CAD Collision Detection: Preventing Design Errors

"Monday, 7:30 a.m. The Toulouse factory is in turmoil. An assembly defect has just been discovered on the latest series of aircraft: two parts overlap by 2.7 mm at the junction of a wing. Production has been halted. Estimated cost: €1.2 million and a 90-day delay. In the crisis room, Pierre, the design manager, whispers: 'If only we had checked the collisions on the digital model..."

This true story illustrates the nightmare that manufacturers regularly experience. In a world where complex assemblies can contain up to 20,000 components from 7 to 12 different CAD systems, interference detection has become an absolute necessity.

Yet the solution exists and is surprisingly simple to implement. It can detect in seconds what would cost weeks and a fortune to correct later.

What if your next production crisis never happened?

Table of contents

• The challenges of collaborative multiformat design
• Impact of undetected assembly errors
• Limitations of traditional methods
• Essential criteria for an effective solution
• 3DViewStation: optimal solution for collision detection
• Collision detection process
• Demonstration through sectoral use cases
• Integration into industrial processes
• Measuring return on investment
• Conclusion and perspectives

The challenges of collaborative multiformat design

Computer-aided design has radically transformed product development processes, but has also introduced new technical challenges, particularly in collaborative environments. Engineering teams now face increasing complexity of digital assemblies that requires powerful tools capable of effectively analyzing component interactions.

Current industrial projects typically involve multiple suppliers and subcontractors using different CAD software. This diversity creates digital mockups composed of multiple formats (CATIA, NX, SolidWorks, Creo, JT, STEP...) requiring perfect interoperability to validate assemblies. A modern automotive assembly can thus contain more than 15,000 components from 7 to 12 different CAD systems.

This increasing volume constitutes an additional challenge. Digital mockups now commonly reach several gigabytes and include thousands of interconnected parts. The processing capabilities required to analyze these complex assemblies often exceed the possibilities of conventional solutions.

• Constant increase in the number of components in assemblies (+30% in 5 years)
• Multiplication of design sources and formats (average of 8 formats per project)
• Reduction of validation times (halved in 10 years)
• Increased precision demands in interference detection

Coordination between teams using different design software adds an additional layer of complexity. Modifications made by one team can create interferences with components developed by other departments, making crucial the existence of a common and reliable collision detection system independent of native tools.

Impact of undetected assembly errors

When interferences between components are not identified during the digital design phase, the consequences can be particularly costly for the company. The financial impact manifests both directly and indirectly, affecting the entire production chain.

A recent study conducted in the aerospace industry reveals that an undetected collision at the digital mockup stage costs on average:

• €1,500 if discovered in the detailed design phase
• €15,000 if detected during physical prototyping
• More than €50,000 if identified in the production phase

Beyond direct costs, the additional delays generated by late correction of interferences represent a major impact. A design revision can delay a product's market launch by 2 to 8 weeks, creating a significant competitive disadvantage and reducing the commercial opportunity window.

Quality problems and non-compliance risks represent another critical dimension. An assembly with interferences may exhibit degraded mechanical characteristics, sealing problems, or maintenance difficulties that will impact the entire product lifecycle.

These repercussions highlight the strategic importance of an effective collision detection system integrated into the product development process. Investment in a high-performance solution thus represents quality assurance with measurable and significant return on investment.

Limitations of traditional methods

Conventional approaches to interference detection present several limitations that reduce their effectiveness in contemporary industrial environments. These methods, often integrated into native CAD software, prove inadequate in the face of current collaborative design requirements.

The complexity of native CAD tools for detection represents a major first obstacle. These features, although powerful, generally require in-depth expertise and specific training. In a context where assembly validation involves various departments and user profiles, this complexity considerably limits the accessibility and adoption of these tools.

The problem intensifies with the need for multiple conversions between formats. Traditional approaches generally impose importing all components into a single format, generating:

• Geometric precision losses compromising analysis reliability
• Considerable preparation time before verification can be performed
• Risks of errors or omissions during successive conversions
• Multiplication of files and versions generating management problems

Insufficient performance with large assemblies constitutes another critical limitation. Traditional systems quickly show their limits when faced with complex digital mockups:

An assembly of 10,000 components can require up to 45 minutes of loading before allowing any interference analysis. This waiting time becomes prohibitive in a context of iterative validation where several successive verifications are necessary. The computing resources required by these traditional tools are also considerable, often requiring specialized and expensive workstations.

The advanced technical expertise required to correctly configure and interpret analyses represents an additional barrier. Complex detection parameters, multiple filtering options, and result interpretation require specific competence that not all participants in the development process possess.

Faced with these limitations, industrial companies are seeking more efficient alternatives capable of meeting contemporary requirements of collaborative multi-format design.

Essential criteria for an effective solution

The identification and selection of a high-performance collision detection solution is based on several determining criteria that guarantee its effectiveness in a demanding industrial environment. These key factors must be meticulously evaluated to ensure successful deployment and optimal adoption by teams.

Performance with voluminous assemblies constitutes the first essential criterion. An effective solution must be capable of:

• Loading assemblies of several gigabytes in a few seconds
• Handling digital mockups containing 20,000+ components without slowdown
• Executing complex interference analyses in real-time
• Maintaining interaction fluidity even during intensive calculations

Multi-format compatibility without conversion represents a major asset for operational efficiency. The ideal solution must offer:

Native support for major industrial CAD formats (CATIA, NX, Creo, SolidWorks, Inventor, JT, STEP, IGES...) allowing direct file opening without intermediate steps. This capability eliminates conversion-related error risks and guarantees analyzed data integrity, while considerably reducing preparation time necessary before validation.

Ease of use for different user profiles constitutes a determining factor for broad solution adoption. The interface must be:

Result precision and advanced analysis options determine the solution's reliability. Essential functionalities include:

• Configurable interference detection (collisions, contacts, proximities)
• Precise calculation of interpenetration volumes
• Intelligent filtering of results by criticality
• Complementary analysis tools (sections, measurements, comparisons)

Finally, integration capability into existing workflows guarantees successful solution adoption within the company's technical ecosystem. The platform must offer:

Robust APIs allowing interconnection with PLM, ERP, and document management systems. This integration streamlines the validation process by making interference checks directly accessible from teams' usual work environments, without disruption in the digital chain.

3DViewStation: optimal solution for collision detection

Faced with the rigorous demands of modern industry, 3DViewStation stands as the undisputed reference in collision detection within multi-format CAD models. This advanced visualization and analysis platform combines power, precision, and accessibility to meet the most demanding needs of industrial companies.

Ultra-high-performance display technology constitutes one of 3DViewStation's major assets. Designed to efficiently process complex assemblies, it allows:

• Loading 5 GB or 20,000 component assemblies in seconds
• Fluid interaction with the most voluminous digital mockups
• Instant launching of interference analyses without preparation time
• Dynamic manipulation of models during collision calculations

The true multi-format compatibility of 3DViewStation eliminates obstacles related to CAD data heterogeneity. The solution natively supports:

The intuitive interface of 3DViewStation adopts modern user experience standards, drawing inspiration from Microsoft Office interfaces to offer immediate usability. This "EASY" approach  ensures rapid adoption by all concerned services without requiring in-depth training.

The comprehensive analysis features offered by 3DViewStation go far beyond simple collision detection to provide an exhaustive suite of investigation tools:

• Configurable interference detection with precise volume calculation
• Wall thickness analysis for manufacturing constraint validation
• Draft angle verification for mold optimization
• Advanced model comparison for modification analysis
• Dynamic section creation for internal assembly investigation

Deployment flexibility represents an additional strategic advantage. 3DViewStation offers a complete range of solutions adapted to each usage context:

The Desktop version for individual workstations, the WebViewer module for browser access without installation, the VR solution for immersive analysis, and server automation capabilities for integration into industrial processes. This modularity allows precisely adapting the solution to each organization's specific needs, with various deployment options.

The open architecture and robust APIs of 3DViewStation facilitate its integration into the existing technical ecosystem, particularly with major PLM systems like TeamCenter, 3DExperience, Windchill, or SAP. This capability ensures data consistency and optimal traceability of interference analyses throughout the product development cycle.

Collision detection process with 3DViewStation

Interference detection with 3DViewStation follows a methodical and optimized process that maximizes analysis efficiency while ensuring result exhaustiveness. This structured approach allows technical teams to quickly and precisely identify potential problems within complex assemblies.

The first step consists of defining the interference analysis scope. 3DViewStation offers several selection modalities:

• Global analysis of the entire assembly
• Verification between specific subassemblies
• Detection between a selection and the rest of the model
• Filtering by metadata (materials, suppliers, statuses...)

Once the scope is defined, the user configures detection parameters according to the specific analysis objectives:

The analysis is launched with a simple click, 3DViewStation fully exploiting the multi-core capabilities of modern processors to provide near-instantaneous results, even on voluminous assemblies. A progress indicator allows following calculation progress, particularly useful for complex analyses.

Advanced result visualization constitutes one of 3DViewStation's strengths. The software automatically proposes:

• An overview of detected interferences in the model tree
• A summary table detailing each collision with its characteristics
• An intuitive color code classifying problems by severity
• Visual highlighting of concerned areas in the 3D model

Navigation between different collisions occurs fluidly and intuitively. A simple click on a result in the table automatically triggers:

Centering the view on the problematic area, optional isolation of concerned components for better visibility, and display of metadata associated with colliding parts (reference, material, design status, etc.). This ergonomic organization considerably accelerates analysis and decision-making.

Result organization and classification allow efficient management of the resolution process. 3DViewStation offers advanced functionalities to:

• Filter interferences by volume, type, or location
• Add annotations and comments on each identified problem
• Assign processing statuses (to correct, acceptable, to verify)
• Group similar problems for batch processing

Export and reporting options complete the process by facilitating communication and monitoring. Results can be exported in different formats:

Detailed Excel reports including screenshots and metadata, lightweight 3D sessions shareable with other 3DViewStation users, interactive PDF documents for design reviews, or direct integration into PLM systems via dedicated APIs. This flexibility ensures effective communication of detected problems to responsible teams.

Demonstration through sectoral use cases

The effectiveness of collision detection with 3DViewStation manifests concretely through numerous application cases in various industrial sectors. These practical examples illustrate the solution's versatility and relevance in addressing the specific challenges of each domain.

In the automotive industry, assembly complexity and supplier diversity make interference detection particularly critical. A leading European manufacturer uses 3DViewStation to:

• Validate electronic system integration in dashboard constrained spaces
• Verify compatibility of parts from multiple suppliers using different CAD software
• Analyze maintenance spaces to guarantee component accessibility in after-sales
• Dynamically control interferences on mobile mechanisms (seat kinematics, door opening...)

The results are convincing: 63% reduction in assembly validation time and 78% decrease in design revisions related to undetected interferences.

In the aerospace and defense sector, precision and reliability are paramount. A major aerospace equipment manufacturer uses 3DViewStation to:

The integration of 3DViewStation in their validation process has reduced by 92% the number of interferences discovered late during physical assembly.

In the field of heavy equipment industrial manufacturing, challenges focus on managing large assemblies and multi-site coordination. A global leader uses 3DViewStation to:

Validate interfaces between modules designed by different international teams, verify compatibility of design evolutions with existing installations at customers, analyze assembly sequences to prevent physical blockages, and simulate maintenance operations in restricted spaces.

This approach has reduced new product time-to-market by 34% while decreasing non-quality costs related to interferences by 67%.

In complex electronic product design, component miniaturization and densification create specific challenges. A telecommunications equipment manufacturer uses 3DViewStation to:

• Verify clearances between high-density electronic components
• Analyze potential interferences during thermal expansions
• Control board compatibility with enclosure mechanical constraints
• Validate accessibility for assembly and maintenance operations