Friday, January 24, 2020

How to easily simplify a complex model of a pair of scissors

Sometimes it is possible to simplify a model that needs to be functional but doesn't need to be exactly the same as the actual one.
In this opportunity I choose a simple pair of scissors, which has some complexity in the uneven form of the handle

Final model of the Scissors
When using images to copy the form, it is difficult to draw intermediate sections, because no all sections will be visible from the photographs. That's where approximations come handy.

Inserted images to facilitate drawing from the real scissors
It would have been better if the side photo had a clearer background, but it is not really an issue.
As always, insert both images in paint, and adjust the size so you can save two images with the same relative size. Insert them in SolidWorks:

Create a drawing in a plane>Tools>Drawing Tools>Image

Then position both images, moving them "minus half the size" in each axis, if you want it centered:

Positioning the images relative to the origin

Then, is time to draw.
Create drawings following the limits of the image. Use splines if necessary. It is recommendable to draw each blade separately, so it can be treated as an assembly, and can be moved as in reality. If not, it will be a solid block.

TIP: you can draw one blade, then put it in a folder "Right Blade", suppress it and draw the second one. Then, you can save two different files, which only difference will be that one blade is suppressed in the first, and the other in the second. This allows for a unique file to modify, and the relative position between them will be easy to handle.

Separate in folders and suppress the one you don't want for the moment




 This model can be extruded pretty much from one drawing per blade. Perform different extrusion operations for every area drawn that you need to give volume to. Select the proper lenght for every extrusion.

Following  we see the basic drawing of the model. Use splines to adjust all curves, following the model. Take your time and use all necessary points to obtain a model that reflects reality.If splines get out of control, add more intermediate points or stop the spline and continue with another one from the ending of the first one.
 Simplifying the shape in the other planes, we can make a good approximation with little effort. The real model has organic curves difficult to copy from the picture.
Basic drawing of the model


TIP:Take into account that avoiding to select the holes in the extrusion will save you time. You won't need to perform an extruded cut later.

In the middle of the drawing+extruding part
Simplifying the extrusion of the handles by using a defined distance to extrude, makes the model much more easier. Coping the real form is a really difficult task, which has to be solved in a different way, to eliminate the problem of the photos, which don't show you the middle sections of the scissors.
(A different approach could be, measuring different points and drawing a line that passes through all those points)

As regards the Anti-Slip shape of the handles, it can give some trouble if done incorrectly.
It will obviously be done by a pattern, a pattern guided by the curve of the hole specifically.

Anti-slip feature
For the sake of simplification, we will draw a rectangle and then use the round feature to adjust the shape.
Start by defining a plane to extrude into the scissors. The position will be approximated by eye (how would you measure that?!)

Define a plane to draw the rectangular shape
TIP: don't define the plane from the inside of the handle and then extrude to the outside. Instead, draw the shape from the outside, and extrude it "to the next surface". Using the first method will probably give you model errors. (For example, I got parts painted black which were defined to be red. When drawn properly, this issue disappeared)

Use the second method to perform the extrusion of the antislip
Perform the matrix with the pattern operation. The direction will be the curve that defines the hole. In "operation and faces", select the extrusion and the round feature (you should round it before applying the matrix feature).
It is possible that you will need to use one matrix operation for every direction, to complete the total anti slip bands.

Matrix (pattern) operation to solve the anti slip bands
I didn't enter into detail in some features which are easy to perform and don't need any explanation to be understood (like the center pin, some rounding features, etc)

Now, you should apply the appearance of black and red plastic to give the same look as the original scissors. It usually can be selected from the menu on the right:

Appearance selection
If you want to experiment with the rendering option, try to search for the most realistic look possible.
The problem is if not done correctly, you can end with a shady, too lit or low contrast image like the following.
The rendering itself deserves a complete study to search for the best possible appearance
Comparing the result with the real scissors, we can conclude that it is not always necessary to make a complex modelling (like the one carried out in the post of the "Candy model") which implies to draw inner sections and guiding lines to use the "covering feature".
On the other hand, the color of the scissor and the selected material is not optimal. If you need the reality and the model to be exactly the same, pay special attention to rendering options.

The result is pretty similar to the obtained model


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