Undercut detection in Solidworks - Dashboard Guide

Dashboard Mode - Undercut detection

Goal

Identify and analyze undercuts in 3D part designs to improve manufacturability and reduce production issues.

Sample Data

Feature ID	Feature Type	Depth (mm)	Area (mm²)	Undercut Present	Severity Level
F001	Slot	5	120	Yes	High
F002	Hole	3	45	No	None
F003	Groove	7	80	Yes	Medium
F004	Boss	2	30	No	None
F005	Cutout	6	100	Yes	High
F006	Chamfer	1	20	No	None

Dashboard Components

• KPI Card: Total Features with Undercuts
  Formula: COUNTROWS(FILTER(Data, Data[Undercut Present] = "Yes"))
  Result: 3
• KPI Card: Average Undercut Depth (mm)
  Formula: AVERAGEX(FILTER(Data, Data[Undercut Present] = "Yes"), Data[Depth (mm)])
  Result: 6 (calculated as (5+7+6)/3)
• Bar Chart: Undercut Severity Count
  Shows count of features by Severity Level (High, Medium, None)
  Data: High=2, Medium=1, None=3
• Table: Detailed Features with Undercuts
  Columns: Feature ID, Feature Type, Depth (mm), Area (mm²), Severity Level
  Rows: Only features where Undercut Present = Yes (F001, F003, F005)

Dashboard Layout

+----------------------+----------------------+
|  KPI: Total Undercuts | KPI: Avg Undercut Depth |
+----------------------+----------------------+
|                      Bar Chart: Undercut Severity Count           |
+---------------------------------------------------------------+
|                      Table: Features with Undercuts             |
+---------------------------------------------------------------+

Interactivity

A filter for Severity Level allows users to select High, Medium, or None. When a severity is selected:

• KPI cards update to reflect counts and averages only for selected severity.
• Bar chart highlights the selected severity.
• Table filters to show only features matching the selected severity.

Self Check

If you add a filter for Severity Level = High, which components update?

• KPI cards show total undercuts and average depth only for High severity (2 features, average depth 5.5 mm).
• Bar chart highlights the High severity bar.
• Table shows only features F001 and F005.

Key Result

Dashboard shows undercut features in part designs with counts, average depth, severity distribution, and detailed feature list.

Practice

1. What is the main purpose of undercut detection in SolidWorks molding design?

easy

A. To find areas that may cause problems during mold release

B. To calculate the weight of the molded part

C. To determine the color of the plastic material

D. To measure the surface roughness of the mold

Solution

1. Step 1: Understand undercut detection purpose

   Undercut detection identifies areas that can trap the part in the mold.

2. Step 2: Relate to molding process

   These problem areas affect mold release and manufacturing quality.

3. Final Answer:

   To find areas that may cause problems during mold release -> Option A

4. Quick Check:

   Undercut detection = problem areas in molding [OK]

Hint: Think about what stops a part from coming out of a mold [OK]

Common Mistakes:

• Confusing undercut detection with weight calculation
• Thinking it measures color or surface finish
• Assuming it checks material properties

2. Which step is essential before running undercut detection in SolidWorks?

easy

A. Adding fillets to all edges

B. Applying a texture to the model

C. Changing the color of the part

D. Setting the correct pull direction

Solution

1. Step 1: Identify key setup for undercut detection

   The pull direction defines how the mold opens and affects detection results.

2. Step 2: Understand impact of pull direction

   Incorrect pull direction leads to wrong undercut identification.

3. Final Answer:

   Setting the correct pull direction -> Option D

4. Quick Check:

   Pull direction setup = correct undercut detection [OK]

Hint: Always set pull direction before checking undercuts [OK]

Common Mistakes:

• Skipping pull direction setup
• Confusing texture or color with detection setup
• Thinking fillets affect undercut detection directly

3. Given a part with a pull direction set incorrectly, what is the likely output of the undercut detection tool?

medium

A. The tool crashes with an error

B. All edges flagged as undercuts

C. No undercuts detected even if they exist

D. Undercuts detected only on flat surfaces

Solution

1. Step 1: Analyze effect of wrong pull direction

   Wrong pull direction means the tool looks from the wrong angle.

2. Step 2: Predict detection result

   It misses real undercuts, showing none detected.

3. Final Answer:

   No undercuts detected even if they exist -> Option C

4. Quick Check:

   Wrong pull direction = missed undercuts [OK]

Hint: Wrong pull direction hides real undercuts [OK]

Common Mistakes:

• Assuming tool crashes on wrong pull direction
• Thinking all edges get flagged
• Believing detection only works on flat surfaces

4. You ran undercut detection but the results seem incorrect. Which of the following is the most likely cause?

medium

A. The pull direction was not set properly

B. The part color was changed after detection

C. The model has no fillets

D. The software version is outdated

Solution

1. Step 1: Identify common error in detection setup

   Incorrect pull direction is the main cause of wrong undercut results.

2. Step 2: Eliminate unrelated causes

   Color changes, fillets, or software version usually do not affect detection output directly.

3. Final Answer:

   The pull direction was not set properly -> Option A

4. Quick Check:

   Incorrect pull direction = wrong detection results [OK]

Hint: Check pull direction first when results look wrong [OK]

Common Mistakes:

• Blaming color or fillets for detection errors
• Ignoring pull direction setup
• Assuming software version causes detection errors

5. You have a complex molded part with multiple undercuts. How can you use SolidWorks undercut detection to improve your design for manufacturing?

hard

A. Ignore undercuts and rely on manual inspection only

B. Set the correct pull direction, identify undercuts, then modify design to remove or reduce them

C. Change the part color to highlight problem areas

D. Add fillets to all edges without checking undercuts

Solution

1. Step 1: Use undercut detection properly

   Set the pull direction correctly to get accurate undercut locations.

2. Step 2: Modify design based on detection

   Adjust or remove undercuts to ease mold release and reduce manufacturing issues.

3. Step 3: Avoid ineffective actions

   Ignoring undercuts or just changing colors does not solve molding problems.

4. Final Answer:

   Set the correct pull direction, identify undercuts, then modify design to remove or reduce them -> Option B

5. Quick Check:

   Correct pull direction + design changes = better molding [OK]

Hint: Detect undercuts, then redesign to avoid molding problems [OK]

Common Mistakes:

• Ignoring undercuts in design process
• Thinking color changes fix molding issues
• Adding fillets without checking undercuts