SolidWorks Sheet Metal: Why Holes Become Ellipses in the Flat Pattern (and the Fix)

When you cut a hole on a bent face in SolidWorks, you get a circular feature in 3D. When you flatten the part, that same hole can appear as an ellipse in the flat pattern — and that ellipse is what gets exported to your DXF and sent to the laser cutter. The laser punches an ellipse. Your hole doesn’t fit the fastener. This isn’t a bug. It’s geometry. But the fix is straightforward once you understand what’s happening. ...

26 June 2026 · 7 min · CadShift

STEP Files Can't Carry K-Factor — Why Your Flat Pattern Is Wrong After Import

A fabricator opens your STEP file. They run Insert Bends. SolidWorks creates a flat pattern. The dimensions are wrong. Not slightly wrong — off by several millimetres on every bend. Enough to cause rework. Enough to get a call from the shop floor. The reason is that STEP files don’t carry k-factor data. They never did. Understanding why, and what to do about it, is the difference between a clean handoff and a rebuild. ...

24 June 2026 · 7 min · CadShift

Cloud CAD Limitations — Large Assembly Performance, Data Sovereignty, and When Desktop Wins

The cloud CAD pitch is straightforward: access your designs from anywhere, collaborate in real time, no IT overhead for file servers. For small teams working on straightforward product designs, it largely delivers on that promise. But engineering teams hitting cloud CAD limits don’t usually fail on the simple cases. They fail six months into a project when assembly component counts exceed the comfortable range, or when a compliance audit asks where the design data is physically stored, or when an engineer needs to work on-site at a customer facility with unreliable internet and the tool won’t load. ...

23 June 2026 · 11 min · CadShift

STEP AP203 vs AP214 vs AP242 — Which Version to Send Your Supplier (and the AP242 PMI Trap)

When SolidWorks shows you the Save As dialog, three STEP variants appear in the dropdown: AP203, AP214, and AP242. Most engineers pick one, never change it, and assume the output is correct. Sometimes it is. Sometimes half the data you expected to transfer isn’t in the file at all, and you find out when the supplier calls. This post explains what each version actually carries, what SolidWorks and Inventor write for each, and which one to choose based on what your recipient needs on the other end. ...

22 June 2026 · 8 min · CadShift

QGIS Buffer Wrong Size on EPSG:4326 — Euclidean vs Geodesic Fix and Projection Guide

TL;DR: If your QGIS buffer is the wrong size, your CRS is EPSG:4326 (degrees) — switch to a projected CRS (e.g. a local UTM zone) before buffering, or enable the Geodesic Distance option in the QGIS 3.28+ Buffer dialog. The QGIS Buffer tool has one requirement that is easy to miss: the distance you enter is in the unit of the layer’s CRS, not the unit of your project CRS, and not any intuitive real-world unit you might have in mind. ...

21 June 2026 · 10 min · CadShift

Estimating Flat Blank Area for Stamped and Formed Sheet Metal in SolidWorks

Bent sheet metal has a flat pattern. SolidWorks can unfold every edge flange, miter flange, and sketched bend into a precise blank geometry, and the SW-Flat Pattern Area cut-list property captures the result automatically. Formed and stamped parts are a different story. A drawn cup, an embossed panel, a hydroformed bracket, a stamped louver grid — SolidWorks models these as solid bodies or as sheet metal with Form features, but there is no flat pattern feature, no unfolding algorithm, and no built-in blank area property. When a fabricator or a quoting tool asks for the blank size, you have to find it yourself. ...

20 June 2026 · 9 min · CadShift

SolidWorks vs Fusion 360 for Sheet Metal — DXF Layer Control and Flat Pattern Quality

The question of SolidWorks versus Fusion 360 for sheet metal comes up constantly in manufacturing communities. Most comparisons focus on modelling speed, K-factor accuracy, or bend table flexibility. What they skip is the output side: what the DXF file actually looks like when it hits the laser cutting operator’s desk, and whether the nesting software can consume it without manual cleanup. This matters because the DXF is the handoff document. Everything downstream — nesting, laser cutting, press brake setup — depends on the geometry, layers, and metadata in that file. A flat pattern that looks identical in both tools can produce dramatically different DXF outputs. ...

19 June 2026 · 8 min · CadShift

SolidWorks BOM Template Corruption — Why 'hide1' and 'hide2' Appear and How to Fix Them

You open a SolidWorks drawing, insert a BOM table, and two extra columns appear with headers “hide1” and “hide2”. They contain no data, they don’t correspond to any custom property you’ve defined, and deleting them fixes the problem — until someone inserts a new BOM from the same template and they’re back. This is a BOM template corruption issue, and it’s specific enough that most Google searches for it return outdated forum threads pointing at deleted Dassault knowledge base articles. Here’s what’s actually happening and how to fix it permanently. ...

17 June 2026 · 6 min · CadShift

CAD Version Control for Engineering Teams — Which System to Use at Each Team Size

The same question comes up on every growing engineering team: “We’re using a shared network folder and emailing DWG files. What should we move to?” The answer depends on how many engineers you have, whether you use SolidWorks, and whether your existing team already runs Git for software or firmware. This guide gives you a decision framework by team size, then walks through the actual tradeoffs of each approach. For the technical setup details — Git LFS configuration, PDM Standard installation, file naming schema design — the CAD version control technical reference covers those in depth. This guide focuses on the selection decision. ...

16 June 2026 · 7 min · CadShift

SolidWorks VBA API Events: Why Your Event Handlers Die When the Macro Stops

You set up a WithEvents handler in a SolidWorks VBA macro. The macro runs, SolidWorks does something (opens a document, rebuilds, saves), and your handler fires correctly. Then you close the macro editor and try to use SolidWorks normally — the handler no longer fires. The macro is gone, and so is your event subscription. This confuses VBA developers who are used to Office automation, where event handlers in a document’s VBA project persist as long as the document is open. SolidWorks works differently. Here’s why, and how to keep handlers alive when you need them. ...

15 June 2026 · 7 min · CadShift