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Converting 2D to 3D CAD typically involves importing 2D geometry into a 3D CAD program file. Importing is commonly done with IGES (Initial Graphics Exchange Specification) files or AutoCAD's DXF (Drawing Exchange Format). Once imported, 2D sections can be given volume by: 1.) extruding a section to a fixed dimension, 2.) revolving a section around an axis, 3.) sweeping a section along a trajectory, or 4.) sweeping and blending multiple sections along multiple trajectories. Once a solid model form is enclosed it can be shelled which means that volume is removed by offsetting the outer surface by some dimension resulting in a thin wall part. This makes the part suitable for casting or molding by some process for metal or plastic manufacturing. A professional CAD designer or engineer will apply drafts and corner radii appropriate for a particular manufacturing process. This expertise is not to be underestimated as design for manufacturing and assembly (DMFA) is the most valuable contribution of the professional CAD designer or engineer. The results of a job well done is quality parts delivered on-time and at the right price whereas failure to employ properly trained and experienced professionals may save the developer money on the front end but cost the developer dearly on the delivery end for error corrections and rework, cost overruns, and schedule delays. [read more]

Manual repair can be tedious. A number of tools can be tried that include modifying edges by moving vertices, straightening crooked boundaries, merging edges, setting tangencies, and dividing boundary curves. New edges can be created by projecting curves onto good surfaces, forcing curves to connect, trimming newly created curves on surfaces, and creating straight lines to replace crooked lines. After these operations are employed zip gaps can be reapplied with probability of greater success. If after all of these tools have failed to remove remaining gaps the next step is to remove the problem surface and create a new one. Removal of a surface can be achieve in the repair tools or by using a surface trim command which involves selecting the boundaries of the problem surface for the trim definition. In the worst case when the data poses excessive boundary repair problems offering at best poor surface data integrity then the last resort is to remodel the part using the imported geometry as data reference only. [read more]