Crafting Custom Grips with xShape: A Pliers Redesign

This video shows how to use SOLIDWORKS xShape to create a custom finger grip for a pair of pliers. It demonstrates using existing geometry as a reference, manipulating surface shapes, and refining the design with symmetry. The process involves cutting the grip to fit perfectly and then integrating it into an assembly.

Key Takeaways

• xShape can reference existing geometry for design operations.
• The Net Surface Primitive is useful for creating shapes based on model edges.
• Symmetry can be enabled to mirror geometry and save design time.
• Surface offsets and the Combine feature are used for precise cutting and fitting.
• Designs created in xShape can be easily integrated into SOLIDWORKS assemblies.

Getting Started with the Pliers Assembly

We begin with a pair of pliers already assembled in xDesign. While it's possible to create new parts directly within an assembly, it's often simpler to work on individual components in their own environments. So, we'll save and close the current assembly to start fresh.

Referencing Existing Geometry

To make sure our new finger grip fits perfectly, we need to bring in the existing geometry of the pliers' handle. We'll insert the 'Handle for Pliers' part into our new design environment. This gives us a direct reference to work with.

Creating the Finger Grip with Net Surface

Now, we switch over to the xShape application. All parts in xShape start with a basic primitive shape. For this project, we'll use the Net Surface Primitive. This tool is great because it allows us to reference the edges of our imported handle geometry. We select two edges for the 'Profiles' and one edge for the 'Guides' where the finger grips will eventually sit. We set the divisions to three in one direction and eight in the other. This gives us nine nodes, which is enough to create distinct grooves for each finger.

To ensure the grip is symmetrical, we enable symmetry along the center plane. This automatically creates a mirrored set of nodes, saving us a lot of manual work. After this, we start shaping the primitive. The video zooms through the detailed manipulation steps, but the key is adjusting the nodes to form the desired finger grooves. Once we're happy with the overall shape, we accept the subdivision.

Cutting the Grip to Fit

The finger grip needs to fit snugly over the handle. To achieve this, we'll create a cutting surface based on the handle's geometry. First, we hide the subdivisional shape we just created. Then, we use the Offset command with a distance of zero. This effectively copies the faces of the handle that will be in contact with our grip. After selecting all the relevant faces, we click OK. We then hide the handle itself and show our subdivisional surface body again.

With the cutting surface ready, we use the Combine feature. We enable the 'Subtract' option and use our newly created surface to cut away the excess material from the finger grip. The result is a perfectly fitted grip.

Finalizing the Design in xDesign

We save and close the finger grip part. Then, we reopen the pliers assembly in xDesign. Now, we can insert our custom-made finger grip. We add the necessary mates to position it correctly and apply a 'Covering Material' to give it the right appearance. The process for creating a palm grip would follow a similar set of steps.

This method shows how xShape can be used to create complex, organic shapes that still integrate precisely with existing parametric designs, offering a powerful way to customize products.