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What are the best ways to create complex curves in SolidWorks?

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SolidWorks is a powerful CAD software that allows you to create realistic 3D models of various products and designs. However, one of the challenges that many industrial designers face is how to create complex curves that are smooth, accurate, and aesthetically pleasing. In this article, you will learn some of the best ways to create complex curves in SolidWorks, using different tools and techniques that can help you achieve your desired results.

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Philippe Guichard

Transforming Ideas into Million-Dollar Products & ventures: the designer serial entrepreneurs partner with | Talk on…
Fynn Eckstein

Innovatives Design für eine nachhaltige Zukunft

1 Sketching Curves

The first step to create complex curves in SolidWorks is to sketch them on a plane or a surface. You can use different sketch entities, such as lines, arcs, splines, and ellipses, to define the shape and direction of your curve. You can also use sketch relations, such as tangent, parallel, perpendicular, and equal, to control the behavior and alignment of your curve. To modify the curvature of your sketch entities, you can use the handles, dimensions, and constraints that appear when you select them.

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Sergio Gedanke
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In my experience, the more control lines ("guide lines") you add across the two leading sections the better. As rule of thumb, I try to cover most of my complex surfaces using loft + guidelines across areas that need tangency and continuity. A good second option is using fill tool which is a great option for more complex transitions and blends between separate sections of an object.

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Rediat Fikru

Industrial drawer at BGI Ethiopia
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Generally speaking, it is advisable to put as many control lines (also known as "guide lines") as possible between the two leading parts. Generally speaking, I attempt to use loft + guidelines to cover the majority of my complicated surfaces across areas that require tangency and continuity. The fill tool, which works well for more intricate mixes and transitions between distinct portions of an item, is a fantastic second option.

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2 Using the Curve Command

The curve command is a useful tool that allows you to create complex curves from various sources, such as sketches, edges, points, and equations. You can access the curve command from the features tab or the tools menu. You can choose from four types of curves: projected, composite, helix/spiral, and equation driven. Each type of curve has its own options and parameters that you can adjust to fit your design needs. For example, you can use the projected curve to create a curve that follows the projection of a sketch onto a surface or a plane.

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3 Creating 3D Sketches

Another way to create complex curves in SolidWorks is to use 3D sketches. Unlike 2D sketches, 3D sketches allow you to draw in any direction and orientation in the 3D space. You can use 3D sketches to create curves that are not constrained by a single plane or surface. You can also use 3D sketches to create curves that cross multiple planes or surfaces. To create a 3D sketch, you can either select the 3D sketch option from the sketch tab or the tools menu, or you can start a 2D sketch and then press the tab key to switch to 3D mode.

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Philippe Guichard

Transforming Ideas into Million-Dollar Products & ventures: the designer serial entrepreneurs partner with | Talk on TED.com | Product Development & Product Design | Bestselling Author & Keynote Speaker
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I like to use 3D sketches for organic shapes (I have been working on chairs and seats lately) with the control of surfaces so that I can apply manufacturing constraints at the same time (such as draft for injection moulding).

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4 Applying Fillets and Chamfers

Fillets and chamfers are features that can help you create complex curves by rounding or beveling the edges of your model. You can apply fillets and chamfers to your model after you have created the basic shape and dimensions. You can access the fillet and chamfer commands from the features tab or the tools menu. You can choose from different types of fillets and chamfers, such as constant radius, variable radius, face fillet, full round fillet, and angle distance chamfer. You can also specify the radius, angle, distance, and options for your fillets and chamfers.

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5 Using the Flex Feature

The flex feature is a powerful tool that allows you to create complex curves by bending, twisting, tapering, or stretching your model. You can use the flex feature to create organic shapes and forms that are difficult to achieve with other tools. You can access the flex feature from the features tab or the tools menu. You can choose from four modes of flex: bending, twisting, tapering, and stretching. Each mode has its own parameters and options that you can adjust to deform your model. You can also use multiple flex features to create more complex curves.

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6 Experimenting with Different Tools and Techniques

The last way to create complex curves in SolidWorks is to experiment with different tools and techniques that suit your design goals and preferences. There is no single or best way to create complex curves, as different designs may require different approaches and solutions. You can try combining different tools and techniques, such as using splines and projected curves, or using fillets and flex features, to create unique and interesting curves. You can also use reference geometry, such as planes, axes, and points, to help you create and manipulate your curves. The key is to be creative and flexible, and to have fun with your design process.

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Fynn Eckstein

Innovatives Design für eine nachhaltige Zukunft
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In SolidWorks, I found complex surface curve modeling highly effective, especially when blending two curves. A standout technique was projecting a curve onto a linear surface extrusion. This method ensures precision and versatility in design. Using design splines, particularly smooth and higher degree splines, significantly enhances the fluidity and complexity of the models, allowing for more intricate and detailed designs

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Dan Phillips

10+ Yrs Expertise in Product & Industrial Design | Specialised in Industrial Design & Engineering | Advocate for Ai in design
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There are so many ways to create complex curves and solidworks can be a great tool for for creating complex but controllable geometry. As an alternative to the above you could create complex curves using intersecting surfaces, for example, a boundary surface intersected by an extruded surface profile. Mutual trim to retain the edge you were trying to create and convert the edge into a 3D sketch. ...maybe not the most straightforward but really easy to manipulate.

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What are the best ways to create complex curves in SolidWorks?

1

2

3

4

5

6

7

1 Sketching Curves

2 Using the Curve Command

3 Creating 3D Sketches

4 Applying Fillets and Chamfers

5 Using the Flex Feature

6 Experimenting with Different Tools and Techniques

7 Here’s what else to consider

Industrial Design

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What are the best ways to create complex curves in SolidWorks?

1

2

3

4

5

6

7

1 Sketching Curves

2 Using the Curve Command

3 Creating 3D Sketches

4 Applying Fillets and Chamfers

5 Using the Flex Feature

6 Experimenting with Different Tools and Techniques

7 Here’s what else to consider

Industrial Design

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