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I prefer .SAT/ACIS because it's Calypso's native model software and when it comes to complex features it seems to sharpen up better than step. But I also happen to create a lot of models myself in Solidworks so I don't often see the problems I have in the past in regard to IGES & STEP
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I have this same problem. Normally I'll export STEP files out of our CAD software because the SAT support is very old and has trashed the geometry before. Thankfully, I run them through an intermediate program for some fixture work and that program natively supports the SAT format.
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Whatever cad model im given is fine i guess, but from my experience i always heal the model but NEVER click the 'Build Geometry' box.
I had a group of parts in a family, say 10 in a row out of 100 that the outer profile shifted by about .005 inch after healing with build geometry. That caused about 2 days downtime because the part was difficult to hard check with manual tools. Only after roughing out a program with THE RIVAL CMM, it checked nearly perfect for that dim. so i got to poking around on the cad model and found some distances were wrong, so i contacted engineering and they confirmed their model was NOT wonky, and Rival CMM model wasn't wonky, and when i loaded a new model in it was true and straight.
When i healed the new model it was still ok, but when i healed it with Build Geometry it moved.
So long story short, i will personally never use build geometry again.
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If you are programming without a CAD model and want to quickly set your clearance planes, then use "build geometry" and it will then let you use the "clearance planes from CAD model" button. This isn't my idea, I stole it from someone on here, but it works great and I love it.
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