5. DieDesign Basic
DieDesign Introduction
The Die Application consists of three main processes:
1. Forming Shapes
Designing the Forming shapes; creating the main forming shapes that will be included in the strip (intermediate
shapes between the flat and the final product). The forming shapes are mainly copies of the master parts which
were changed using the Bend, Unfold and Unbend operations.
2. Designing the Strip
Nesting, Designing the strip layout, dimensions, carrier, stations (adding forming shapes), creating the Punch,
Trim, etc.,
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6. 3. Die Design
Creating the actual die (not covered in this exercise).
DieDesign Wizard
The DieDesign Wizard assists you in setting up a new Die document by prompting you to define the appropriate
parameters.
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7. DieDesign Wizard
Select the Die Setup icon to enter the Progressive Die Design Wizard. The Progressive Die Setup
Wizard dialog is displayed.
Set Master Part
Click the open file icon to load the first ELT document.
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8. The Die application can deal with up to two different forming shape parts. A Mirror part is considered as a
different part.
You may also import a part in any other format (such as DXF, IGES etc.).
Load the master.elt
Set Master Part 1
Select the second Open File icon to load the second ELT document, as shown below.
Load the mirror.elt.
The assembly name is provided automatically. You may change the name if required. The assembly, by
default, is created in the current pass.
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9. New Folder
Check the Create New Folder checkbox to create a new folder for the die assembly. The Copy Masters to
Folder checkbox becomes available.
Check the Copy Masters to Folder checkbox, as shown below.
Click OK.
The Copy Masters to Folder option enables you to copy and move the master files under the same location
as the assembly file. It is an optional step in order to set a clear and organized environment.
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10. The Assembly Structure
The Die assembly is automatically loaded with the main sub-assembly (meaning, the Strip Application
assembly).
The Strip Application assembly consists of three sub-assemblies, as follows:
1. Strip: The Strip is composed of the following parts, each of these parts are described below:
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11. a. Strip Part
The Strip Part contains the strip itself, the punches, and all strip operations such as
Progressive Copy, Punch/Trim, Composite Curves, Copy Mirror, and more.
Note that the punches and the strip are objects included in the part, they can be edited through
the relevant operations (Strip Dimensions,Edit the relevant Composite or Punch/Trim
operation).
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12. b. Assisting Part.(Note that the assisting part will be created only after an assisting entity is created).
The Assisting Part contains all assisting operations such as; Sketches, Corners, Planes and
more.
They can be edited through this part.
c. Forming Shapes (added to the strip)
All Forming Shapes that were added to the strip are included in the strip application.
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13. Each one of them is an instance of the original created forming shape.
d. Blanks (included in the strip)
Blanks are contours that are used as input for the Nesting. The number of the blanks in the
strips is determined through the Strip Dimension operation. (meaning, the number of
progressions).
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14. 2. 1st Forming Shape
3. 2nd Forming Shape
You may set up two different forming shape parts. (If you select one part, the assembly will contain only one set
of forming shapes).
Each forming shape assembly (1st Forming Shape or 2nd Forming Shape) will contain all the intermediate
shapes that will be created and later placed as stations in the strip.
Forming Shapes
Create the main forming shapes that will be included in the strip. The forming shapes are mainly copies of the
master which was changed using the Bend, Unfold and Unbend operations.
FormCS
The first stage in defining the forming shapes is to define the Form CS.
1.The Form CS is the "master" UCS (Work CS) for a forming shape part. The positioning of the parts in the
forming shape assembly is defined according to this UCS.
2. The connection in the strip assembly is done between the strip UCS (at a certain station) and the forming
shape part Form CS.
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15. 3. Because the Form CS lies on the strip UCS, and it is the Z=0 of the carrier, we will choose to define the Form
CS on a face that will not change its height (this will be the ”Zero Z level” of the forming shape), and will be used
as a reference plane for other faces that will be changed (using Bend, Unfold, etc.).
Create a UCS that will be later defined as the Form CS
Activate the master part. Create a UCS as indicated in the picture below:
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16. Activate the mirror part (under the 2nd Forming Shape) and repeat the same process.
FormCS 1
From the DieDesign Guide, select the Form CS icon.
Select the previously defined UCS of both parts (at once).
Add New Forming Shape
Note that in this stage you are creating the forming shapes which you intend to place in the strip. It is a planning
stage, which means that not necessarily all forming shapes will be used in the strip.
From the DieDesign Guide, select the Forming Shape/Add icon:
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17. Select the master part to add a copy of it as a new forming shape, and click EXIT or click the OK button.
Three more options for add a forming shape are available, as follows:
1. Click the Open file icon to open another ELT file.
2. Click the Importfile icon to Import a file directly from DI.
3. Check the Add New checkbox toadd a new empty part.
Add New Forming Shape 1
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18. Accept the default Copy Part Import option.
By selecting this option, the system creates a new part, imports the master and disassociates it.
The Copy Part option, is a copy of the master part like the Save as option.
Press the locating buttons to see how you may relocate the part as required.
Place the part in its default location.
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19. The Forming Progression value determines the distance between two sequence parts. Change the
Forming Progression value to 75, as shown below.
Skin
Skin: A thin reproduction of the outside surface of a part detail, or model. Using the skin option enabled a clearer
analyze of the operations
Select the Die Skin icon from the Die Design Guide.
The entire part is selected.
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20. Select the upper face as indicated by the arrow in the picture. (The group of faces belonging to the selected
face will remain as is, while the bottom faces will be removed.)
Note: This skin shape will be considered as the final part in the die strip.
Click OK.
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21. Face Corner
Enables adding corner (round) to faces on sharp corners (free edges) of a skinned object.
Note that the area marked in red rectangle has sharp corner. We will now use the Face Corner option to round
these corners
Select the Face icon from the DieDesign Guide, select the Face Corner option. Drag a box to select the
four corners as indicated in the picture below.
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22. Set the Global Radius Value to 0.1. Then select the two upper corners and set a radius value of 1, as
shown below and click OK.
Unfold
The Unfold option creates flattened faces out of a given 3D model (which contains planar and cylindrical
faces).
Note that the flat forming shape of the model is one of the first shapes in the die strip.
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23. The order for creating die forming shapes is very flexible. You may start with a final part (on the left side) and
then create the first forming shape (on the right side) and then continue from left or right or vice versa.
We will now add a new part and unfold it to create a flat form of the model.
From the Die Design Guide, select the Unfold option.
The default option Create a New Part is displayed. (This option adds a new forming shape and flattens the
model in one operation).
Select the Skin forming shape (Master#1).
Unselect the faces of the dimple. These faces will not be unfolded. Click the middle mouse button to Exit
and enter the 3rd stage.
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24. The K Factor
The K Factor determines the neutral face. The length of the neutral face (sheet) is the total length of the
unfolded model (meaning with flat faces).
Set the Thickness value at 2.
Set the Global K - Factor value at 0.5.
Select the Create Wire & Faces option.
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25. Enter the File Name = Unfold.
Note that the cylindrical faces are colored in yellow. Move the mouse over these faces. The information
regarding the Original Radius and the Natural Plane Radius is displayed, as follows:
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26. You may change the K-Factor of each of these faces by clicking the required face and applying a different
K-Factor value, as follows:
Unfold1
From the feature guide, select the first optional stage to add faces that will not be unfolded but will just be
transferred to their new location (according to the islands they belongs to).
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27. Select the faces of the dimple (using the By Box option).
Click OK.
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28. Bend
Bending an object (or several objects) with reference to a given axis by specified angles
Add a new Forming Shape. Name it Bend. Select the previously created forming shape.
Relocate the part, by placing it before the Unfold part.
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29. Note that the distance between the forming shapes is too small. Enlarge it to 114 (this number has no
meaning, we just want to spread the forming shapes apart), as shown below:
Click OK.
Bend1
From the Die Design Guide, select the Bend icon.
Select the object to be bent as indicated in the picture below. Exit
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30. Select the Natural plane and the Bending line (in the same step) as indicated by the arrows in the
pictures below. Exit
Bend2
Enter the following values:
• Thickness: 2
• K Factor: 0.5
• Bend Angle: 90
• Bend Radius: 2.5
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31. Press the Preview button. If necessary, change the direction of the arrow to obtain the correct bending
direction.
Note that the system automatically detects the optional faces to be bent around the line axis, in reference to
the fixed natural face that was selected previously.
To unpick the other wing and to perform the bend locally only on part of the optional faces, select the first
optional stage.
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32. Pick a point on the relevant faces on which you want to perform a local bend, as shown in the pictures
below.
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33. Click OK.
Unbend
Un-bend (un-fold) a specific region of the die part to a flat area or ‘by angle’ (in refers to a flat face).
Add a new forming shape. Name it Unbend. Select the skin part as the reference part (shown below) and
then click OK.
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34. Place it after the skin part, as follows:
From the Die Design guide, select the Unbend icon.
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35. Select the planar face and the cylindrical face as indicated by the arrow in the picture below and exit.
Note that the other face that will be unbent is selected automatically.
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36. Set the following parameters:
• Thickness: 2
• K-Factor: 0.5
• By Angle
• Angle: 45
• Fix Radius – Fix Center
Fix Radius – Fix center
Fix Radius – Fix Center:
The center of the original cylinder face remains the same, the new length (L1) of the cylindrical face is
determined by the Angle (30). The remaining area of the cylindrical face will be flattened tangent to the
cylindrical face.
Before Unbend After Unbend
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37. Click OK.
Unbend1
Repeat the same operation on the other side. In this case use the Fix Radius – Move Center option.
Fix Radius – Move Center
The new arc length (L1) is calculated according to the defined angle. The remaining area of the cylindrical (L2)
face will be flattened. The center of the arc will move by a delta value of L2.
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38. Click OK.
Stitch the faces.
Unbend2
Add a new forming shape. Name it Unbend1. Select the previous Unbend part as a reference part.
Click OK.
Place it after the Unbend part.
From the Die Design Guide, select the Unbend icon.
Select the planar face as indicated by the arrow in the picture below:
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39. Pick the cylindrical face as shown in the picture and then Exit.
Add the rest of the faces as the faces to be transferred.
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40. Click Apply.
Unbend3
Unbend the other cylindrical face.
Select the reference face.
The adjacent cylindrical face is automatically selected. Select the other faces to be transferred.
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41. Click OK.
Create Wire
Flat Pattern Result (Blank)
We will now create the flat pattern result of the 3D model, in order to place it on the strip as the initial form of the
final part. In this example, the part is composed of flat and cylindrical faces. Therefore, in this case we can use
the simple Unfold operation rather than using the Blank operation.
Select the Unfold icon, to add a new Unfold forming shape.
Select the reference face of the 2nd Forming Shape (skin) as indicated in the picture.
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42. Unselect the faces indicated by the arrows.(These face will not be unfold) Exit.
Make sure you use a K-Factor of 0.5.Name it Blank and then select the Create Wire option.
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43. Click OK.
From the Die Design Guide, select the Forming Shape icon and then select the Relocate option.
Place the new forming shape at the most right location and then click OK.
Add Mirror Part
Flat Pattern Result (Blank)
Add a new Forming Shape.
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44. Select the Open file icon, and load the 1_Mirror skin file and then click OK.
Using the arrows, place it on the right hand side of the mirror part.
Click OK.
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45. Add the following files in the order shown below:
• 2_unbend
• 3_unbend
• 4_Mirror bend
• 5_Mirror_unfold
• 6_miror_blank
Repeat the same operation with the rest of the mirror forming shapes
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46. Strip
Nesting
Strip
Nesting
In this stage we will cerate the strip.
From the Die Design Guide select the Switch to Strip icon.
We will now define the Nesting.
Nesting Definition:
The blank shapes are brought into the strip and are placed in a Layout manner.
Controlling the utilization of the strip by arranging the blanks in the most efficient way.
From the DieDesign Guide, select the Nesting icon and then select the Two different Parts option, as
shown below:
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47. Select the two blank forming shapes (Blank and Mirror Blank)
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48. Nesting Parameters
We will now define the parameters of nesting. These include, orientation and distances.
Change the Min Distance value to 3.00.
Use the Flip option if required.
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49. Change the Strip Width option to Float (marked in red below) .
Change the Shift value to 46.000.
Rotate the rows as follows:
• Row 1 = 270
• Row 2 = 270
Use the arrow icon (shown below) to define the rotation angle by selecting two points to define the direction.
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50. Set the other parameters as shown in the picture and click OK.
Expand the other parameters
Note how the position and orientation effect the parameters such as Net Utilization, Scrap Area and more. and
more.
Strip Dimensions
We will now define the following dimensions of the strip:
• Width
• Margins
• Start Margin
• Number of Steps
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51. From the Die Design Guide, select the Strip Dimension icon.
Set the dimensions as follows:
• Strip Width: 236
• Start Margin: 21
• Top Margin: 3
• Bottom Margin: 3
• No of Progressions 8
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52. Click OK.
The structure of the strip assembly, is as follows:
• Strip Part: The strip which represents the metal sheet. After completing the Strip Dimension stage, the
strip (rectangle skin) face is created in the Strip Part. The strip is editable, through the Strip Dimension
option.
The strip contains all Punch/Trim, Progressive Copy operations and composite curves. These
operations will automatically be created under the Strip Part.
• Assisting Part: The Assisting Part contains all wire operations such as Sketcher, Corner and more.
These operations will automatically be created under the Assisting Part.
• Blanks: After completing the Nesting stage, the blank parts are added to the Strip sub-assembly as
instances. In addition, two new parts are added.
Punch/Trim
In the following step we will use the Punch/Trim functions to trim the strip in a specific station or in several
stations. In addition to the trimming operations we will create the Punch. The Punch trims the strip part in a
specific station or in several stations (in one operation) in order to simulate the actual cutting of the strip.
The user creates a punch (in addition to the trim) with specific attributes for automatic use in the die set.
The user selects a closed 2D wire (sketch, composite or wire body) and will trim/punch the strip in a single
station (not necessary where the wire is located) or in few stations in one operation.
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53. Design the Carrier
The carrier is the part of the sheet that remained untrimmed along the stations. This part carries the blank until
its final shape in the last station.
From the Die Design Guide select the Curves icon and then select the Sketcher option.
Note that it is important to open it from the Die Design Guide as it activates the correct part.
Add the reference points.
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54. Create the sketch shown in the picture below.
Note that we have added the reference points for your convenience, but it is possible to create a rougher sketch
which penetrates the blanks. As you will see later, this does not interfere with the creation of punches.
Progressive Copy
This is special tool copying any type of geometry (excluding the strip faces) to a defined position (or multi
positions) along the strip according to the pre defined step
Copy also entities from the forming shape parts (like dimples) to the strip (to several stations in the strip
We will now copy the carrier shape to the end of the strip.
Select the Progressive Copy icon from the Die Design Guide.
Note that it is important to open it from the Die Design Guide as it activates the correct part.
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55. Select the Carrier sketch. (Note that the Sketches & Composite filter is on.)
Select the following parameters:
• Don’t Mark First Appearance
• Copy to End
Create the Pilot
The pilot is centralizing the sheet metal to ensure that the blank will be positioned accurately in each progressive
station.
Create a pilot hole sketch, as shown in the picture below.
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56. Note that it is important to open it from the Die Design Guide as it activates the correct part.
Create the Pilot Punch
From the DieDesign Guide select the Punch icon.
Select the Pilot sketch. Accept the default parameters: Punch, Trim 2D, Keep Scraps and Trim To End.
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57. Click OK.
Create Punch
Create more sketches as a preparation for further punches.
Create the following sketch. Add three lines, as shown below.
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58. Exit the Sketcher. Create a round corner for each corner. Set the Radius Value to 1.
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59. Create a composite curve using the Punch/Trim Curve - 2D –Single Indication option.
Click somewhere inside the area of the composite curve you would like to create.
The system automatically finds the smaller closed contour that surrounding the pick point.
Click OK.
Create Punch 1
From the DieDesign Guide select the Punch icon.
Select the contour previously created.
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60. Accept the default parameters.
Click OK.
Create Punch 2
Repeat the same operations with the same punch on the other side. However, in this case move the punch
to the third station (one after the station of the sketch).
Select the previously created contour.
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61. Create another punch:
Create another sketch as shown in the picture below:
Apply corners set the Round value to 1.
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62. Create Punch 3
Create a 2D Single indication composite.
First select a point as indicated by the arrow in the picture below.
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63. To add more areas to be included in the composite curve, select more points as indicated by the arrows.
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64. Click OK to confirm the composite. Create another punch. Move it to the next station.
Mirror Wire
Copy the composite (mirror)
Show the previously created sketch (under the last punch operation in the strip part).
Create a plane XZ in the middle of the strip.
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65. Select the Mirror Wire option. Select the composite, select the mirror plane.
Create the punch.
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66. Copy the Dimples
In order to copy the dimples from the forming shapes, you must first trim the area of the dimple.
Select Trim.
Select the contour as indicated by the arrow in the picture below:
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67. Click OK.
Create Trim on the other side.
Copy the Dimples 1
From the DieDesign Guide, select the Progressive Copy icon.
Select the faces of the dimples of one of the forming shapes.
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68. Select the second shape (the first one turns to yellow).
Accept the default parameters and click OK.
Note that the dimples are automatically placed in the right location and orientation.
The Don’t Mark First Appearance option will not create a Punch for the copied shape. To create a Punch,
toggle this option.
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69. Copy the Dimples 2
Repeat the last operation for the mirror part.
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70. Select OK.
Create more Punches
Create another six punches as shown in the picture below:
Create the last two punches:
First create two lines as shown in the picture
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71. Create corners of Raduis = 1 on both sides.
Create More Punches 1
Create a 2D composite.
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72. Create a punch which starts in the third station. After selecting the composite curve, pick the contour at the
third station in order to place the punch there.
Create the other punch, starting from the second station.
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73. Edit Punch
Right-click on the last punch that was created, a popup submenu is displayed. Select Edit Feature.
Select the forth station.
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74. Place the Forming Shapes
First, trim the blanks from the fifth station to the end (repeat the operation with the mirror blank). Use the
Trim 2D+3D option to trim the dimples too.
Trim the blank on the other side.
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75. We will now add forming shapes to the strip.
Hide the contour of the last trimmed shapes.
From the DieDesign Guide, select the Forming Shape icon and then click Add.
Select the first forming shape (from the right) of the first row.
Select the fifth station point.
The system automatically displays all available points in the strip to place the forming shape in.
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76. Click Apply.
Place the Rest of the Forming Shapes
Add the second forming shape on the right, and place it in the next station.
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77. Add the third and the fourth forming shapes.
Note that the fourth forming shape is placed in the last station of the current size strip. We will therefore
enlarge the strip and its number of progressions (meaning, stations).
Edit Strip Dimensions
Select the Strip Dimension icon.
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78. Set the Number of Progressions to 11.
Click OK.
Place the rest of the forming shapes.
Place the skin part (last shape) twice.
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79. Add the Final Punch
Create Punch. Select the carrier contour (create a 2d contour) of the last progression.
Final result Master_DD.ctf.
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