’s SLA5000. Each part was meticulously finished by The filters manufactured with the fibres will show hand with a polished gloss finish. Details such as nuts and significantly increased adsorbent capacity and improved bolts were added afterward to achieve the production look. adsorbent kinetics. These will lead directly to a significant The filter elements were built from scratch using reduction in filter bed size/weight and power requirement. traditional model making techniques with a painted finish. In order to house this lightweight technology, new Custom graphics were produced of the Parker logo and lighter materials will be required, and concepts are applied prior to lacquering. under development to introduce plastic housings and Wherever ‘multiple’ components were required, Paragon components as opposed to the traditional pressed and cast created a master pattern, again through stereolithography, metal systems. before producing silicone tooling and polyurethane vacuum castings. Many of the parts such as the manifold Model making elbows, butterfly valves and pipe elbows were common to Although the system is still at a developmental stage, both assemblies and all produced through vacuum casting. Parker domnick hunter was keen to demonstrate the The majority of the pipe work was fabricated from stock technology and evaluate the reaction from interested tubing, with unique parts such as ‘T’ pieces and ‘S’ bends parties, so the decision was made to prepare two full-size produced as SL. All of the piping was fully assembled and static demonstration models to exhibit at the Eurosatory painted to represent a brushed stainless steel finish. International Defence Exhibition in Paris and The A standard Hepa filter supplied by Parker domnick hunter Farnborough Air Show. was mounted in the top of each unit and this was enclosed Paragon Rapid Technologies was already a supplier of Rapid Prototyping to Parker domnick hunter and the Parker within a fabricated acrylic cover carefully thermo formed and bonded, offering full visibility. The heat exchange units group, and with its traditional model making skills, paired were also fabricated from scratch, but with white painted with extensive stereolithography and vacuum casting finish. The final models were delivered on time. capabilities, was an obvious partner to produce the high “Although Paragon is at the forefront of prototyping profile concept models. technologies, it was very refreshing to have the need to call As the product was still conceptual, the design did not upon the more traditional skills of our model makers, and reflect production processes. Paragon worked alongside to combine that with our regular processes,” says Paragon Parker domnick hunter from an early stage, advising on business development manager Darren Webb. “The whole processes and solutions for manufacture and assembly. Concepts were developed for two versions, a linear design project was very fluid, with design changes and additional components added at various stages as we were building. and a rotary configuration. The system essentially consists We were very happy with the end result and certainly look of a series of Filter Cartridges, assembled into manifolds, forward to producing further exhibition models.” with pipe work to connect to the ancillary pumps, valves The overall effect is dramatic. The models were well and Hepa filters. All of this is fitted into a box as an received at the exhibitions, and made it possible for the enclosed unit. Parker engineers to explain how the concept will work. As the models were required for display and exhibition, a Such was the interest at the exhibitions that Parker domnick clear protective case was required. The case was fabricated hunter is now developing the concept for manufacture, for from 8mm clear acrylic to the design of the production the intended vehicle applications as well as for use with enclosure, to serve the dual purpose of protecting the internal components while being representative of the final fixed building and shelter applications unit, including all inlets and outlets. www.paragon-rt.com

The next generation

The models were well received at the exhibitions, and made it possible for the Parker engineers to explain how the concept will work

 Although Paragon is at the forefront of prototyping technologies, it was very refreshing to have the need to call upon the more traditional skills of our model makers, and to combine that with our regular processes

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CASE STUDY

BEST FOOT FORWARD

» Timberland has transcended its humble work boot origins to become one of the hottest lifestyle brands on the planet. We look at how it uses rapid prototyping to great effect

 The pressure is intense to quickly and affordably turn the marketer’s vision and the consumer’s taste into a reality that performs well, feels good and looks great

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hether for work or recreation, Timberland products are a compelling blend of form and function. Engineers and marketers in the $1.5 billion company, based in New Hampshire, USA, collaborate closely in the development of every product, from initial concept to prototype, sample and, ultimately, in volume production. The shoe must look good and perform well. While the upper is mostly fashion design, intense engineering comes in where the foot meets the insole and the outsole meets the street, with concepts such as arch-support and tread patterns refined in CAD software. Until 2002, Timberland hired model makers to turn 2D CAD drawings into 3D prototypes. At a cost of $1,200, each took a week to create, the lead-time hamstringing the company’s ability to refine their models. As a result, it lengthened its design cycle or lived without the desired refinements. “A 2D CAD drawing left too much to the imagination,” says Toby Ringdahl, computer-aided design manager in the company’s footwear product development and engineering group. “When the prototype was finally ready, it wasn’t exactly what people imagined. But a week is a long time to wait for a new iteration.” So Timberland assigned Ringdahl’s team to evaluate rapid prototyping options.

Prototypes now take $35 and 90 minutes to make, enabling engineering and marketing employees to collaborate more often, and printing rapid colour prototypes on-site has enabled Timberland to compress its typical design cycle from three weeks to two. The Spectrum’s large build area delivers additional time saving. Engineers can print full-size prototypes flat on the build area instead of on an incline, saving three hours of printing time. Spectrum’s speed has resulted in product quality improvement. In the weeks Timberland recoups, it can pump out dozens of iterations of a design. More designers, engineers and marketers can see more products in a shorter time, helping refine footwear for fit, function and style. “We can now quickly do innumerable iterations and variations,” Ringdahl says. “And the designers and marketing managers can be sure the product is what Timberland is expecting and what people on the street are demanding.” The investment in Spectrum also eliminates ancillary costs like time-consuming trips to examine shoe moulds in overseas plants. Since Timberland can now reach consensus for designs on 3D physical models, there’s no need for careful examination of the production shoe mould. Colour is a key benefit, better conveying design intent. Spectrum’s unparalleled resolution enables details like lugs and print on the sole, or speed hooks on the upper to show up perfectly. “The closer the prototype is to real life, the less you leave to the imagination. Unfortunate surprises are eliminated,” says Ringdahl.

Increased sales

3D printing is making a direct impact on revenues. Collaboration between designers, engineers and marketers creates a product that is exactly 3D printing in house what the market Timberland chose the ZPrinter 310 System from Z demands – meaning Corporation; arguably the fastest, most affordable 3D printer. Its speed and the low cost of printing materials more sales – and sales outdid rapid prototyping machines from other companies. people can show prototypes In 2005, Timberland invested in the Spectrum Z510 to major retail chains, an advantage over competitors System, the first high-definition colour 3D printer, who come with just sketches. providing 24-bit colour and 600 dpi resolution. Z Corp. has Timberland expects to reap additional benefits from 3D the only technology that can print parts in full colour, which printing in the future. Its engineers will use shape can be used not only to produce a lifelike object, but for analysis software and the Spectrum Z510 System to print stress analysis, product labelling, or to highlight revisions. prototypes that call out pressure points and interference in the insole. “The pressure is intense to quickly and affordably turn Better, faster, cheaper the marketer’s vision and the consumer’s taste into a The Spectrum Z510 accepts CAD files from Timberland’s reality that performs well, feels good and looks great,” says 3D mechanical design software and produces physical models affordably and quickly, making a substantial impact Ringdahl. “Z Corp. printers have done exactly that for us.” on efficiency and spending. www.zcorp.com DEVELOP3D OCTOBER 2008 41

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INTERVIEW

artyn Day: It must be one of

those life changing experiences to bail out of a company the size of EDS, start up the privatelyfinanced UGS, and be out on your own? john Clendening: In 2004 it was very exciting, and we joked that we’d got a billion dollar company to start up and get off the ground – it felt very entrepreneurial and the business remains so. It felt like we were getting an entirely new company off the ground, from a branding perspective. We had a billion dollar revenue stream under our belts and a long history of very strong customer relationships, so we had the wind at our backs to start with. Our responsibility as a business is to drive profitable growth and keep our shareholders and/or superiors happy, and in spite of all of the changes we’ve experienced, we’ve had 20 consecutive quarters of year-on-year revenue growth. That started when we were part of EDS, continued through the UGS days, and now into Siemens. The Siemens acquisition closed in May 2007, and under Siemens we’ve had four full growth quarters: we’re aiming towards five at the end of September. The first full quarters as part of Siemens have continued our string of success, so it’s been great so far.

MD: So what’s been the driving force behind that growth? JC: First I’d say we have a very intense customer focus and

it drives everything we do – a lot of people say that, but we back it up with numbers. Our top 100 customers have been with us for an average of 18 years, and we’ve got a customer maintenance renewal higher than average in the software industry. The overall software industry is 82 per cent, the PLM industry is at 92 per cent and we’re at 96 per cent. Our focus is all about the customer and what we do for them, and we didn’t lose that in the transition. We stayed focused on what we do best. Siemens didn’t change that and they didn’t force us to get overly caught up in integration activities to the extent we would lessen the intensity of this focus.

 One of the things that really helped was that we did not integrate our sales force with Siemens sales – ours was kept whole and independent. This doesn’t mean we don’t leverage opportunities in the market when we have them with Siemens, like the big VW win we announced a few months ago – but for the most part, it was business as usual and it’s all about customer relationships. That was a lesson that we learned from our EDS relationship because the integration there did not have clear delineation of responsibility for joint accounts between EDS and UGS – I think that had a negative effect on us. We all learned that lesson and we’ve all benefited from it. MD: Your renewed efforts in marketing have been most visible with the recent launch of Synchronous Technology in Solid Edge and NX. JC: We really wanted to make a statement to the market,

and one of the reasons we put so much effort and pizzazz behind it was that we were so fundamentally excited about the technology because we knew it was breakthrough technology in the CAD space: it was incumbent on us to make sure the market really understood. Siemens really accelerated the synchronous technology launch to market. They saw the technology in due diligence when they were looking at buying us, and they got so excited about it that they were able to put R&D money in, so they accelerated the technology to the point where we could start testing it in actual products. Would we have launched this technology as UGS? I suspect the answer is yes. Would we have launched it as quickly and effectively as we did without Siemens? I think the answer is no. It was a really important aspect of the launch, because it was our first opportunity since the acquisition closed to come to market with something very specific and say, “This is a perfect example of bringing together Siemens and UGS.”

We have a very intense customer focus and it drives everything we do – a lot of people say that, but we back it up with numbers. Our top 100 customers have been with us for an average of 18 years



MD: What’s the integration story between the two companies, Siemens and UGS? JC: We had about 100 people involved in the integration,

working full time or part time, pulling together different processes for every administrative function you could

SEMINAL THOUGHTS » Siemens PLM Solutions has had many names, brands and owners over the past ten years. In every guise, the company has developed a consistent reputation for developing high-end modelling tools for engineers. Martyn Day talked to John Clendening, senior vice president of marketing communications for Siemens PLM Software, about the company’s progression

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4 created was because it’s almost a semantics issue. Siemens often uses the term ‘digital factory’, which we think of as Tecnomatix, but Siemens uses that term for all of PLM. On the Solid Edge thing, one reason we put so much effort behind synchronous technology and were so excited about it was we believed it’s a breakthrough technology. Another was that we wanted to make a statement about how Siemens accelerated it to market and the third was we wanted to show that Siemens saw CAD (including Solid Edge) as being a fundamental part of the business they were investing in. Parasolid is a core part of our business. If you look at all the competitive products that use it, one thing that will never change with us is focus on open platforms and open systems, and Parasolid is one way that we exemplify that in the market. Siemens is adamant about openness; all of its technology is produced in the same way.

1 “Would we have ●

launched [sync tech] as quickly and effectively as we did without Siemens? I think the answer is no”

2 John Clendening, ●

senior vice president of marketing communications, Siemens PLM Software

3 “We wanted to ●

show that Siemens saw CAD (including Solid Edge) as being a fundamental part of the business they were investing in” 4 “We’re working on ●

intelligent production components with the integration of process design with automation design”

think of: HR, marketing, sales. The whole deal. That was very intensive, but the feet on the street, the sales people, they were kept out of that 95 per cent of the time because we wanted them to focus on the customer in the market. I am an example of the people who were almost full time for three to six months, starting with the acquisition announcement to post-close. Integration is now complete. We have a project called Archimedes, which is something that has come out of the integration that’s driving towards new software. It is essentially the idea to create a crossSiemens industry sector software initiative, to design and develop new software solutions that unify with Siemens focus on production. We’re working numerous use cases on how this will provide the basis for the new solutions. We haven’t set a date for launch but we’re working with the two other Siemens business lines [Siemens Automation Systems and Siemens Motion Control Systems], doing joint R&D to come up with these new software and product solutions. We are calling one of the developments Adaptive Manufacturing. With Teamcenter, we’re working on intelligent production components with the integration of process design with automation design. Another is Virtual Commissioning, which is essentially the validation engine for process automation and MES. MD: Looking at the Siemens product ranges, the two areas that don’t fit in are Parasolid and Solid Edge . Does Siemens understand why UGS had these products? JC: It’s interesting that you bring this up. We heard from

the very beginning from analysts and journalists that they weren’t sure if Siemens was going to be committed to the CAD market. We think that the reason this perception was

MD: We are in turbulent economic times. What’s the outlook for PLM given the financial situation? JC: I could talk to you about that all day. It’s fascinating,

and I’m also saying that as a consumer. Two things come to mind. Number one, over time as the PLM toolkit has expanded, it is increasingly being looked at as missioncritical technology. If you need to get products out, this technology is front and centre to doing that, so that’s a very positive thing for PLM. I think it’s good for the industry. The other trend I would point to as a positive for continuing PLM investment is innovation. Although everybody uses that word, the thing we always talk to our customers about is that PLM is again the only real enterprise app focused on top line growth, especially now that it’s expanded to that enterprise level application. The others are focused on bottom line growth, such as controlling and maintaining costs, and there’s nothing wrong with that: you have to get product out the door as efficiently and quickly as you can in order to drive the top line growth that the market is always going to expect from a leader. MD: So companies are compelled to invest in PLM technology, even in economic down times? JC: I think that leading companies always want and need to

get the best products out as quickly and as efficiently as they can, which is top in the minds of people looking for good value. Good value is more important to consumers now more than ever before. Value is where PLM comes in, and at the end of the day that’s what we provide to a company: the opportunity to get something through the process, from idea to market, to get through that innovation curve internally faster than they can do without us. Then to get the product out the door and into the hands of the customer as fast as possible. I don’t see the value in that equation ever going away. DEVELOP3D OCTBER 2008 43

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INTERVIEW

Visiting The SpaceMouse Mothership

» Al Dean visits the home of 3D navigation device masters to interview 3Dconnexion chairman Dieter Neujahr, and gets an intriguing insight into the CAD market and how 3D navigation is more complex than you might believe

connexion has been part of the fabric of 3D design for many years. Back when there were two products on the market – the SpaceMouse and the SpaceBall, courtesy of LogiCAD3D and Labtec respectively – the CAD world had two similar devices working to similar ends, to provide a hardware based interaction device for navigating 3D. Computing peripheral giant Logitech’s acquisition of the two companies (it had always had an interest in LogiCAD) and integration of them into the 3Dconnexion brand saw the development of the products accelerate. Alongside the professional SpaceExplorer and SpacePilot products, the company launched the more cost effective SpaceNavigator at the end of 2006 to infiltrate the growing consumer level 3D world, where applications such as Second Life and Google Earth were rapidly gaining momentum. This year the company has been conducting extensive research into how and why people adopt it for 3D design work, what the paybacks are and where the value lies. And with new, undercover products in development, it seemed a good time to visit the SpaceMouse mothership, an hour outside Munich in the sleepy Bavarian town of Seefeld, to speak with Dieter Neujahr, the company’s chairman.

Al Dean: Where is 3Dconnexion at in terms of adoption in the professional market, particularly mechanical 3D-based design, and how do you plan to push things further? How you get people to see the value in your devices? Dieter Neujahr: That’s one reason why Logitech formed

3Dconnexion – to find the next big thing in motion control device technology. We still expect the next generation of operating systems to be 3D. Vista, to an extent, already is, as are some flavours of Linux – and it’s also coming on the Mac platform. But so far we are reaching our core market of mechanical CAD. We are in a very good position. For example, our penetration in Germany for professional CAD 3D applications is somewhere between 61 per cent and 79 per cent: roughly two-thirds of 3D mechanical CAD engineers are using a 3Dconnexion 3D mouse. AD: Nearly 70 per cent of CAD using engineers in Germany are using one of your devices? That’s an incredible statistic. DN: Pretty much everyone is using one – Volkswagen,

Porsche, BMW, Airbus and all the suppliers, at every stage.

When I go to tradeshows in Germany and we hit our core market of mechanical CAD engineers or design engineers, of the people that don’t know the product, 20 per cent buy it on the spot. That’s typically the SpaceNavigator. The next 30 per cent are harder to win and the last 25 pe cent we never get. They say, “I’m too old, I’ve been using these tools for 20 years and it’s too much to learn.” In the US we also have a pretty comfortable situation, and we’re penetrating. So the game is really refreshing the installed base and coming up with new stuff that excites them. Antonio Pascucci, our head of Engineering and Product, is an Italian, but he’s more German than a German. He says, “Quality, quality, quality.” This is certainly an issue, particularly in Germany where we need to refresh product to maintain revenue; the products never stop working, they never break. Each time Antonio brings out a new product, its more durable. We estimate that the lifecycle for each mouse is around five to seven years, and they’re being used after that until people are ready for something new. AD: I guess it’s an alternative to the Apple philosophy of making nice things, but with short term build quality. DN: We’re not in the commodity business yet, and our

devices are still made for a professional mechanical designer who works multiple hours with our device every day. It’s a pretty sizable market – worldwide its 1.6 million seats and growing, say nine to ten per cent each year. They’re early adopters, the people that go for anything cool, and we want to work with people that live in a 3D world. We have a big push in adding more and more applications, and that actually needs a lot of software work. Our software development team is three or four times the size of our hardware R&D team, so you might think we’ve a hardware company, but the truth is we’re not. Sometimes we’re lucky and the software vendors integrate our software natively within their application, but in many cases they provide an API and we develop the drivers for their 3D engine. Each time there’s a new revision or upgrade, we have to rewrite the driver. When people look at our driver, which is 80-90Mb, they wonder what the hell we’re doing. It’s a 3D mouse, but for a 130 applications… AD: That’s a lot of different drivers DN: Yes, it’s a huge amount of work, and we hope that with

the proliferation of 3D mice a single driver will be built into the operating system. It’s actually more than writing drivers, its setting standards, because we want people to have an excellent and superior 3D navigation experience

3Dconnexion chairman Dieter Neujahr is confident about the future

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In Germany our big challenge is refresh and the fact that we make devices that are incredibly durable and well built. How many technology products do people continue to use when they’re seven or even ten years old? Economically, that’s the challenge in Germany but in other markets, including Japan, our penetration is really low and this is where we need to evangelise the concept of 3D navigation. AD: How do you do that with something that breaks your habits as a professional? DN: The only way is to let people touch it and play with

 It’s actually more than writing drivers, its setting standards because what we want people to have an excellent and superior 3D navigation experience and it needs to be consistent

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and it needs to be consistent. We have an SDK which we give to software developers on the web, or they can buy it (which includes a space navigator). That provides them with the ability to integrate 3D navigation with our devices, and they can do anything with it. This is a concern – if you have someone implement the driver so when you lift the controller cap the model rotates, that’s not what we want, and we don’t certify these applications. You have to have an interest in making the software industry understand that people expect a certain consistent behaviour when using a 3D mouse. That’s something I initially underestimated – it’s a huge communication challenge with the different vendors and software industry. We used to aim at mechanical engineers using a single application, so consistent navigation in 3D wasn’t an issue. Increasingly, our customers are using multiple applications. If you’re using Catia or SolidWorks, then you want the same consistent method of navigation in Maya or 3dsmax or Cinema 4D. So we see from that information that there’s a trend to multiple complex 3D applications. This brings us to another issue and that’s how to reduce complexity, and that’s why our study was such an eye opener (Ed: available at 3dconnexion.com/productivity). “Productivity increases” are a nice claim but you need to prove it – which we were able to do. The real eye opener was that 3D mouse users perceive that the quality of their work and their ability to detect errors in their product development processes has gone up tremendously. Not only do they feel more productive, but they do better design work – apart from the side effects of comfort. If you read our white paper, there are more studies where people really tried to quantify reduction in mouse movement and in how much they can reduce hand movement and strain on your hands using a 3D mouse compared to a standard 2D mouse. Engineers usually need to be educated that the left hand is useful for more than a few modifier keys – so you do three or four per cent of work with your left-hand and the rest is with the right. When you use a 3D mouse, it’s balanced across both. Engineers need to have exact navigation and assume there’s a steep learning curve. So our research tried to quantify that. When you’re in a production environment, there’s nothing worse than being handed something that changes the workflow – it decreases productivity. That’s a huge perception and being able to quantify it was fascinating. Existing users said that they were proficient in using the device and much faster in a shorter space of time.

it. In the UK, we use an evaluation programme. When people touch it, it’s sold. Another thing that helps is word of mouth. I compare it with vintage wine, the older the customer gets, the better they become at selling the device for us. The longest standing customers are happier and happier and are more likely to recommend the product to a colleague or a friend. That’s the number one reason people buy the device. Since the launch of SpaceNavigator, we’ve tripled the number we are selling. It brought us to people that thought they couldn’t afford the device or are outside the mechanical CAD market. We see a lot of development with 3D monitors and we’re seeing a huge shift towards 3D. There’s a lot of fantasy in there, but it’s a clear trend. AD: Why do you think you are the only player in the space? DN: One reason is that there’s a hell of a lot of work to be

done, for hardware and software support. You have to provide great navigation; it has to be immersive, intuitive. There have been a few competitors that have tried button mapping but you get a choppy navigation process. We tried that in the past but it’s a really unpleasant way to navigate. We want to have a smooth, superior, intuitive experience and that’s really difficult to achieve. It took a lot of work to make software vendors understand that the way they train users to navigate in 3D space is bad. They give the users a way to move in 3D with a standard mouse. That isn’t optimal – that’s a huge effort, much more than just button mapping. People have tried it, don’t like it and don’t use it. Also, it’s still a relatively small market, we’re 15 years into the business and I’ve yet to see devices that are as well thought out as ours, whether its finger driven or the Wiimote – all of these technologies are great, but they lack the controls a professional needs to work in a 3D environment in a relaxed way. It’s important for people to be able to put their hands down. If you want to design in a 3D environment for eight hours a day, pointing fingers… AD: Then you’re going to be crippled in three days flat. Arms like Popeye, but you’re done. Game over. DN: Right, it’s not natural. People need to work in a

comfortable way. It’s not just the six degrees of freedom and zooming and panning at the same time, it’s about speed control. A little pressure on the sensor, a small movement in 3D; a lot of pressure and you get a lot of movement. On most other devices, you can’t do that. This concept of two-handed navigation with a device that does not move to control your movement in 3D environment is, in my opinion, unsurpassed for what a professional 3D CAD user needs to have today. Especially when you work predominately in 3D. We have a lot of patents around it so we’re well covered. Frankly, I would love to have a good competitor, a big one, which puts a lot of marketing dollars behind it to evangelise the concept of 3D navigation. Then it comes down to a better product and better marketing and I believe we can win, hands down. DEVELOP3D OCTOBER 2008 45

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PROFILE

What is OpenGL 3.0? » Rob Jamieson delves into the mysteries of OpenGL’s latest application programming interface, and looks forward to it being put to the test

application are greatly reduced. This is because redundant code can be discarded, which, if implemented correctly, results in a more reliable and better performance.

old school versus new school

All this stuff to make your 3D graphics go that extra bit faster, look that extra bit fancier. Can’t beat a schematic can you?

 This latest version takes extensions from OpenGL 2.x and makes them the core functions. By doing this, performance is enhanced

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Despite this, there is a lot of software from the 1990s in use today, for example OpenGL 1.1, which uses old versions of the API to draw lines (vectors) and graphics on the screen. While retro might be fashionable, in the technology industry not updating the software can dramatically affect the performance that an application can get from a piece of graphics hardware. This is one of the reasons that some applications don’t see as much performance from newer graphics cards as others. The good news is that applications that use older APIs are decreasing as 3D becomes more important and as users want to see more in realtime. You might think that since OpenGL 3.0 is a new standard it will only work with the latest graphics hardware. This is not the case, as the functions have been present in previous generations of hardware. This is partly due to the support of later Direct X versions, which have made extensive use of shaders (code that exploits pure hardware calls to the GPU). Direct X has been implemented into some CAD applications and, I’m told, has a fairly easy API to programme in. This is understandable when you consider that the origin of DX lies in games design. Creating n last month’s article I mentioned that OpenGL some functions, such as having wires in a mesh without 3.0 had been announced at SIGGRAPH but, compromising performance, can prove a little more before I talk more about this, let’s look at what challenging with DX, but this is being remedied to some OpenGL 3.0 is and how will it affect CAD degree with DX10 and later versions. applications in the future. I’ll first explain how One of the other key points of OpenGL is its multiple graphic 3D engines interface with the OpenGL platform support. OpenGL support is available on API (application programming interfaces). Microsoft Windows, Linux and Mac, which means that if a Graphics cards contain discrete components software company wants to have multiple platform support, that have dedicated tasks. Basic components such as Siemens UGS NX or Autodesk Maya, then OpenGL include the GPU (graphics processing unit) that does the actual number crunching and the graphics memory, stores is the only solution. Direct X API is owned by Microsoft so the API only supports Microsoft Windows. In the case of data locally and performs calculations. GPUs are made up Direct X 10 or above, it’s only supported on Microsoft Vista of various designs but, generally speaking, the faster the and not Windows XP. From what I’ve seen the difference in clock speed MHz and more ROPs (raster operations) they geometry performance implemented with DX9 (Windows have, the higher the performance. Important criteria for XP) and what you have in Direct X 10 (Vista) is quite small. graphics memory are the speed of the GDDR5 (graphics So what are the new functions in OpenGL 3.0? This latest double data rate) and the number of MBs. Once this has version takes extensions from OpenGL 2.x and makes them been established, the software graphics driver, which is updateable, then interprets commands given to it and talks the core functions. By doing this, performance such as to the hardware. Sitting above this is the main API, which in VBO (vertex buffer objects) used in Catia is enhanced. This enables you to store geometry in the frame buffer (on the most cases will be either OpenGL or DirectX. Applications graphics card) without having to move data back and forth that display 3D data on the screen are written using either over the PCI-E bus. For the full detail spec you are better off of these APIs. going to www.opengl.org. As with everything, there are technology advances As with most things in life, you will not be able to judge on hardware but also on software. To make the most of all of the benefits until they are being tested in a bunch of current hardware your software must be kept updated. applications. What I find interesting, however, is that the This not only refers to the main 3D API version, but standard is being set by companies in competition with one also to the 3D application that places the ‘calls’ to the another. So, although relevant hardware and a modern API API and subsequently to the hardware. As OpenGL API are critical, to move forward this needs to be implemented has been around since 1992, there is a lot of support in the CAD software or the art will not progress. for functions that may no longer be in use today. But by The art in this case means better 3D performance, creating a new API with modern functions, the chances loading larger models in real-time and less waiting for you. of incompatibilities between hardware, driver, API and

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CASE STUDY

» Sogeti, a provider of consulting, technology and outsourcing services, is achieving new levels of efficiency and productivity through the automation and management of simulation processes by adopting management solutions from MSC.Software

managing simulation Knowledge at Sogeti

ogeti Group (a member of the Cap Gemini Group) offers professional services that focus on three key complementary business areas: IT application management, IT infrastructure services and high tech consulting. Sogeti enables its clients to leverage global technological innovations, and achieve above average results from their IT programmes. The company employs more than 18,000 people in over 200 locations in Europe, the US and India. One third of the High Tech Consulting division’s 3,000 employees are dedicated to engineering R&D. Much of Sogeti’s growth in the simulation field has been focused on the extremely strong aerospace sector in the region, but since 2005 the unit has diversified its customer base as other industry sectors have increasingly recognised the power and value of simulation techniques in improving the effectiveness of design and engineering processes. Sogeti has been a major user of MSC.Software’s core analysis packages and an early adopter of a number of advanced engineering techniques.

Finding a path to order In the automotive supply chain, data translation is a fact of life. With Class A surfaces, PMI data and feature trees adding to the complexity, it’s important to have a strategy for translation

As its simulation business grew, Sogeti saw that effective management of simulation content was critical to its ability to profitably and reliably offer services to its customers. “Around five years ago we recognised that simulation content management was going to be a key issue,” explains Philippe Sottocasa, simulation Centre of Excellence manager at Sogeti’s High Tech Consulting division. “We were working with huge and sharply increasing data sets and it was becoming ever more important that our internal quality systems were extremely robust.” Furthermore, increased globalisation is driving compliance in R&D efforts in the aerospace sector. “You might take a substantial

work package and divide it up between different regions, both to reduce cost and to fulfil contractual off-setting requirements to place work in customer countries,” says Sottocasa. “You need to ensure that everyone on the project uses a constant methodology and the same calculation tools. You also need to keep a detailed record of everything that was done for audit purposes.” After some attempts to build its own data management tools using a general purpose database, Sogeti turned to MSC.Software to evaluate SimManager as a more powerful and effective solution. “We were already heavy users of the full range of MSC software,” recalls Sottocasa. “When we heard about SimManager, we realised that it was designed to meet exactly the challenge we were facing – effectively managing and distributing all simulation content, managing and automating processes, and ensuring that we could capture the pedigree of all the data we produce.”

The Solution Sogeti selected SimManager, MSC.Software’s simulation content and process management solution that eliminates time wasted in searching for data and streamlines the process of distributing standard methods, processes, material properties, and other content. Isolated, discipline focused teams gain real-time access to simulation content and run simulations in a managed environment that ensures reliable results. And, since SimManager is capturing not only models and data, but also contextual information describing who, why, and how they were created, a complete audit trail is established for the simulation process. SimManager solutions include: Creation of a simulation knowledge base that facilitates collaboration and streamlines content distribution

Managed simulation processes that improve consistency

Automation of methods and processes to dramatically reduce repetitive, manually intensive work

Open support of existing simulation investments including third-party CAE tools, HPC hardware and methods.

With more consistent and reliable simulation throughout the enterprise, SimManager gives product development executives the confidence to replace physical prototypes with more rapidly developed and less expensive virtual prototypes. A greater number of design possibilities can be evaluated, enabling product innovation and lasting competitive advantage. Sogeti carefully thought through its business requirements to ensure that they achieved a robust, universally applicable and productive solution. “Before we even began to work with SimManager, we spent two years really analysing our processes and methods, talking to our customers about their requirements and doing everything we could to build the most effective system,” says Sottocasa. “The factors that make simulation data management challenging to implement are exactly the same factors that make it essential.” A second key element in Sogeti’s simulation management strategy has been the use of MSC.Software’s SimXpert system to capture, automate and share best practice methods. SimXpert 48 OCTOBER 2008 DEVELOP3D

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1 leverages the MD Nastran multi-discipline solver engine and provides users with the ability to create and share reusable simulation templates that ensure consistent results. For Sottocasa, the use of templates to automate simulation methodology has two main advantages. First, they help to improve efficiency and maintain quality by establishing standard practices that can often be automated. Second, templates help Sogeti to capture and retain expert knowledge inherent in existing people and processes. “It was important for us that we had a mechanism to retain the knowledge of our more experienced personnel and help newcomers to make use of it,” he says. Building a system that met the user and management requirements of the entire organisation took the implementation team 18 months. As Sogeti investigated and documented the processes their teams used, it found that rather than simply automating a repetitive series of tasks, a system was needed that could maintain the ability of engineers to make decisions that made the overall workflow very flexible and dynamic. In addition to process complexity, there were globalisation factors affecting the company’s business. Sogeti engineers and facilities reside in France, Germany, the USA and India, requiring a solution that could scale to these global requirements. Finally, Sogeti needed to make the cultural changes required to get all its specialists used to working within the new system. “The most powerful simulation management system in the world is no use if it is so unwieldy that your staff find ways to bypass it,” explains Sottocasa. “So it was a critical part of the implementation to build a culture of engagement, ensuring that our people were happy with the way it was all going to work.” One step to ensuring this was investment in improved IT infrastructure. “If it takes too long to check out a model from the management library, our analysts are going to become frustrated very quickly,” says Sottocasa. “So we ensured that we had the storage, network capacity and processing power to give our people improved responsiveness as part of the implementation.” An extensive period of testing and an ongoing dialogue with users and customers also helped to refine the system. “One thing we found during testing was that although you might expect all processes to start in the same way, quite often our people were only involved in part of a process, so they needed a way of entering the workflow in the middle of a process. If the system won’t let you do that because you haven’t entered critical data earlier, then it fails.” SimManager addresses this concern by enabling flexible access to content, methods, and procedures from anywhere within the overall simulation processes. Even the way simulation information is entered into the management system was substantially refined during the testing and implementation phase. “We started off using thin clients where our users could enter information and make requests for data access, but that proved too labour intensive and unpopular,” recalls Sottocasa. “Instead we adopted a rich client approach where the interface to the SimManager system was built directly into the user’s application environment. If they were using CATIA, they can check out and check in data without ever leaving their CATIA desktop.”

2 Today, Sogeti’s fully functional system controls more than 20TeraBytes of simulation content for numerous client projects worldwide. When the team began SimManager implementation, they designed in only 2TB of storage, but the dramatic growth in the power and popularity of numerical simulation, and the gains already realised in productivity, have increased storage requirements by an order of magnitude in only two years.

The Benefits The rewards of implementation are being reaped across the entire Sogeti organisation. “First of all, we have seen big productivity gains. We now know that all simulation work is being done with the right data at the right time, so the need for any re-work has largely been eliminated,” says Sottocasa. Project managers have benefited as the SimManager system gives them a clear view of the progress of a project. “Our project managers now spend less time chasing up their teams to find out what is going on, and more time driving their projects forward.” Sogeti’s customers are also extremely pleased with the improvements in quality assurance that come with a documented audit trail that guarantees that correct data and best practice methods have been used. The SimManager system has even delivered savings in IT infrastructure costs. “The storage of simulation results can use up huge quantities of disc space,” explains Philippe Sottocasa. “But because we now record the precise way every simulation was conducted, we don’t need to store those results files over the long term. If we need them, we can simply re-run the simulation using the automatically retrieved data and the associated process.” Sogeti is now making use of its own experience to help several of its customers to implement similar simulation management systems. “Thanks to our own experiences with SimManager, we are now extremely well positioned to offer this kind of help to our customers,” says Sottocasa. “Our background in simulation means that we understand the technology challenges very well and can ask the right questions, and we also now have a robust methodology for the integration of SimManager into the engineering environment.” For Sottocasa, Sogeti’s successful implementation of the MSC. Software SimEnterprise approach is only a starting point for ambitious ongoing plans. “The time is right for a new wave of optimisation in simulation practice. The next generation of simulation processes will see 30 per cent savings in time and cost compared to even today’s best practices,” he says. “Simulation content management will be the backbone of those improvements, but what we see today it is only an essential first step.” Now Sogeti is building what it considers to be the next stages – a comprehensive framework to manage workflow, control the use of IT resources, and ultimately to optimise the efficiency of the simulation process from end to end. “In the world of simulation and virtual product development we are moving into virgin territory once again,” he concludes. “There is a lot of work to do, and our collaboration with MSC.Software is an important component in the future success of that process.”

1 Sogeti now runs ● a common platform across multiple sites retaining security where needed, but ensuring flow of data and information 2 The interface ● through which all simulation tasks are managed, web accessible and online

www.sogeti.com

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REVIEWS

SOFTWARE REVIEW

PhotoView 360

» To great fanfare, during the 2009 beta cycle SolidWorks unveiled a new rendering application that set the blogging world alight. Now that the dust has settled and the shipping version is out, Al Dean takes a look at PhotoView 360

endering. It’s a wonderful thing. The ability to take a digital model of a product that doesn’t exist, create a photorealistic image of it to show, in exact detail, exactly how it’s going to look if and when you manufacture it, is a wonderful thing. But creating those images is a royal pain in the backside. Take a look at the rendering tools integrated into any 3D product development system and you’ll find something based on a half decent rendering engine (or in some cases, a clunky old one), but the workflow, the sheer effort required to apply materials, to create textures and lighting conditions, doesn’t make for an enjoyable experience. Preset materials are rubbish, the lighting set-ups are

At a glance: PhotoView 360

» PhotoView 360 » SolidWorks Price: see text www.solidworks.com

1 PhotoView 360 ● is a standalone application, licensed alongside SolidWorks, that brings progressive rendering, HDR based lighting and scene setup to the SolidWorks community. It removes many of the bottlenecks associated with creating photorealistic images

unrealistic and the results are pretty woeful unless you invest a hell of a lot of time getting to know the ins and outs. A prime example of this is PhotoWorks, which has been part of SolidWorks for the past decade. It’s been through some changes (dropping LightWorks in favour of Mental Ray a few years back), the workflow has changed pretty consistently, but still it’s a pain to use. Yes, there are experts out there that use the system and create stunning imagery – just look at the guide to making the most of PhotoWorks that Rob Rodriguez gives us on page 32. With talent, you can achieve great things. But when deadlines are looming, pressure is on and you need to create a decent image, do you have time to mess around? One advisor to our magazines put it nicely in an email: “I don’t get paid any extra to do

n Based on Nexus rendering engine from Luxology, developers of Modo n SolidWorks integrated but standalone n Reads RealView visualisation settings from SolidWorks parts and assemblies and reuses it as the basis for present real-time rendering n Uses progressive rendering to provide high quality previews of renders before you calculate – can’t save out instant snapshots though n Supplied with a range of materials and environments which both match the existing SolidWorks presets and extend them

rendering work, my boss just expects it.” With this in mind, SolidWorks has released PhotoView 360. I put it through its paces. PhotoView 360 is based on the Nexus rendering engine from Luxology, the team behind the sub-divisional modeller, Modo. Nexus is a progressive renderer. What that means is that the system streams the rendering into the display, so you start with a basic pixelated view, and things refine with each pass. If you leave the model alone (not changing materials, view and so on), then you’ll eventually end up with a pretty nice rendering without doing much. The speed with which that happens depends entirely on your hardware set-up. But the key point is that as you play with views, material and environment set-ups, you get a good idea of what you’re working on, getting closer to the ideal than using traditional rendering tools.

n Uses HDR images for both scene set-up and lighting – reducing bottlenecks in rendering workflow n Doesn’t have a customisable library of materials and doesn’t save changes back to the source SolidWorks data n Can’t access different configurations and view set-ups from the source SolidWorks data n Standalone yet tied to legacy PhotoWorks licensing – standalone purchase option could be useful for visualisation specialists

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But how do you set-up those renders? PhotoView 360 is a standalone application that installs alongside SolidWorks. It reads in SolidWorks parts and assemblies directly, and picks up a couple of things from the state you saved the model in when you last accessed it, such as the active configuration and the last view setting. But perhaps most critically in terms of workflow, it also picks up the RealView settings. RealView is the name given to the hardware-based shaders that SolidWorks incorporated in the last few releases to present models in a more realistic manner and to provide a range of different background environments for the models you’re working on. PhotoView 360 picks up on these and the materials/textures are matched to those in SolidWorks. So the model appears in PhotoView much as it would in SolidWorks with RealView switched on. With the progressive rendering, the photorealism starts to filter through and within seconds you get a pretty good image. Alongside the environments, PhotoView also includes a matched range of materials/ textures that can be applied to the model, plus some extras. The system has an interesting workflow in that you open up the materials library, find the material you want, then drag and drop it onto the geometry you want to apply it to. There’s an interesting filter in the UI, so that you can pre-select what you want to apply the material to – face, body, part or assembly. There’s no feedback as such, but the display will re-pixelate then stream in the higher quality image. When you apply to instances of a part, all of the instances have the same material applied – handy for assigning materials to fasteners and such. One of the biggest pains for any rendering system is the set-up of lights, but the recent adoption of HDR based lighting across the CGI industry has reduced the timescales and difficulty associated with lighting set-up. Because these files contain both scene setup and high quality lighting information in a single file, the set-up process is incredibly quick – you pick the environment you want your product in (and there’s a healthy range to choose from) and you’re done. When you’ve got your render set-up, you have to go through the process of calculating it to achieve your final image output. The settings are pretty self-explanatory and you can get the image format and resolution you need in a short space of time. One thing

that’s clear is that the rendering engine in use here is pretty efficient and gets you that final rendered output in a very short space of time, particularly when you compare it with rendering systems of old. The good news is that because of the preview functionality, you’re pretty sure that when you do hit that ‘final render’ icon, the image that you have to wait for is the one you want.

In conclusion PhotoView 360 is on its first release and it shows. You can’t select preset views as you might have in SolidWorks, can’t access those camera views you might have set-up, you can’t save views and, perhaps most annoyingly, you can’t snap the model to the floor of the rendering environment automatically – models are brought in just above the floor. Which makes very little sense, unless you’re working on jetpacks or other levitating devices. But alongside these functional criticisms, there’s one thing that anyone who’s read DEVELOP3D over the past few months might pick up on – PhotoView 360’s similarity to HyperShot from Bunkspeed. I’ve made no bones about it; I love HyperShot. It’s clean, efficient and creates killer results. From what I can see, PhotoView is pretty much a straight copy of the HyperShot workflow – I can’t comment on the technology underneath and its origins (I’m not too sure which predate which), but it appears pretty similar. And when you have one thing mimicking another, you often find that it’s the fine details, the smaller points that get missed – and it’s those smaller points that can make the difference between ‘okay’ and ‘fantastic’. PhotoView doesn’t have some of the finer points. The view controls are a match for SolidWorks, but when you’re trying to create killer rendering, you need different controls. How you rotate the view around a model is critical – and the SolidWorks view method doesn’t cut it. There’s a sticking point here. There’s also the question of licensing. PhotoView is aimed at people that don’t have the time to learn the intricacies of PhotoWorks, but need to create high quality images – according to our research, that’s an increasingly large number of users across a huge spectrum of industry sectors. Essentially, it’s applicable to almost everyone involved in product development. But to use it, you need to have a bundle of

 When deadlines are looming, pressure is on and you need to create a decent image, do you have time to mess around?



2 With drag and ● drop materials and environments, the system gets you closer to realism with minimal hassle and the progressive rendering means that you can see the effect of edits immediately - so you can make decisions without having to wait .

SolidWorks that includes PhotoWorks. In terms of current bundles, that’s SolidWorks Professional and Premium, as well older bundles such as SolidWorks Office or standalone PhotoWorks licenses. Another question this raises is how does PhotoView 360 fit into the rest of SolidWorks? PhotoWorks has been there for many years and is directly integrated into the animation/simulation tools, so is it going to be replaced? Not until the Nexus engine gets built directly into SolidWorks, and that’s going to take some work – but is it worthwhile? Yes, the set-up times are very quick, and reusing your material assignments makes much more sense. I guess the question is what do the majority want? A fully featured rendering/animation system, or just the ability to quickly create a static image? Our research indicates that static images are still by far the biggest requirement for rendering out. So perhaps PhotoView 360 is best left as standalone. It’s quick, clean and for a first release, impressive, but it still needs work to make it a great tool that achieves ultra impressive results. I’m sure it’ll become more integrated into core SolidWorks, working in concert with the animation tools already there. I just hope it retains that cleanliness and streamlined workflow and doesn’t get bogged down as PhotoWorks inevitably did.

PhotoView Workflow

1 A 3D model in ● SolidWorks with RealView materials and environments assigned. While this looks good for interactive work, it’s not good enough for some purposes, such as marketing, presentations and the like

2 The SolidWorks ● native data is read into PhotoView 360. The rendered image streams into the display, so you can see how it looks. Using the same view manipulation controls as within Solidworks, you can adjust the rotation of the model

3 The system provides ● a range of preset materials, so if your materials aren’t up to scratch, you can swap them out and change them (with the advanced tab)

4 Once you have your ● scene set-up as you want it to look, you choose your environment. There’s a range of preset environments that cover most of the bases – these provide the background scenery and the lighting for your render

5 ‘Quick Check’ to make ●

sure everything is as you need it. When you’re happy, hit ‘Final Render’ and the system starts to create the image you need at the resolution you require. PhotoView is fully hyperthreaded so it takes advantage of multiprocessor machines

6 The final image, in all ●

its glory – you still have to wait for the rendering to complete as you did with older generation rendering products, but the system helps to ensure that you get what you want first time

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SOFTWARE REVIEW

AcuSim 1.7

» Al Dean takes a look at the new kid on the computational fluid dynamics block and finds a system that uses technology from the FEA world to great effect in pushing the boundaries of what can be realistically simulated.

t’s not often that you get to look at brand new technology, and it’s certainly not every day (or indeed every year) that you get to see a brand new CFD solver code. But this is exactly what I was presented with on a recent visit to SSA, which has just signed up as UK reseller for a new product from AcuSim. As you might guess, you don’t start developing a new computational fluid dynamics software product willynilly, so it’s good to know that the team behind the product was formerly at Centric, developer of Spectrum, which was acquired by Ansys some time ago. Centric was one of the first companies to try its hand at fluid structure interaction simulation. If you’re not up to speed with this, it’s the ability to have both CFD and FEA working in concert to accurately simulate how fluids have an effect on the structure of a product and vice versa, to gain a true, real world understanding. Unlike many initial release simulation codes, I’m pleased to say that the AcuSim user interface, AcuConsole, is pretty well developed. It’s not all whizz bang and Windows ribbon based, but it’s clearly laid out, and the operations you need are arranged in a way that makes perfect sense. The graphics display window takes up the vast majority of the user interface, for viewing, interrogating the mesh, boundary conditions and, ultimately, the results. File and view operations are in toolbars around

 AcuConsole is not all whizz bang and Windows ribbon based, but it’s clearly laid out, and the operations you need are arranged in a way that makes perfect sense

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that window, but the majority of the action is found in the tried and tested panel to the left, which contains an extensive list of all the inputs for each simulation run. While this is a very long list, it provides you with a fantastic guide to setting up a CFD simulation, following industry standard workflows, where you begin by defining volumes with fluid properties (or movement or structure), then surfaces, then walls, inlets and outlets and so on. As you work through the list, it’s pretty clear where you need to add information. The system has a good number of presets libraries, such as material models for air, metals and fluids. Unlike many other standalone CFD applications, AcuConsole is not supplied with any tools for creating geometry from scratch, so you need to import data from

The AcuSim interface is well thought out, leads you through the process of setting up a CFD analysis and guides you to where you need to add information and set variables

2 The component ● we are interested in imported into AcuSim

4 A sphere is added ● to define a mesh refinement area around the wing, as well as massively refining the boundary layer

your CAD system. The system reads in data from Pro/Engineer (both parts and assemblies), Parasolid and ACIS, as well as Catia readers. It also reads in decks from other FEA systems, such as Nastran. Once your data is read in, then comes the fun bit – meshing. And in the case of AcuSim, all is not as you might expect

Finite elements and CFD

» Acusim » Acusim Software + SSA From £16,000 per year www.acusim.com www.ssanalysis.co.uk

What’s interesting about AcuSim is that the system doesn’t use the traditional CFD finite volume method of creating meshes, but instead uses one that’s more akin to finite element analysis, where highly ordered meshing is far less critical and models run quickly and accurately without the upfront effort typically associated with CFD. This also gives you huge benefits when you’re

AcuSim Workflow

1 The geometry in the ● authoring CAD system

3 The faces have been ● colour coded to show the various boundary conditions, inlet, outlet and various wall definitions

5 You can show ●

the mesh using a dynamic section, great for visualising the internals of a mesh

6 Results in Fieldview, ●

which reads the AcuSolve database directly

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go with the flow

According to that source of mildly accurate information, Wikipedia, fluid structure interaction occurs when “a fluid interacts with a solid structure, exerting pressure on it which may cause deformation in the structure and thus alter the flow of the fluid itself”. Essentially, what this means is that when a fluid (that can be liquid or air)

passes over a more rigid object, that fluid can deform the solid. In turn, the deformation of the solid causes a change in the fluid flow, so its characteristics change, which effect the deformation again. The best analogy I’ve ever heard is to consider one of those nasty little plastic stirrers you get in service stations. When you stir your tea,

looking at more advanced simulation tasks, such as moving frames and complex geometric forms. The system also includes a pretty nifty set of mesh refinement tools for getting the exact mesh you require on wall boundaries without a great deal of input. Another area in which this aspect of the system gives you huge benefits is fluid structure interaction (see the box for a brief guide). One of the challenges of fluid structure interaction is that the foundation meshing used in CFD (the fluid part) is dramatically different to that used in FEA (the structure part) and the interaction between the two needs to overcome this difference. Of course, the reason a system like AcuSim is so interesting to those conducting that type of work (and it’s not alone in this approach – it may well be because there aren’t may FEA-based CFD codes out there), is that similar solution processes are used, so the process becomes more connected. AcuSolve is excellent for tying up to Abaqus in particular, so AcuSolve takes over control of both the fluid based calculations done in AcuSolve and the structural simulation done within Abaqus, so you have a single point of access for set-up and solving.

the stirrer swirls in your tea and it bends because of the resistance from the tea. In turn, the bending changes how the tea resists the stirrer. Computationally speaking the simulation of this effect is incredibly complex and is only now starting to be solved. You need both computational fluid

If there’s a failing with AcuSolve as it stands, it’s the fact that the system doesn’t have fully integrated results visualisation tools. At present the system is supplied with ParaView, a cross platform application for reading and presenting simulation results data, and it gives you all the tools to slice up models, create the plots and extract the data you need to create your reports and document results.

In conclusion We haven’t delved deeply into the technicalities of AcuSim for a couple of reasons. Firstly, the system has a great deal of functionality and as such, its use is going to vary widely depending on the industry you work in. Use of the system would be different if you’re working in oil and gas,

dynamics (for fluid flow) working alongside finite element analysis (for deformation and such), and the process is highly iterative in nature. Because the two fields are quite different in approach, in addition to the computing power required to achieve something feasible in terms of accuracy, this could be the next big thing in simulation.

compared to aerospace, compared to petrochemical. So who is the target market? The answer, in general terms, is that AcuSim is ideal for anyone interested in higher-level simulation tools at a more affordable price. In specifics, it’s ideal for those looking at fluid structure interaction at a high level and anyone with hyper accurate solution requirements. That said, it’s also ideal for the general purpose CAD market as the FE based meshing is so much more tolerant of messy meshes than many CFD codes. The bottom line is that AcuSim is fast, accurate and easy to use – which sounds like a marketing message from a vendor, so let’s put it this way: it provides high level functionality not compromised by ease of use, and has the potential to take you further than more mainstream solvers.

Solving and calculation Once you have your simulation study set-up, the system lets you crack on with it quickly. AcuSolve is highly parallel and it scales nicely across multiple cores and mutiple processors. The really interesting thing is that AcuSim does not charge for multiple processors. While it’s not a well known fact, those involved with higher-end, more traditional simulation technology will be aware that many vendors charge per CPU, or even worse, per core. So, if you want to run your simulation solver across multiple processors, you get charged. The good news is that AcuSim doesn’t believe this is the way forward and charges for the software, rather than penalising you for having more advanced hardware.

 AcuSim is ideal for anyone interested in higher-level simulation tools at a more affordable price. In specifics, it’s ideal for those looking at fluid structure interaction at a high level and anyone with hyper accurate solution requirements

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9/10/08 00:30:56

SOFTWARE REVIEW

Ansys Engineering Knowledge Manager 1.1 » The manufacturing world is used to managing workflows and managing data, but can the same be said of simulation? In the first of two articles, Al Dean takes a look at Ansys Inc’s brand new offering to help gain control of simulation data and processes

imulation is a field that’s both mature and growing exponentially at the same time. The traditional realm of the finite element analyst or the computational fluid dynamic analyst is one that’s well established within many industry sectors, and it’s getting entrenched into more, with a new breed of engineer and design focused technology gaining traction in the mainstream. As with the 3D CAD revolution before, adoption brings a whole new set of problems, and as with any technology which provides benefits, the quantity of data we’re generating is growing. As each design iteration is tested, validated, assessed and reported upon, data is created, but unlike many design-related processes, it’s done in an ad-hoc, often random manner.

» Engineering Knowledge Manager » Ansys Inc Price: On Application www.ansys.com

1 The EKM workflow ● tools allow you to define all manner of process, batch processing and automation using the information you have available, and provides you with the key to capturing knowledge and reusing it

Some organisations might use PDM/PLM systems to capture simulation data as part of the workflow, or allow the user to link it to the generating CAD data, but systems that support that explicitly are few and far between (think Windchill, Teamcenter and Enovia). The majority are using file structures, shared network drives and such, and the whole thing can get very messy indeed. The use of advanced simulation tools can generate massive datasets. We’re not talking gigabytes: we’re talking terabytes of data at a time in set-up and results data. On top of this, consider the wealth of knowledge contained within this data and the work put into it. When that data is stored and perhaps lost and then the knowledge goes with it, there’s no method of capturing that expertise and reusing it. And with today’s skills shortage across

At a glance: Ansys EKM

n Storing simulation data, results and other information n Server based database that indexes based on simulation metadata, enabling quick searches for information n Browser and platform independent so anyone can access the system, from wherever they need to n Controlled but pervasive access to critical performance information about your products

the whole industry, the big picture adds up to the need for something a little more specialised. Enter industry heavyweight Ansys and its Engineering Knowledge Manager (EKM) system, released in April. Let’s take a look at the first release. EKM is a hosted application, so it resides on a server, whether that’s a centrally located resource in your office, central and accessible over the web, or just installed on a single user machine (all of which are possible). The idea is that you access it through a standard web browser. What’s interesting with this, compared to other ‘web-based apps’, is that you can do so with any browser, on any platform, so PC, UNIX and Mac users are okay (which makes a nice change). Accessibility is key, so this is absolutely essential. You can remotely log in and access your simulation data and files, run scripts and visualisation tools, and even kick off simulation runs. Out of the box, the system is configured to integrate with all of Ansys’ applications, whether that’s Ansys Structural, Workbench, Fluent, CFX and now Ansoft, but of course, and it’ll also work (with a bit of effort) with other simulation codes, whether bought in or in-house. Whatever system you’re working with, EKM works pretty much like any data management system. The data is kept in structured folders (which are customisable) within a vault, access is controlled by log-in by groups or individuals, either on a per folder or individual file basis. The UI is very spare, with the file property and interaction window taking up most of the window, with a series of navigation options to the left, namely, ‘applications’, ‘my processes’, ‘my work items’ and ‘repository’ – all of which will become clear. The first step, as you might expect, is to add data. When you upload data, the system does two things. Obviously it transfers the data to the vault for storage purposes, but alongside this, the system

n Ability to formalise workflows and standard simulation routines n Distribute access to simulation routines in a controlled and central environment n Integration with ANSYS simulation codes including Ansys Structural, Workbench, Fluent and CFX, as well as potential to integrate with third party apps and in-house code

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3 strips out all of the metadata from it and stores it in a separate database. EKM is tuned for simulation data, so alongside the usual part and file name, date and author attributes, it also extracts all manner of simulation related data – whether that’s the solver code used, boundary conditions or materials. The segregation of this data is key. Firstly, it makes searching based on simulation specific terminology and properties almost instantaneous. Secondly, it allows you to find the data you want more quickly, without having to load potentially huge datasets. Lastly, it means you can conduct very quick comparisons of files, again, without a data loading overhead. When you do want to look at the data, the system uses cut down viewing applications to allow you to make a final check that you have the correct data before you start loading it – if you’re accessing terabytes of data over a web connection, you’re going to want to make damn sure it’s the right data. Once you have your data within this central location, you can make it accessible to whoever needs it. This is one of the big ground level benefits of EKM, the ability to centralise data and make it accessible. By doing so, you widen understanding and the ability to reuse the knowledge it embodies. But what if you want to push things further? Then we get into the realms of standardisation of workflows and processes – and that’s something EKM is working towards. Alongside the storage, search/retrieval and accessibility factors inherent within EKM, it has a set of tools that allow you to start to capture knowledge about how simulation tasks are performed, formalise them into templates that contain that knowledge, then distribute those templates to a wider audience. Using a series of links to the various applications in a workflow charting type interface, you can very quickly take a signed off simulation process

4 and create a closed workflow that steps the user through the set-up, definition of a problem, calculation and results interrogation. The set-up process is pretty easy assuming you have a solid knowledge of what you’re doing, and time invested in a thorough look at how your experts conduct common simulation tasks can pay real dividends, as that data is captured and reusable and the more you reuse it, the more value you derive from the whole process. There’s a huge information bleed in every organisation unless you’re using tools to capture the many things that make up your intellectual knowledge. Within simulation, you have the perfect embodiment of both the digital model and how it correlates to the real world, with real world constraints and conditions and under real world loading conditions. When you look at the current move towards using real test data to further enhance the accuracy of simulation tasks, greater multi-physics capabilities coming on-stream, all of which reduce the use of assumption, then it’s clear that anything that relates to controlling and managing simulation is absolutely critical.

In conclusion As a technology, EKM is interesting. At first sight, those with experience of PDM and PLM will see it as pretty rudimentary, with check in/check out, file storage, access control, and workflow management. And they’d be entirely correct. It is pretty basic on the surface, but underlying that simplicity is one hell of a lot of functionality and capability. If you look at the way the system extracts, stores and maintains all manner of metadata, way over and above what you’d get with a standard data management tool, you have the ability to find the information you want, to a very granular level. That granularity means that you can locate the simulation data you’re looking for more quickly, giving greater

2 EKM will extract all ● manner of standard and simulation specific metadata from your data, enabling quicker searching to a very granular level 3 Revision control is ● key to EKM 4 Reports can be ● auto generated where needed to automate reporting as well as set-up and calculation 5 Because EKM ●

has such levels of metadata available, the system allows you to perform searches based not only on standard metadata, but also simulation specification information

potential for re-use. The fact that it can do so when working with extremely large datasets makes it all the more impressive. This is the first area where the system should be of interest to those with large quantities of simulation data, from small organisations right through to large scale, multinational enterprises. On top of this, you have the ability to capture knowledge and reuse it, to distribute simulation processes to a much wider audience in a safe, controlled manner, making the whole system look much more interesting. If there is a concern, it’s the simple fact that with the inherent link between 3D geometry and simulation data, it would make sense to have everything within a single, searchable database and available from the same interface. But when you look at what else can be done outside of pure management and control, then the argument diminishes. Ansys is not alone in trying to add some order to simulation data – other vendors are attempting the same thing, although each with slightly different approaches. The good news is that Ansys has added a lot of value that can, once you’ve captured that data, start to squeeze additional value from it. DEVELOP3D OCTOBER 2008 55

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7/10/08 10:49:04

SOFTWARE REVIEW

VISI Series 16.0

» In the first of a two part review, Al Dean takes a look at the latest release of VISI Series from Vero Software, a system with incredible power that has been driven by one of the most demanding industries for geometry wrangling: mould and die.

or those unfamiliar with the names VISI or Vero, the company has roots within Italy’s Olivetti Group, and has been quietly working away with both in-house developments and acquisitions over the past few years to create VISI, one of the true, fully featured CAD/CAM systems. To qualify that, very few cover the majority of bases – which is what VISI is increasingly able to do. As you might expect, when you have a manufacturing focused system, there’s always a core concentration of mould and die – whether it’s part of a grand plan or a happy accident. When you find CAD/CAM developers that do a good job, they’re typically mould and die focused.

compare and contrast

VISI covers much more, with full support for all manner of machining (3-axis, 5-axis and high speed machining), but also into lesser known – but increasingly critical – areas such as progressive die design and mould flow analysis. In the first part of a couple of reviews looking at specific areas of VISI 16, we’re going to focus on the 3D modelling portion of the offering. VISI is a fully featured hybrid modelling system, allowing you to work with surfaces and solid data in a free-form manner. Intelligence is added to your model where appropriate, but in comparison to many mainstream systems, its tools for working with large quantities of problematic geometry are excellent. When dealing with a complete mould stack, you could be

If you work within a sub-contract environment, then you’re going to be very used to design changes or late stage revisions in designs. When you work with mould design, you need to be sure that you get that mould on the machine and have it cut in as short a time as possible – changes come in late, but you can’t afford for these to delay things. This scenario highlights a tool that should take identifying design changes down

to individual surface entities. This tool compares two geometry files, and colour codes the faces to show which are new, have been removed or added. The system will explode the geometry into sheets separated by colour/ status. You can then quickly choose which geometry to swap out and replace with newer data revisions, and form a cohesive model in an incredibly short space of time.

» VISI » Vero Software From £5,500 www.vero-software.com

looking at 2,000 plus parts. It might not sound huge, but when you consider that many of those parts are going to contain complex surface data, the power becomes apparent. Rather than going through the whole system, I’m going to have a look at some of the updates to V16 which have made it even more efficient in a pressurised production environment.

User interaction and experience

1 VISI is heavily ● focused on the mould and die industry. Many of the tools are highly tuned with an emphasis on speed and reliability

The VISI UI has been overhauled over the last few release cycles and its appearance and workflow are now fresh, modern and clearly laid out – you certainly wouldn’t think it was the first system to implement Parasolid on the Windows platform. This release sees core enhancements aimed at making navigation of the 3D model easier, a good example being view rotation. The middle mouse button rotates the model, but hot zones have been added around the edge of the screen so that clicking that middle button near the top, bottom or sides will lock a virtual screen axis for rotation – making precise rotations of your model much easier. Another pretty cool update is that CTRL+F2 will snap the view to the nearest orthogonal view.

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2 Alongside the usability improvements, there are some updates that make working with geometry much easier. There’s been a continuation of the consolidation of commands that’s been a theme in the last few releases. This now sees many common or similar commands merged into a single operation that covers all use cases – a perfect example is that previous releases had separate operations for extruding surfaces solid and now there’s just one extrude command. As a brief guide, 30 commands have been reduced to ten or so. As we’ve said, VISI’s background is not part authoring, but working with other people’s data – specifically improving bad data so it can be used in the unforgiving production world. Tools like the new Dynamic Surface Analyser give you an understanding of how a model is constructed, and that offers you more information to base your edits on. It provides you with dynamic information about the geometry such as relative and absolute co-ordinate positions, fillet radii, draft angle, geometry type and important CAM attributes such as hole type and drilling information. Any trimmed geometry is also presented as a wireframe ghost in its natural untrimmed state (which is vital if you’re editing surfaces). This release also sees a lot of work done to make the system more productive, by taking a common workflow, usually entailing many steps and carrying them out in a single operation. A fantastic example is the re-trimming tool, which has been reworked to carry out an untrim/fix/retrim/ merge series of operations in a single step. Streamlining these repetitive tasks will certainly free up the designer and generate huge time savings. Another is the new auto-constrain surface, where you select

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3 the geometry on which you want to build a surface and the system finds the best type of surface to use, reorders the curves and generates the surface based on geometry criteria, again in a single step. Perhaps the ultimate example is the bend relief operation, used on stamping dies to great effect. To create the die face, you need to create an offset but this can cause problems with tight radii and tears or metal creasing in production. So the system has tools which can add ‘bend relief’ to those tight radii. There are a couple of other updates that can assist work with problematic data, one of the most interesting being the Validate Bodies operation. This analyses your model to find faces that might cause problems downstream (self intersecting faces or inconsistent edges for example) when you’re trying to form a solid body, and fixes them. This is the sort of thing that could really drive you crazy as you chase bad surfaces around a model trying to form a solid object.

In conclusion VISI is an incredible piece of kit. If you just look at the modelling aspects (we’ll get onto the really meaty cutting metal related portion next month), then it’s incredibly powerful. Today’s CAD users are more discerning that ever before. We’re all used to the ability to work quickly and efficiently with geometry, and while the majority are certainly using one of the mainstream midrange modelling tools, when you’re dealing with import data or working with complex surfaces, you’ll quickly run into the one problem those types of systems have (and let’s be clear, I’m talking about SolidWorks, Solid Edge, Inventor et al). Those systems work best with native data, because they’ve

5 2 Electrode ● construction is fast and simple using VISI with its wide variety of extraction methods 3 Dynamic Surface ● Analyser highlights information such as co-ordinate positions, fillet radii, draft, and important CAM attributes 4 This shows the ‘Auto ● Constrained Surface’. VISI will analyse the construction geometry, re-order the data and create the most suitable surface 5 VISI can validate ●

data, highlight the problem zones and automatically reconstruct or heal the geometry

been designed as authoring systems with the end goal being a 3D model or a 2D drawing derived from it. A system like VISI (and there are others in the same class) differs in that the end goal is a production model on the back of which machining or tooling design is going to take place. When you focus on the mould and die market, the processes often rely on your ability to analyse, validate and fix the geometry your client provides, then to ensure that you create the best mould tool you can – because production success is directly attributable back to that underlying geometry. While VISI has all of those surface-based modelling tools you’d need, the system also has a massive range of tools that support the entire process, whether that be mould design or electrode extraction and design, as well as supporting the creation of production drawings in a very automated manner. While it’s not recognised as a standalone modelling tool, but as part of a bigger, more fully encompassing offering, I’m pretty damn sure that VISI could take the Pepsi challenge with any other modelling system on the market today – and win.

6/10/08 22:05:50

APPOINTMENTS

final_landscape_aw:Layout 1

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Design Draughtsman £18.00 - £20.00 Per Hour

This is a brand new role working within an established design and development team within the automotive sector. Location: Commutable from Leeds, Wakefield,York, Huddersfield Role Duration: 3 Months Reference: LS813/610/PD Apply now with your CV to Paul Dickens enquiries@ata-selection.co.uk or call 01332 861336

global reach, local delivery

Design Development Engineer £25,000 - 35,000

Your position will take concepts from the creative design team before producing 3D solid models on Pro-E. Location: Leicestershire Reference: 9309/610/RS Apply now with your CV to Christian Addison enquiries@ata-selection.co.uk or call 01332 861336

Design Engineer Excellent - Negotiable

Contractors wanted with experience of Catia v5. Location: Home Based Reference: 0612/614/JN Apply now with your CV to Sam Powell enquiries@ata-selection.co.uk or call 01332 861336

Design Engineer Negotiable

Catia V4 & V5 design engineer required for a 6 month fixed term contract. Location: South West & Wales Reference: C5616/610/MD Apply now with your CV to Mark Dismore enquiries@ata-selection.co.uk or call 01332 861336

We recruit nationally for clients across the UK. Visit our website to register for the latest vacancies.

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APPOINTMENTS

BEWBODFE DBSFFST '03 "650.05*7& &/(*/&&34

!DVANCED 2ESOURCE -ANAGERS IS ONE OF THE 5+gS LARGEST %NGINEERING 2ECRUITMENT #ONSULTANCIES 3ENIOR $ESIGN %NGINEER )NTERIOR 3YSTEMS .' .ORFOLK /UR !UTOMOTIVE CLIENT BASED IN %AST !NGLIA IS LOOKING TO RECRUIT A 3ENIOR $ESIGN %NGINEER 3TRONG PROVEN EXPERIENCE OF INTERIOR TRIM SEATING AND RESTRAINTS SYSTEM DESIGN .ICHE VEHICLE EXPERIENCE PREFERRED #ATIA 6 6 PREFERRED

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(ARNESS $ESIGN %NGINEER #ATIA 6 *(! -IDLANDS ! LEADING AUTOMOTIVE TIER SUPPLIER OF HARNESS %$3 SYSTEMS IS CURRENTLY SEEKING A #ATIA 6 DESIGNER TO WORK ON A CONTRACT BASIS 4HE IDEAL CANDIDATE WILL HAVE PROVEN EXPERIENCE IN WORKING WITHIN THIS PRODUCT FIELD 4HIS IS A -IDLANDS BASED ROLE

a P H CONTRACT

$ATA #O ORDINATOR $ATA !DMINISTRATOR *(! .ORTHAMPTONSHIRE ! P ! PRESTIGIOUS -OTORSPORT %NGINE DEVELOPER SUPPLIER IS CURRENTLY SEEKING AN ,#! $ATA #OORDINATOR ADMINISTRATOR TO JOIN THEIR -OTORSPORT TEAM 0ROVEN EXPERIENCE IN A DATA CO ORDINATION OR ADMINISTRATION ROLE IS IMPORTANT %XPERIENCE WITH ,#! DATABASE MANAGEMENT IS ADVANTAGEOUS FOR THIS ROLE

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3ENIOR #!% &%! 3TRUCTURAL !NALYST *(! #AMBRIDGESHIRE ! MA ! MARKET LEADER IN DIESEL ENGINE DEVELOPMENT IS CURRENTLY SEEKING A PROVEN #!% &%! ENGINEER (AVING A PROVEN BACKGROUND IN STRUCTURAL ANALYSIS THE SUCCESSFUL CANDIDATE WILL UTILISE SOFTWARE SUCH AS !"!153 .!342!. AND 0!42!. TO DEVELOP ENGINE AND POWERTRAIN PRODUCTS

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3$2# )DEAS %LECTRICAL (ARNESS $ESIGNER '$ -IDLANDS /UR AU /UR AUTOMOTIVE CLIENT WHO SPECIALISES IN %$3 (ARNESS AND WIRING SYSTEMS REQUIRES AN 3$2# )DEAS %LECTRICAL (ARNESS DESIGNER TO JOIN THE TEAM ON A LONG TERM CONTRACT BASIS 2ESPONSIBILITY

4O PACKAGE WIRING HARNESSES USING ) DEAS IN LINE WITH CUSTOMER REQUIREMENTS AND THE CUSTOMERgS DEADLINES

4O USE $IGIBUCK AS PART OF THE DESIGN PROCESS AND TO VALIDATE HARNESS PACKAGING

4O PREPARE AND SUBMIT CUSTOMER ENGINEERING CONCERNS TO ACTION CHANGE

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4O ATTEND CUSTOMER PACKAGE MEETINGS TO ENSURE THAT THE HARNESS PACKAGING IS SUPPORTED BY THE DESIGN OF OTHER COMPONENTS

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APPOINTMENTS recruitmentregister•com

www.beechwoodrecruit.com TRANSMISSION DESIGN ENGINEER

ANALYSIS ENGINEERS

Automotive Consultancy • Warwickshire

Offshore Oil & gas Consultancy • Woking

This leading automotive, powertrain and transmissions consultancy is now seeking a Transmission Design Engineer to join a small but experienced team producing layout and detail designs, predominantly for motorsport transmission projects. Qualified to degree level in mechanical or automotive engineering, you will be proficient in producing 3D solid models and manufacturing drawings using ProE or other main platform CAD system. BC300v5

This leading international consultancy specialising in the engineering, analysis and design of subsea structures for the deepwater offshore oil and gas industry is now looking to recruit Analysis Engineers to be involved in the structural design and dynamic analysis of subsea equipment, including riser systems. Qualified to degree-level in Mechanical, Structural or Civil Engineering, Physics or Maths, you will have an aptitude for carrying out analytical work. CA689v8

CAD COORDINATOR

ANALYSIS ENGINEER

Power Conversion Systems • Glasgow This new and successful company, a global specialist in Power Conversion, is now seeking an experienced CAD Coordinator to ensure the smooth operation of the Drawing Office. Successful candidates will hold a HNC or equivalent in Engineering or Electronics and must have experience of creating accurate CAD Drawings to tight deadlines. GL338v37

CAD DESIGN ENGINEER (CATIA V5)

High Performance Composites • Austria Successful candidates will be required to develop composite components, make analytical calculations of fiber reinforced plastic and metal components and systems, to compile analytical reports and test plans and coordinate material and components tests to define permissible limits. You should have mechanical and materials knowledge with focuses on Lightweight design, fatigue and construction as well as FEM-knowledge (Nastran, Patran, I-deas, Marc). CA1108v2

Automotive Emission Control • Lancashire This is an opportunity for an ambitious CAD Design Engineer with experience of CATIA V5 to join a world leader in the emission technology industry serving light and commercial vehicle manufacturers worldwide. Working directly with Project Engineers, you will be responsible for the design of heavy duty automotive exhaust systems. BC362v2

DESIGNERS Designers are now required to join this leading international energy services company based near Baden in Switzerland. In this role you will create CAD Models and drawings for the manufacturing and inspection of gas turbine parts. Successful candidates will be educated to HNC level or equivalent and have successfully completed an apprenticeship in technical design. German would be beneficial but is not essential. CA1046v17

DESIGN ENGINEER Aircraft Composites Industry Based Vienna, Bratislava and Upper Austria We are seeking a Design Engineer to join this leading high performance composites company in Austria. You will have technical experience in the area of mechanical engineering, aircraft technology or carbon fibre technology. You will also have experience of CAD software (ideally Unigraphics or CATIA V4). CA1108v3 CVs please to George Lowi, indicating your salary expectations and companies not to approach: Beechwood Recruitment Limited, 221 High Street, London W3 9BY Email: cv@beechwoodrecruit.com Tel: 0208 992 8647

www•beechwoodrecruit•com

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Appointments Register

virtualcareers•co•uk

mechanicaljobs•com

Gas Turbines • Switzerland

softwarejobs•co•uk

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APPOINTMENTS

Bespoke Permanent Engineering and Technical Recruitment

Premier Technical Recruitment excel in the provision of bespoke permanent recruitment solutions to the major engineering sectors throughout the UK, including Automotive, Aerospace, Nuclear, Defence, Pharmaceutical, Food and FMCG and Materials Handling markets, and supply these technically demanding and highly competitive sectors with a range of engineers. Current live vacancies include: Mechanical Design Engineers – Lancashire to £40k + benefits – Aerospace Catia v4/v5 Simulation Engineers – Senior & Graduate – Northampton to £35k – AutoMod exp.req’d Mechanical CAD Design Engineers – Leicester to £36k – AutoCAD for Materials Handling Mechanical Design Engineer – West Midlands to £36k – ProEng (Wildfire) -Nuclear sector Mechanical Design Engineer – Manchester to £35k – Robotic and Automation systems Aerospace Mechanical Design – West Midlands, Derby and Coventry – to £36k + o/t Senior Mechanical Design – Leicester to £40k + benefits – Automation & SPM Mechanical Design Engineer – Birmingham to £37k – Building Services and M&E projects With our experienced team of recruitment professionals, competitive Terms and Conditions of Business and absolute commitment to candidates and clients alike, Premier Technical Recruitment are proud to work with engineers and recruiting managers throughout their careers - and look forward to demonstrating our capabilities to you. Have a look at our website www.premiertechnicalrecruitment.com for up to the minute vacancies, call Premier Technical Recruitment on 01827 68400 or email your cv detailing your requirements further to paul.simcox@premiertechnicalrecruitment.co.uk

High Impact Opportunities! Project Design Engineer - M5 Corridor

Our client develops, designs and integrates high performance composite materials into military vehicles and aircraft to protect Armed Forces personnel. With an established and growing order book, they are seeking to expand their Design and Project Engineering team with the creation of this new and varied opportunity.

� � � �

To manage the design, sub-contract manufacture and installation of fabricated structures for naval vessels Produce 3D CAD models of fabricated steelwork using Solidworks CAD Produce 2D Production drawings, select and manage sub-contract steel fabricators Liaison with MoD Customers and equipment manufacturers during design and commission of structures

Joining a dynamic and growing team of customer focussed engineers, this role requires a combination of technical and engineering skills with project management and liaison experience. To be successful you must therefore be able to demonstrate the following characteristics:

� Strong practical design skills using 2D and 3D CAD, including steel fabricated structures, preferably in Naval or Marine applications � Excellent project management skills and the ability to expedite projects smoothly and in a timely fashion With a wide variety of interesting responsibilities this role will ideally suit candidates seeking the chance to see projects from bid to final delivery and sign-off.

To apply please forward your CV to Stephen Brown Email s.brown@europrojects.co.uk or apply on line at www.europrojects.co.uk

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To advertise in this section please Contact Tony Baksh on 020 3355 7313 / tony@x3dmedia.com

8/10/08 23:03:35

APPOINTMENTS

SolidWorks – London & South East £28,000 ~ 35,000 basic +£40,000 (Commission) + car Engineers Interested in a Sales Career – An Opportunity with a Market Leader Solid Solutions Management require additional regional account managers at its London & South–East offices due to continued strong growth within the CAD/CAE market. With an established and extensive client-base, plus a strong track record for delivering customer satisfaction, the opportunities exist to easily exceed targets. Commercial experience is not essential as we offer full training and career development to individuals with the drive and commitment to go the extra mile and that can demonstrate: •

The ability to understand the needs of our customers and to work closely with the technical support team to provide technical solutions to meet client needs

•

Management and development of account relationships, providing proactive advice and exceptional customer service

•

Responsibility for proactively identifying and securing new accounts across a wide range of sectors involved in design

If you are academically qualified, have a track record of achievement and are keen to focus your energy on the needs of our engineering design customers, we would like to hear from you. Please send your CV to:

Alan Sampson

recruitment@solidsolutions.co.uk

We are recruiting…… .....join our winning team! • Applications Engineers – (3 years SolidWorks Experience) • Developers – (VB.net essential) • Sales Administrators

www.driveworks.co.uk …. for more information and to apply We are the team behind DriveWorksXpress - THE Easy-to-Use

Design Automation Choice for SolidWorks DriveWorksXpress is now included FREE in EVERY seat of SolidWorks worldwide Simply enter the values that drive your outputs Great for designs that are “the SAME but DIFFERENT” each time

and then let DriveWorksXpress and SolidWorks generate your new variations quickly and easily

Generate new CAD models & new drawings

The result? - New and accurate assemblies, parts and manufacturing drawings

Downloadable Tutorials & Examples available from

www.driveworksxpress.com

(Strictly No Agencies)

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APPOINTMENTS

PRINCIPAL MECHANICAL ENGINEER Midlands

c.£50,000 + benefits package

Taylor Hobson is an ultra-precision technology company operating to the highest technical standards and delivering solutions for the most demanding applications on a global basis. In order to maintain competitive advantage there is heavy R&D investment, which has created a culture of continually evolving IP and product portfolios, to support clients through a worldwide infrastructure. The business is part of AMETEK Inc. a $multi-billion corporation with an impressive financial performance and a corporate growth plan that truly delivers value for stakeholders across the globe. The position of Principal Mechanical Engineer is a key role in this technology intensive business and is vital to support the product development programme which seeks to reduce time to market and increase responsiveness thus generating further business growth. To be successful you should be a high-energy engineer with organisational and interpersonal skills as well as mechanical understanding and analytical ability. You will have a consistent track record of product development within a medium volume environment where technical complexity is evident and be comfortable at all stages of the product cycle. Your motivational skills, drive and self-confidence will have been developed through exposure not just to your technical remit but also to the sharp end of customer accountability; in short an engineer who thrives on commercial and technical challenge. Additionally, you should have an honours degree in an engineering or science discipline - chartered status and/or a postgraduate qualification will be an added advantage - and be able to demonstrate a broad understanding of mechanical, electronic and software engineering, gained in a customer-orientated, market-led business. To apply please send your CV, together with a cover letter to our retained consultant kevin.mcmahon@wetherbyconsultants.com quoting reference 0908-107.

• Global Consultants • Universal Augers ad.qxp

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Mechanical Design Engineer £Competitive + Excellent Benefits

Cambridgeshire

Universal Augers is a manufacturing company based in Kimbolton, Cambridgeshire. It was established in its current form in 1990 and over the past 17 years has grown to have offices in Sydney, Singapore, Shanghai and Dubai. Universal now turns over in excess of £15,000,000 per annum. Universal's primary business is the design and manufacture of augers or drilling tools used in the construction industry along with all the accessories these tools require. There is also a quarrying and recycling business that deals in both high volume sales of consumables as well as one-off replacement parts for these industries. Universal's expanding manufacturing business requires support from a design team providing manufacturing drawings, assembly details, stress analysis, new design solutions, reverse engineering, Bill Of Material information and production tooling design. Our engineering team is technology led and uses the latest techniques to ensure Universal Augers remains at the forefront of auger development in the UK. The role is for a mechanical design engineer / draughtsperson who has experience of medium to heavy steel fabricated structures. The key skills we would require are: Fluent 3D CAD skills.We currently use Solidworks and would prefer candidates to also be skilled with this system. A good understanding of static analysis / FEA. Our current system is CosmosWorks. A proven track-record designing and detailing weldments, fabrications, castings and mechanical assemblies.We would prefer a candidate with HNC or degree level qualifications in a relevant field. The candidate will need good communication skills to be able to work with the members of the company in all disciplines to ensure that engineering information is provided at the right time, to the right people and in the right forms. The role allows the successful candidate the freedom to develop new skills and experience in many areas such as automation, MRP systems and Computer Aided Manufacturing as well as the core areas shown above. Universal Augers are able to offer an excellent employment package including healthcare and pension benefits to suitable candidates along with a modern, comfortable working environment and the freedom to develop a successful career. Please send your CV and covering letter to Simon Raglione-Hall. simon@universal-augers.com, or in writing to Universal Augers, Brook Road, Bicton Industrial Estate, Kimbolton, Cambridgeshire, PE28 0EY. For an informal discussion please call 01480 861440 Account Operator Operator Amends Job No.

Date

Client

Size

Media

1077724 1/10/08 Wetherby 125x180 www.universal-augers.com Consultant

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Professional Engineering

Handler

(Set by) Chris

(Last Amend) A

Ad set from master

Spell Checked

Yes

To advertise in this section please Contact Tony Baksh on 020 3355 7313 / tony@x3dmedia.com

8/10/08 23:04:22

APPOINTMENTS

OC Robotics (based in Bristol, UK) is the world leader in snake-arm robot R&D, design and manufacture. We have a unique product and an exciting future. We are growing quickly and need talented engineers to join our team. We work in aerospace, defence, nuclear and medical, although our technology is so ﬂexible in application that we could address almost any market sector.

Junior Software Developer

Senior Software Engineer

Mechanical Design Engineer

Salary: £22k - 28k

Salary: negotiable

A science or engineering graduate with strong software skills to design, implement and test software to control snake-arm robots.

An experienced software engineer to design, implement and test software to control snake-arm robots.

You must be able to demonstrate:

• Outstanding proven software development skills • Very good mathematics and physics background including numerical methods • Excellent ability to think in 3D • Excellent C/C++ with understanding of OOD/UML and real-time programming • Good written and verbal communication skills

An experienced mechanical design engineer with strong intuitive and analytical engineering skills to join our team, to take a lead design role in new snake-arm robot projects.

• Good software development skills including C/C++ • Very good mathematics or physics background, including numerical methods • Excellent ability to think in 3D • Good written and verbal communication skills

You must be able to demonstrate:

You must be able to demonstrate: • Proven mechanical engineering design skills • Excellent ability to think and design in 3D • Good written and verbal communication skills

For more information please visit www.ocrobotics.com/jobs DEVELOP3D OCTOBER 2008 65

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COMMENT

In the last month, we have all learnt a lot about the credit crunch, investment banks, multi-billion dollar rescue packages and bail-outs. While the long-term impact is unknown, most predictions seem bleak. Martyn Day asks if engineering firms will have to tighten their belts

am sure that, like me, you have been addicted to the news this last month, reading about the financial crisis that’s hit the planet. The numbers involved in the Wall Street bailout of $7billion, and billions in fees paid to shore up British banks and building societies, have been beyond my comprehension. It all makes paying £5 for a glass of wine in London seem pretty good value. We went from credit crunch and talk of recession to the financial equivalent of Armageddon in a matter of weeks, and now we are left trying to work out what the hell all this will mean looking forward. For that, you need to have some knowledge of how we reached this disaster point in the first place. Whenever I have trouble understanding ‘City things’, I always turn to my school friend, Wyn, who used to trade things called ‘Swaps’ and then moved into risk management. He trained as an engineer, being very good at maths and science, but got tempted by the dark side after graduating, heading for the bright lights and financial rewards of banking, rather than working on an oil rig. I remember about four or five years ago Wyn tried to explain to me how there was too much debt in the system, and how the whole of this CDO (Collateralised Debt Obligation) market was going to end in tears because nobody knew what they were worth and boards of banks didn’t understand their liabilities as the products were too complex. He also pointed out that most of the bankers he was meeting had never actually traded through a recession or been through a financial crisis. I think it’s fair to say that most have that experience now. Low interest rates over a long period of time, coupled with lax lending criteria, have enabled individuals and companies to leverage up the amount of debt they can take on, and this expansion in cash availability

 has fuelled some good times for us, our economies and bankers’ bonuses. This debt was packaged up and sold to all sorts of financial firms, and when the defaults started nobody knew who had what liability. The banks stopped trusting each other, refusing to trade with one another, leading to intervention by national governments. We don’t know how this rescue plan is going to play out or how much confidence these moves will bring, but the UK and the US have done a good job of nationalising a large proportion of the mortgage debt. Still, it’s likely that interest rates will go up and mortgages will suck even more money out of people’s expendable income, leading to further drops in demand for products. So what does all this mean? The banks’ appetite for lending money has gone and will not return for a long time, so engineering companies that have cash in the bank are in a good position, while those that have been debt-fuelled in the past will start finding it difficult. Already automotive manufacturers in the US have gone to the government and asked for access to $25billion in loans for new tooling as Wall Street doesn’t see them as a safe investment. Undoubtedly people are cutting back on their purchases at the moment and a brand new car, coupled with the current price of petrol, isn’t high on the list, so automotive will certainly see tough times. In the States, Chrysler has already stopped offering leased purchases. GM’s problems are well known: it announced a $10billion cost cutting plan and $5billion in asset sales to shore up its liquidity. We may well see some big automotive names vanish. But it’s not all bad news. Firms such as John Deere and Caterpillar have run their businesses cautiously, watching their cash flow and building assets. Many manufacturers have become more efficient users of capital. Engineering firms have followed companies like Toyota and reduced capital spending by

The biggest worry is the lack of investment that comes with tough times, but there’s no reason why this should inhibit innovation as there’s always a market for good ideas



getting rid of inventory and shrinking the floor space needed for production. The George W Bush war on terror has been good to most defense companies, which have significant amounts of cash on their balance sheets after several years of strong earnings. Profits have been fuelled by high-level Pentagon spending on Iraq and Afghanistan and new weapons programmes. That’s not to say a forecasted drop in demand isn’t going to hurt, but the primary reaction is mainly a reduction in expansion plans and delays on acquisitions. From the engineer’s perspective, recessions have always meant having to do more with less. Fortunately, as most software is on subscription these days, you will always have access to the latest and greatest tools. Being skilled in the use of any of the popular modeling and analysis tools makes you eminently employable as our industry has been facing a shortfall of engineers for many years. The only ‘IT casualties’ I know of so far have been in the back-offices of banks, of which there are now substantially fewer. The biggest worry is the lack of investment that comes with tough times, but there’s no reason why this should inhibit innovation as there’s always a market for good ideas. In conversations with my banking friend, discussing economic bubbles and Blair and Brown’s claims of ‘The end of boom and bust’ cycles, Wyn told me, “The only way to end boom and bust cycles is if you can get rid of greed – and I don’t know any way of doing that.” Despite what our procrastinating politicians choose to tell us, the backlash of greed has struck again. We will always have these cycles and we have to cope as best we can, however painful or brutal the next two or three years are. Martyn Day is currently suffering from Man Flu, and annoyed that he didn’t get to eat any gelato on a recent trip to Bologna. Not that he could afford it at the current exchange rate.

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6/10/08 20:36:39

Congratulations on winning three BTCC titles! Driver’s, Team’s and Manufacture’s - 888 Race Engineering do it again.

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Vauxhall’s British Touring Car team, VX Racing, has successfully secured all three championship titles (Driver’s Team’s and Manufacturer’s) at this weekends closing round of the HiQ MSA British Touring Car Championship (BTCC) at Brands Hatch. The championship winning VX Racing Vectras were designed by Triple Eight using ATI FireProTM Graphics Cards/AMD CPUs to help them on their way to this season’s success. © 2008 Advanced Micro Devices, Inc. All rights reserved. AMD, the AMD Arrow logo, ATI, the ATI logo, FireGL, FirePro and combinations thereof, are trademarks of Advanced Micro Devices, Inc. All other brand names, product names, or trademarks belong to their respective holders.