CAD file formats

CAD file types are categorized into native formats specific to software
(e.g., .dwg, .sldprt) and neutral formats for cross-platform sharing (e.g., .step, .stl). Key
types include 2D drawing files (DWG, DXF), 3D modeling files (STEP, IGES, Parasolid),
and 3D printing formats (STL, OBJ). Choosing the right format depends on
interoperability and manufacturing needs.

Commonly Used CAD File Types

DWG (.dwg): Native file format for AutoCAD and many CAD systems; stores 2D/3D data,
layers, and metadata.

DXF (.dxf): Drawing Exchange Format, used for interoperability between different CAD
programs, especially for 2D data.

STEP (.stp, .step): Standard for the Exchange of Product Model Data, a neutral 3D format
for sharing data across different CAD systems and manufacturing.

IGES (.igs, .iges): Initial Graphics Exchange Specification, a standard for 3D CAD data
exchange.

STL (.stl): Standard Tessellation Language, used primarily for 3D printing and rapid
prototyping, representing 3D surfaces as meshes.

Parasolid (.x_t, .x_b): A geometric modeling kernel format, often used to share solid
models between software.

Native CAD Formats

These are specific to the software they were created in and usually offer the best
performance within that system:

AutoCAD: .dwg, .dxf, .dwt (template)

SolidWorks: .sldprt (parts), .sldasm (assemblies), .slddrw (drawings)

Autodesk Inventor: .ipt (parts), .iam (assemblies)

CATIA: .CATPart, .CATProduct

Creo: .prt, .asm

Siemens NX: .prt

Neutral CAD Formats

Designed for interoperability between different applications:

STEP: Best for, 3D data transfer.

IGES: Common for surface models.

DWF: Design Web Format, for sharing 2D/3D designs for viewing.

OBJ: Often used in 3D printing and modeling, particularly for mesh data.

Other CAD File Formats

PDF: Used for sharing 2D drawings and sometimes 3D models.

OBJ: Similar to STL, used in 3D printing and computer graphics.

DWF: Design Web Format for sharing 2D/3D data.

CAD File Formats and How to Export Them for 3D Printing

There are a lot of CAD (computer-aided design) file types out there, each with its own
names, formats, and parameters. From STEP files to STL files, to IGES and more, it can
be difficult to differentiate between them. This article will help you understand the
difference between these file types, and which are best for uploading to a 3D printer’s
CAD software or sending to a 3D printing service.

There are, in general, two main CAD file format categories:

Native

Native CAD files are copyrighted intellectual property of the system/CAD program for
which they are utilized. They contain the most detail and functionality because they
don’t consolidate or gloss over areas of a 3D CAD design file for 3D printing

Examples: .dwg, .blend, .x_t, .sldprt, .sldasm, .ipt, .iam, .skp

Neutral

Neutral CAD files are open-format and not copyrighted intellectual property of any
system or CAD program. They are useful for sharing files across two or more different
CAD platforms, but they result in a small amount of fine detail loss when converting to a
neutral file type

Examples: .stl, .amf, .obj, .stp, .step, .3mf, .iges

CAD files may also be distinguished based on the method by which they were created
and how they are structured:

Parametric (solid)

Mesh (NURBS)

Parametric Modeling

In 3D modeling, a parametric model is one that consists of solid blocks or vectors that
have both magnitude and direction. Parametric modeling is a process whereby the shape
of a model’s geometry is automatically changed when a dimension value is altered; it’s
based on designing features and constraints of a solid body or assembly.

The implementation of parametric modeling originates through the CAD software’s

programming, which determines the dimension and shape of the solid model. Typically,
parametric modeling software (such as 3D AutoCAD) utilizes feature-based modeling
tools to allow the manipulation of a model’s attributes.

Mesh Modeling

A mesh model, on the other hand, is a collection of small triangles (tessellations) that
make up a surface. A mesh model is typically created when a part is 3D scanned, which
results in a copious amount of data points (dots) that comprise a point cloud. The mesh
is created by resolving these points into variably sized triangles by connecting the dots.
Although uncommon due to the complexity and tediousness of the process, a mesh may
also be manually created.
Mesh files are primarily utilized for the following scenarios:

Inspection of a part to determine if it conforms with designed dimensions or features.

This involves 3D scanning a part and overlaying the 3D scan on a parametric, solid CAD
model. The areas where the two do not overlap are utilized to determine if a scanned
part is out of tolerance.

Engineering analysis of a design. Mesh models are utilized for a variety of engineering
simulations and analyses, such as finite element analysis.

3D scanning of legacy parts to source them and/or reverse engineer them.

3D printing directly from a scan. 3D printer files support STL files so a mesh in an STL
format can be directly printed.

If you compare these two types of models to a 2D image file, a parametric model is like a
vector file (.AI, .SVG, .DXF) while a mesh model is more like a pixel image (.PNG, .JPEG).
Just as a pixel image approximates a vector file, when converting a parametric model to
a mesh model, a mesh file (.STL) approximates a parametric file (.STEP).

Best Parametric File Types for 3D Printing in 2022

For 3D printing, both mesh and parametric structured file types are acceptable. Let’s
dive into the optimal CAD models for 3D printing and which types of CAD files Fictiv
experts recommend.

There are 3 main parametric file types used in 3D printing:

STL (Stereolithography or Standard Tessellation Language)

STEP (Standard for the Exchange of Product model data)

Native CAD

First Choice: STL Files

There are two types of STL files:

ASCII: Large file size and not recommended

Binary: Compressed file, which is better for saving and sharing

STLs were originally developed by 3D Systems specifically for additive manufacturing

and are widely known as the industry standard. They are neutral and easy to implement.

However, STL files for 3D printing aren’t without their shortcomings. For example, there
are no associated units (dimensional ambiguity) and holes or gaps (watertightness) can
cause issues when producing parts. Experts say that STL files may be replaced by newer
and better optimized file formats.

Second Choice: STEP Files

There are 2 main types of STEP files:

AP203: Originally created for the aerospace industry

AP214: The newest standard, originally created for the automotive industry

We believe that STEP files are the best file format for transferring CAD data. STEP files
carry all the parametric data required for manufacturers to accurately read the size and
geometry of the part you need.

Pro tip: STEP AP214 will save the colors and layers in your CAD program when exporting
as an STL. When saving for multi-material prints, we prefer this standard since it helps to
distinguish the different solid bodies.

Third Choice: Native Files

As a reminder, native CAD files are copyrighted intellectual property of the system/CAD
program for which they are utilized. There are many different CAD programs and even
more native file types. Here are some of the popular programs and file types Fictiv
accepts:

Autodesk: .ipt

Dassault Systèmes: .sldprt, .3dxml, .catpart, .catshape, .cgr, .dlv, .exp, .model, .session

PTC: .prt

Siemens PLM: .jt, .par, .prt, .x_t, .x_b

Other
programs: .3dm, .vda, .prt, .x3dv, .ifc., .mf1, .neu, .prc, .sab, .sat, .u3d, .vda, .xas, .xpr

How to Export an STL File for 3D Printing

The basic steps for exporting an STL file for 3D printing are:

Modeling: Obtain a solid model or mesh model of the component you wish to 3D print.
Note, it is best to utilize neutral or open-source file formats.

Slicing: Convert the 3D model into something which can be printed. This utilizes slicing
software and requires some of the printer information to be input.

Obtaining a 3D-printable model: Create a file containing the instructions for the 3D
printer to perform the printing (toolpath information). The most common format is a G-
code.

Common STL Export Considerations

It’s common to run into problems when exporting an STL file. Since a lot of people use
STLs, we’ll point out a few important considerations and walk through specific
exportation steps for the most common CAD [Link], you can skip the
export to STL and upload your native CAD files for an instant quote on our platform
today.
Resolution

The most important consideration is the resolution of your model. If you try to export an
STL with a low resolution, your model will look faceted. If you export an STL with too high
of a resolution, your model will become very large and difficult to share.

Two Main Program Settings

There are two main settings to consider with every CAD program:

Chordal Tolerance or Deviation: This is the maximum distance between the surface of
the original design and the surface of the STL triangle created.

Angle Control: This is the allowable deviation between adjacent triangles. You should
think about approximating a curved surface with lots of flat triangles. The more shallow
the angle, the closer the approximation is to the curved surface.

Specific Settings by CAD Program

Solidworks

File > Save As

Set save as type to STL (*.stl)

Click on Options

Set Deviation to 0.0005in and the Angle to 5 deg

Click save to export the file

Autodesk Inventor

File > Save Copy As

Save as Type > STL

Click the Options button, and choose the High detail level

Save

Rhino

Check out our expert article with tips and tricks for exporting to Rhino. If you’re looking
to convert a STEP file to an STL file, check out one of the numerous free, online tools that
can do the work for you!

Define CAD.

Computer-aided design (CAD) is the use of computers (or workstations) to aid in the
creation, modification, analysis, or optimization of a design. This software is

used to increase the productivity of the designer, improve the quality of design,

improve communications through documentation, and to create a database for

manufacturing.
 CAD Data formats:

CAD formats are divided into

1. Native CAD formats

2. Neutral 3D formats

3. Specialized formats

1. Native CAD formats : Most popular 3D CAD file formats are native CAD

formats. That’s because native formats create and let you access the most

information possible about your 3D CAD file.

Following are some of the types of Native CAD formats.

● AutoCAD (.dwg): This is the most popular 3D CAD file format because,

it’s the original. It’s the native file format for Autodesk’s AutoCAD

program, the first widespread CAD program in the field. The extension is

short for “drawing” and is a compact binary format.

● Blender (.blend): Blend files are special beasts. They’re a scene description

format from the 3D modeling and animation software Blender.

● Parasolid (.x_t): Parasolid is a geometric modeling program, and its file extension
contains 3D CAD file information like geometry, topology, and color from your drawing.

● SolidWorks (.sldprt and .sldasm): These two file extensions, coming from SolidWorks,
are short for “SolidWorks Part” and “SolidWorks Assembly”. .sldprt provides details on
specific parts within an entire system, allowing a comprehensive study that can then be
reassessed with an overview of how it fits into the rest of the 3D CAD file.

● Inventor (.ipt and .iam): Much like SolidWorks, Autodesk Inventor has

complementary formats for parts and assemblies. .ipt represents a single

item of design, like one ball bearing in a wheel setting, while .iam is meant

for assemblies, or files with more than one interacting part, like a screw

going through a latch.

● SketchUp (.skp): Originally developed by @Last Software, Sketch Up and

its 3D CAD file format was bought by Google in 2006 and by Trimble in

2012.

2. Neutral 3D formats are useful for sharing between different CAD

programs. These 3D CAD file formats don’t inherently collect as much

metadata as native CAD files, so there’s some level of fine detail loss when

using them, but they’re great for collaborative work.

Following are some of the types of Neutral 3D formats.

● Stereolithography or “Standard Tessellation Language” (.stl): The STL

file format uses rough triangles to describe the surface shape and area of

your 3D CAD design.

● Additive Manufacturing (.amf): This is an open standard for describing

objects within additive manufacturing and is most commonly used in 3D

printing. It’s a 3D CAD file format based on XML, which allows any CAD

program to describe any 3D object to build on any 3D printer.

● STEP (.stp and .step): STEP stands for Standard for the Exchange of

Product model data, and it stores 3D images in an ASCII format.

● Wavefront (.obj): First developed by Wavefront for its own Advanced

Visualizer animation software, the OBJ file format has been adapted by

scores of other 3D graphics software.

● 3D Manufacturing Format (.3mf): Recently developed by the 3MF

Consortium, 3MF is an open-source file format striving to become a

standard in the additive manufacturing world.

● Initial Graphics Exchange Specification (.iges): Invented by the US Air

Force as a national standard CAD file format, IGES lets users exchange

circuit diagrams, wireframe, freeform surface, or solid modeling representations of

product models.

3. Specialized Formats : 3D CAD work encompasses a lot of industries and

types of projects, from machine part modeling to video game character

building. This variety creates an ever-expanding need for new types of 3D

CAD file formats that can handle the viewing and manipulation of unique

data.

Following are some of the types of Specialized formats.

● Autodesk (.3ds): The 3DS format specializes in importing and exporting

your drafting files. It’s designed to facilitate easy model moving between

CAD software, which means it only stores essential geometry, texture, and

lighting data.

● Collada (.dae): Sony originally created this format as a way to share 3D

graphical files over a wide range of software.

● X3D: This 3D CAD file format is the improved successor of VRML. X3D is

based on XML and is a royalty-free standard for declaratively representing

3D graphics.
 Basic Principles of Additive Manufacturing Process

● All additive manufacturing (AM) models are built by joining single layers of

equal thickness.

● The layer is shaped (contoured) in an x-y plane two dimensionally. The third

dimension results from single layers being stacked up on top of each other,

but not as a continuous z coordinate.

● The models are therefore three-dimensional forms that are very exact on the

building plane (x-y direction) and owing to the described procedure are then

stepped in the z direction, whereby the smaller the z step is, the more the

model looks like the original.

● The stair-step effect is a typical characteristic of the additive manufacturing

process that can never be entirely eliminated but can be reduced by

decreasing the layer thickness.

● A larger layer thickness, up to around 0.2 mm, is most oſten used for

fabbers or for reducing the building time on other additive manufacturing machines.

● Depending on the type of contouring (scanning, plotting, and so on) and

the chosen AM process, the object is contoured continuously in the

building plane (x-y plane).

Need of STL format

● STL is a file format native to the stereolithography CAD software created by

3D Systems.

● STL has several backronyms such as "Standard Triangle Language" and

"Standard Tessellation Language".

● This file format is supported by many other software packages; it is widely

used for rapid prototyping, 3D printing and computer-aided manufacturing.

● STL files describe only the surface geometry of a three-dimensional object

without any representation of color, texture or other common CAD model

attributes. The STL format specifies both ASCII and binary representations.

Binary files are more common, since they are more compact.

● An STL file describes a raw, unstructured triangulated surface by the unit

normal and vertices (ordered by the right-hand rule) of the triangles using a

three-dimensional Cartesian coordinate system.

● In the original specification, all STL coordinates were required to be positive

numbers, but this restriction is no longer enforced and negative coordinates

are commonly encountered in STL files today. STL files contain no scale

information, and the units are arbitrary.

STL Format

● In order to obtain an STL data set of the part, the surfaces of the part are

approximated by triangles.

● Volume elements exhibit at least two surfaces, the inner and outer surfaces. Both of
them differ only by the normal vectors.

● The definition of the surface by triangles is called triangulation or

tessellation. This leads to the so- called STL data. It is regarded as a de facto

industry standard for AM processes, but it is actually nowhere standardized.

● This contributed to the fact that this process, long before it was discovered

for additive manufacturing, was used for shading and thus for the

visualization of three-dimensional CAD lattice models.

● Decisive for the establishment of the STL format as an interface for additive

manufacturing was the early publication of the interface formulation.

● The STL interface, which has been known since then as the stereo

lithography interface, could be used by both machine manufacturers and free

software businesses.

● This was especially beneficial to the development of special software that is

offered by independent developers and made a lasting contribution to the

user-friendliness of additive manufacturing systems.

● The STL data contains the normal vector as shown in Figure (positive

direction outward, away from the volume) and the coordinates of the three

vertices of each triangle. An ASCII or binary file can be created.

● The amount of data is much lower for binary files, but ASCII files are

comparatively easy to read and control in the source code.

Advantages of STL:

● Given that the surface is based on triangles, it is possible to cut the model

at any desired z coordinate. Also, when the CAD model is not available,

STL models permit any desired scale at random without reversing into the

CAD.

● Because the intersection contains only data elements of a type that can

be described by relatively simple means, syntax errors of the ASCII version

in programming of the interface are very easy to recognize and eliminate,

and therefore they pose practically no problem.

● In contrast to contour-oriented intersections, smaller errors may be repaired

relatively easily. It is also an advantage that a triangle provides a higher

quality of geometric information than does the contour vector.

Disadvantages of STL:

● It generates a large volume of data, especially when the surface quality

is improved by refining the net of triangles.

● STL files contain only geometrical information. Information about color,

texture, material, or other characteristics of the physical model are missing.

Data loss/ Errors

● During the transformation of the CAD internal geometry data into STL files,

different errors can occur that affect the quality of the physical component.

The errors are categorized by Hoffmann as

○ construction errors,

○ transforming errors, and description errors.

Construction errors

Construction errors are based on unnecessary data inside the component that

are the result of combining the single elements incorrectly in the CAD system

● These errors are problematic for the AM process. For example, LLM

processes include unnecessary cuts because of these errors. The

consequences range from additional expenses during the building process to

the total loss of thepart.

● The consequences range from additional expenses during the building

process to the total loss of the part.

● Construction errors do not affect components that are produced by

polymerization and sintering processes.

Transforming errors

● Transforming errors exist when the convergence of the mathematically exact

con-tour by triangles is inaccurate and the number of transforming errors is

larger the lower the number of triangles chosen.

● With the increased accuracy in defining the surface made possible by

increasing the number of triangles, the amount of data increases enormously.

● In practical terms, the fineness of the triangulation is not problematic if

approved settings are used.

Description errors

● Description errors are primarily attributable to three causes:

○ Gaps between triangle patches (boundary error),

○ double triangle patches (overlap),and

○ Incorrect orientation of individual patches (disorientation).

● Gaps (and double triangle patches as a special form of gaps) are the result of

inaccurate boundaries that border on each other.

● The existence of differing resolution densities of geometries can cause

boundary errors on the edge on the opposite side. These are called “naked edges.”

● Such defects are irrelevant for visualization and also for processing with cytter
diameters in the range of millimeters. In applications with lasers that exhibit a beam
diameter of 0.1 mm, such defects have a negative effect.

● When the surface is oriented incorrectly, the normal vector points to the inside of the
model. In general, the human eye can assign such surfaces

Correctly, but for generating machine data these results are problematic. The

result is that the inner and outer sides cannot be separated.

● When the machine-specific layer information is generated, all gaps have to

be closed. This process is called the repair of the data set. Normally, special

modules of front-end software do this automatically. While repairing semi

automatically, manual intervention leads to faster and better results.

Need of Slicing in 3D printing

● 3D models are sliced into instructions for 3D printers by the process known

as slicing. It essentially "slices" the 3D model into thin layers and then

determines the path for each layer to be printed to get the best strength,

shortest printing time, etc.

● A 3D CAD model, often an STL format file, is converted into G-code,

which the printer may use. The three main categories of parameters that can

be adjusted in a slicer program are as follows:

○ Layer heights

○ Shells

○ Infill percentages, and

○ 3D print speeds.

● Print bed settings, filament diameter, extrusion multiplier, and extruder

temperature are included in filament settings. A printer's settings include the

diameter of the nozzle, the shape of the print bed (L x W), and the Z offset.

Advantages of CAD

● Increases Productivity

CAD software allows designers to lower production costs, work faster and

smarter, and ultimately leads to quicker project completion.

● Higher Quality Designs

The use of CAD allows design teams to control the quality of the final

engineered product. It’s easy to investigate an error, diagnose the problem,

and solve it all using the software before any prototypes are made. This not only saves
time, but also money.

Fashion design is one industry that uses CAD often. It allows designers to

create clothes and see how they would fit on virtual models, all without

spending a dime on manufacturing.

● Easier to Read

CAD drawings are easily read, as they’re standardized and organized.

Legibility is increased, and there are no issues with reading the drawings.

● Simplified Sharing

CAD makes collaborating easy, even for remote teams.

● Documenting the Design

CAD software is excellent at documenting all aspects of a design. The

measurements, angles, and dimensions of a product are all conveniently

recorded and saved for future use.

Limitation of CAD

● Skill of the Designer

CAD (and CAM, its counterpart) are tools for a designer to use to create a

design. Like all tools, they are only as useful as the one handling them.

While a computer can tell you what a design will look like when you use

either steel or wood, the user is the one who makes the decision, which

inevitably affects function. CAD software also can’t tell you which design is

more aesthetically pleasing, and in some industries, that overrides function.

● Designing Physical Objects in a Virtual Workspace

Designing virtually allows the user to create perfection without concerning

themselves with real-world constraints.