Best Practices for Fixing Solidworks Import Errors
Written by
Jason Lichtman

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On
June 3, 2016
In
Design

If you’re like most Solidworks users, you probably collaborate with other people on projects. Generally speaking, that’s a good thing. After all, two heads are better than one, right? However, not everyone uses Solidworks, so the people you collaborate with likely end up sending you files with extensions like IGES, STEP,  X_T, etc.

You import whatever files were sent to you and then see what appears to be a huge problem: The file you imported has a dozen or more errors. Sound familiar? This has been a recurring theme throughout my career and is one of the most frustrating things that comes up over and over again.

Here are a few best practices for fixing Solidworks import errors, so you can spend more time designing and a lot less time fixing errors.

Best Practices for Dealing with Solidworks Import Errors

The best practices discussed in this article are broken up into a quick & dirty strategy, as well as a much more thorough, deep-dive strategy. I recommend starting with the quick & dirty approach and escalating to the deep-dive approach if needed.

Note: The content discussed from here on out is highly technical and uses a lot of jargon. If you aren’t familiar with a command that I discuss, please refer to the glossary at the end of the article for more information. If that still isn’t enough, type the name of the command into the search bar in the top right corner of Solidworks. It will bring up a lot more information about the command than I can fit into this article.

Quick & Dirty Strategy

1) The Magical “Attempt to Heal All” Button

Solidworks has a built-in Import Diagnostics wizard that will assess imported geometry and sometimes fix it for you. The tool is quite powerful and should not be overlooked. If the wizard does not pop up automatically when you import geometry, you can open the wizard by clicking: Tools > Import Diagnostics. The icon looks like this:

Import Diagnostics Wizard - Icon.jpg

The wizard will list all “faulty faces” (they are exactly what they sound like) and “gaps between faces”, which are basically missing surfaces or holes in your model. Once open, the wizard may look like this:

Import Diagnostics Wizard Showing Errors.jpg

Note: If you are intentionally importing a surface body (a body that is not completely enclosed and therefore “solid”, the surface’s boundary will come up as a “gap”. In that case, you can ignore that particular gap.

Once this wizard lists all of the errors, it gives you the option to “Attempt to Heal All”, “Attempt to Heal All Faces”, or “Attempt to Heal All Gaps”. Try these and watch as most, if not all, of your errors are resolved for you quite painlessly. If all goes well, the wizard will ultimately look like this:

Import Diagnostics Wizard with Everything Fixed.jpg

2) Decide for Yourself if You Can Ignore the Errors

If you have tried out the Import Diagnostics wizard and have not had success, you should ask yourself, “What am I going to do with this CAD model?” If you only plan on reviewing it, don’t waste your time trying to fix it. You can put a CAD model into an assembly and overlay it against other parts for comparisons, etc., without ever fixing the import errors. However, if you will ever be making design changes to that CAD model, OR you are using the CAD model as is for 3D printing or cutting molds, fix those errors right away!

3) Try to Have the File Re-Sent to You in Another Format

Import errors are often caused by translating the content of a file from one 3D modeling program’s behind-the-scenes coding language to another’s. Some of these programming languages translate more accurately between each other than they do with others. The same is true with spoken language, as well. It might be easier, for example, to translate a Spanish phrase or joke into Italian, instead of into Russian, because those languages have similar roots. In this case, Spanish and Italian are Romance languages, while Russian is a Slavic language.

In light of the above, consider asking the person who sent you the file to resend you a file type that is more compatible with Solidworks. The same geometry imported through a different file type may import into Solidworks with no errors at all, OR with errors that are easily fixed with the Import Diagnostics wizard.

In my experience, parasolid files (*.X_T) import the best into Solidworks, followed somewhat closely by STEP files. IGES is perhaps the most universal 3D file type. It was created in the late 70’s (you read that right) and is shared by almost all 3D modeling programs created since then. In my personal experience, however, IGES files tend to produce the most errors. So, despite the widespread use of IGES files, I try to avoid importing them whenever possible.

4) Can Someone Else Do This for You?

The next thing you should ask yourself is, “Can someone else do this for me?” Consider asking an intern to do the error-fixing work for you, so you can maximize the utility of your time and provide valuable experience for the intern. In my opinion, one of the best ways to become a Solidworks surface modeling pro is to spend time fixing surface errors.

For other tips & tricks for becoming a Solidworks pro, read 4 Tips & Tricks to Become a Solidworks Pro.

Deep-Dive Strategy

If you’ve tried all of the steps in the quick & dirty strategy for fixing Solidworks import errors, and you’re still seeing errors on your screen, it’s time to dig deep to clean up your CAD model. Keep your head high and try the following methods to fix your part:

1) If Your Part is Symmetric, Cut Your Part in Half BEFORE Trying to Fix Errors

Why do twice the work, when you could do half instead?

  • If your part shows up as a surface, use the Trim Surface command (Insert > Surface > Trim)  to cut it in half using the symmetry plane.
Trim Surface - Icon.jpg
  • If your part shows up as a solid, use the Cut with Surface command (Insert > Cut > with Surface) to cut it in half using the symmetry plane.
Cut with Surface - Icon.jpg

In some cases, the error within the file is serious enough that Solidworks will not let you cut the part in half. This can be super frustrating. Here are some strategies that you should try, in my personal order of preference:

  1. Create a new Reference Plane that is slightly offset from the correct symmetry plane. Use the new Reference Plane to trim your error-filled surface, or cut your error-filled solid nearly in half, making sure that you keep the slightly bigger side. Good enough.
  2. Delete every face on one side of the part. For any face that crosses the symmetry plane, either don’t delete it at all (consider where you are to be good enough), OR apply the Split Line command to split it on the symmetry plane. Then, delete the half of the split face that you don’t want.
  3. Offset every error-free face on one side of the part by 0mm and then use the Delete Body command on the original solid or surface.
  4. Although offsetting one half of the model achieves the same result as deleting one half of your model, this method is much less ideal because it is much less likely to work. When you are offsetting faces, if you miss certain faces OR pick a face that contains a hidden error, the command might not even complete. This method is the last resort for cutting your model in half and takes the most amount of time to successfully complete.

Method #2 for cutting my part in half is by far my most commonly used, based on practical experience. It does come with a little-known tip:

In many cases, you will try to use the Delete Face command (Insert > Face > Delete) with the option set to “delete”, and the command itself won’t work on your model. In fact, it won’t let you delete ANY of your model’s faces. Not even one! That’s crazy!

Delete Face - Icon.jpg

Here is the workaround:

Use the Delete Face command (Insert > Face > Delete), with the option set to “Delete and Fill”, as shown below. 

Delete Face - Icon.jpg

Now, choose a single face from your model at random. Nine times out of ten, the command will work, and it will replace that face with some weirdly shaped surface. Ignore the new surface. Now, try the Delete Face command again, on whatever face you want, using the “Delete” option. Now, it will allow you to delete the face(s) Solidworks wouldn't let you delete before. Does this make any sense? Of course not, but this method does work on some versions of Solidworks. Try it out for yourself and see if this workaround works for you!

Delete Face and Fill.jpg

2) Rerun the Import Diagnostics Wizard on Half the Model

As mentioned at the beginning of this article, the Import Diagnostics wizard is an excellent tool for fixing import errors. However, the Import Diagnostics wizard will only work on NEWLY imported geometry. Once you add commands to the feature tree, the Import Diagnostics wizard will grey itself out and become unavailable. If you have made changes to your part (including cutting or trimming your part in half) and would like to re-run the Import Diagnostics Wizard, save your updated part as a parasolid (*.X_T) and then delete all of the features in your feature tree, OR start a new Solidworks part file. Now, import the parasolid you created.

Note: You can import parasolid files into an already open Solidworks part by using Insert > Feature > Imported.

Since the newly imported geometry will be the only feature in your feature tree, the Import Diagnostics wizard will be available to you again. So, re-run the Import Diagnostics wizard and use the “Attempt to Heal All” button.

3) Delete any Remaining Problematic Faces and Fill them Back in

If you are still getting a few faces that are showing up with errors, delete them. They’re not worth it. You can fill them in using a variety of tools, such as Filled Surface (Insert > Surface > Filled),

Filled Surface - Icon.jpg

 Surface Loft (Insert > Surface > Loft),

Lofted Surface - Icon.jpg

and Boundary Surface (Insert > Surface > Boundary Surface).

Boundary Surface - icon.jpg

 Having a surface that is off by 0.005mm is still better than one that has a geometry error in it that will keep giving you headaches down the line.

Notes:

  • If you’re already in the Import Diagnostics wizard, you can right click on the problematic face within the list of problematic faces and choose “Delete”.
  • Otherwise, you can use the Delete Face command (Insert > Face > Delete), with the option set to “Delete”.
Delete Face - Icon.jpg

4) Save Your File as a Different File Type and Then Re-Import it

This is my absolute last resort. I cannot stress that enough. When I encounter a geometry error that simply won’t go away, no matter what I do, one of my last options is to save that geometry as an IGES file and try importing it again. I already explained that IGES files tend to not translate well into Solidworks. In this case, you’re hoping for a translation mistake from Solidworks into IGES and/or from IGES back into Solidworks. 

You’re hoping that a translation mistake could end up being a good thing. How? You’re hoping that the new set of faulty faces and/or gaps are more easily fixed by the Import Diagnostics wizard than the original errors were to begin with. This sounds crazy, and it is. That’s why this is the last resort. Believe it or not, this does sometimes work. Thankfully, I rarely have to try it out.

Summing Things Up

We’d all like to spend more time designing and less time fixing errors. This article provides several strategies for fixing import errors in Solidworks, when you import non-native files. Remember to use the Import Diagnostics wizard to your advantage, ideally on only half of your symmetrical model. 

Also, don’t forget that you can use the Import Diagnostics wizard, even after you have manipulated a CAD model, if you follow the proper steps. Now that you know the best practices for dealing with import errors, share what you’ve learned with your friends, and try the best practices out yourself. And don’t forget, as Dale Carnegie once said, “Knowledge isn’t power until it is applied.”

Glossary of Solidworks Commands

  • To create a new Reference Plane, use the Reference Plane command (Insert > Reference Geometry > Plane)
Reference Plane - Icon.jpg
  • To trim a surface with a Plane, use the Surface Trim command (Insert > Surface > Trim)
Trim Surface - Icon.jpg
  • To cut a solid using a Plane, use the Cut with Surface command (Insert > Cut > with Surface)
Cut with Surface - Icon.jpg
  • To offset faces of a surface or solid, use the Surface Offset command (Insert > Surface > Offset) and set the offset distance to 0
Surface Offset - Icon.jpg
  • To split a face using a plane, use the Split Line command (Insert > Curve > Split) and choose the option for Intersection
Split Line - Icon.jpg
Split Line - Option for Intersection.jpg
  • To delete an entire surface or solid, use the Delete/Keep Bodies command (Insert > Features > Delete/Keep Body)
Delete or Keep Body - Icon.jpg
  • To delete faces of a surface or solid without filling in the resulting hole, use the Delete Face command (Insert > Face > Delete) and set the option to “Delete”
Delete Face - Icon.jpg
Delete Face and Don't Replace.jpg
  • To delete faces of a surface or solid and automatically fill in the deleted face(s), use the Delete Face command (Insert > Face > Delete), and set the option to “Delete and Fill”
Delete Face - Icon.jpg
Delete Face and Fill.jpg
Written by
Jason Lichtman
Professional product design and development consultant with a specialty in plastic consumer products, especially for injection molding.
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