Best Practices for Generating Developed Sections in AutoCAD/BricsCADGenerating accurate developed (flattened) sections from 3D models is a frequent requirement in sheet-metal design, ductwork, piping transitions, and architectural detailing. Both AutoCAD and BricsCAD provide tools to create developed sections, but workflows, commands, and best practices differ slightly between them. This article presents a practical, step-by-step approach to creating reliable developed sections, with tips to avoid common pitfalls and to speed up repeated tasks.
What is a developed section?
A developed section (also called a flattened or unfolded section) is a 2D representation of a 3D curved or bent surface laid flat without distortion of true lengths along the surface. It’s essential for producing cutting patterns, CNC nesting, and fabrication drawings where material must be cut and bent or rolled.
Key requirements for a usable developed section:
- True-length measurements along the surface
- Accurate seam and bend locations
- Allowance for material thickness, bend radii, and seams
- Clear labeling for fabrication (dimensions, notes, grain direction, etc.)
When to use AutoCAD vs. BricsCAD
- AutoCAD: industry-standard with strong integration to manufacturing toolsets (e.g., Inventor, AutoCAD Sheet Metal) and wide third-party plugin support.
- BricsCAD: cost-effective, similar command set, and native Sheet Metal tools that offer both direct-modeling and sheet-metal-specific workflows which can sometimes simplify unfolding tasks.
Choose based on available licenses, team familiarity, and whether you need native sheet-metal functions or will rely on 3D solids/surfaces and manual flattening.
Prepare your model: modeling best practices
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Model intent
- Model the part as a single solid or consistent set of solids/surfaces where possible.
- For sheet-metal, use dedicated sheet-metal features (flanges, hems) when available.
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Clean geometry
- Remove duplicate faces, tiny slivers, and internal geometry.
- Ensure edges intended as seams are single, continuous edges.
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Material thickness and bend radii
- Model actual thickness and an accurate bend radius or use a neutral-factor approach for bends if your software supports it.
- Decide whether to flatten the neutral surface or the outer/inner surface and be consistent.
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Seams and split lines
- Plan seam locations where cutting/welding will occur.
- Use split/trim tools to define clear boundary edges for unfolding.
AutoCAD: workflows and recommended commands
AutoCAD does not include a full native sheet-metal unfold tool in the core product; however, there are several approaches:
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AutoCAD + Inventor or AutoCAD Mechanical/Sheet Metal Toolsets
- Best for complex sheet-metal parts. Model in Inventor or use the Sheet Metal toolset and run the Unfold/Flat-Pattern feature.
- Export flat pattern back to AutoCAD as DXF/DWG for documentation.
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Using 3D solids and custom flattening routines
- For simple tapered or development-friendly surfaces, use:
- FLATSHOT (creates 2D projection views) — not a true development but useful for simple patterns.
- MAPEXPORT or manual projection to create patterns from 3D geometry.
- For conical/frustum developments, calculate true lengths using basic trigonometry and spline/line tools.
- For simple tapered or development-friendly surfaces, use:
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Third-party apps and LISP
- Consider industry plugins or LISP routines specialized for developed sections and pattern generation.
AutoCAD practical tips:
- Keep a separate layer for developed patterns.
- Annotate bend allowance/allowance notes generated from your calculation method (K-factor, bend allowance tables).
- Use dynamic blocks for standard flanges and tabs to speed repetitive parts.
BricsCAD: native sheet-metal tools and workflows
BricsCAD’s Sheet Metal module streamlines many developed-section workflows:
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Create sheet-metal parts
- Use the Sheet Metal environment to create faces, flanges, and bends. BricsCAD maintains sheet-metal-specific properties (thickness, bend radius, K-factor).
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Use Unfold/Flatten
- The UNFOLD or FLATTEN command in BricsCAD Sheet Metal creates accurate developed sections automatically, including bend allowances and cut-line placement.
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Modify and export
- Edit seams, add reliefs, or flatten multiple bodies. Export flat patterns as DWG/DXF for CNC nesting or fabrication.
BricsCAD practical tips:
- Set material, thickness, and bend parameters accurately before unfolding.
- Use the “Create Flat Pattern” feature to generate a drawing view linked to the model—update propagates if the model changes.
- For complex rolled surfaces, consider approximating with small facets or using sheet-metal tools to model as a series of bends.
Unfolding complex shapes: strategies
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Break into simpler sections
- Split a complex shell into logical panels that can be unfolded individually and then joined in the flat layout.
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Use true-curve developments
- For conical or ruled surfaces, compute generator lines and their developed lengths. Use parametric equations or CAD tools that support true-curve development.
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Approximate when necessary
- When precise development is impossible or impractical (e.g., double-curved surfaces), approximate by patterning with small facets or use specialized software (e.g., paneling tools, finite element flattening).
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Compensate for thickness and bend relaxation
- Apply K-factor, bend allowance, or empirical corrections based on material testing.
Dimensioning and documentation for fabrication
- Show bend lines, seam lines, and relief cuts clearly.
- Indicate bend direction, bend angles, and where the datum is taken.
- Provide material specs, thickness, and surface finish.
- Include grain direction for anisotropic materials.
- For CNC, export DXF with clean polylines and no overlapping entities.
Common pitfalls and how to avoid them
- Inaccurate seams: Ensure seam edges are continuous and aligned with intended cuts.
- Ignoring thickness: Model and account for material thickness and bend radii.
- Over-reliance on projections: FLATSHOT and similar projection tools do not produce true developed patterns for many shapes.
- Mismatched units/scale: Verify units before exporting DXF for CNC.
- Unclean export files: Remove stray geometry, layers, and zero-length entities.
Automation and templates
- Create templates with layers, dimension styles, and title blocks for flat patterns.
- Use parametric features or dynamic blocks for repeatable flange sizes and tabs.
- Implement scripts or LISP routines (AutoCAD) and parametric tools (BricsCAD) to batch-generate flat patterns.
Quick checklist before sending to fabrication
- Material, thickness, and bend radii specified.
- Flat pattern validated against model dimensions.
- Bend allowances and K-factors noted.
- Seam and relief locations shown.
- Exported file cleaned (single closed polyline per cut edge).
- Nesting/layout optimized for material usage.
Conclusion
Generating reliable developed sections requires upfront planning: clean geometry, correct material/bend parameters, and choosing the right tool for the complexity of the part. Use BricsCAD’s native sheet-metal tools for an integrated flattening workflow when available; use AutoCAD with Inventor or third-party plugins for complex industrial sheet-metal workflows. Consistent templates, clean exports, and clear fabrication notes will reduce errors and speed production.
If you want, I can:
- Provide a step-by-step BricsCAD Sheet Metal unfold example with screenshots (if you can upload a model or allow images).
- Create AutoCAD LISP snippets for simple conical developments.