How to Re-design and Model the B surface and C surface of Front right door switch panel using its Class A surface using CATIA V5

Objective: To use Class A surface and make B surface using it then making the C surface then join the bodies and make it into a complete Plastic solid of 2.5mm thickness.

Workbenches Used:

1. Part Design
2. Generate Shape Design

Commands used:

1. Creating new geometrical sets and renaming them
2. Point using Circle centre
3. Creating a new axis system
4. Bisecting Line
5. Offset Surface
6. Extracting the Surface
7. Converting the edges by using Intersect 3D lines
8. Extrapolating the extracted surface
9. Applying the fillets to Surface edges
10. Trim out the edges which are excess
11. Split the edges where you can not use trim
12. Curve Smooth
13. Sweep Surface
14. Join surface
15. Solidifying the surface body

Procedure:

1. First we have to create a point inorder to create a new axis system.
2. We can create axis systen and should select an option not as current axis system in order to fix that axis system.
3. Now we have to create tool axis which helps you to find out whether the part is manufacturable or not.
4. In the below figure the green dotted line is the tool axis of the part that we have re-designed.
6. After creating the tool axis extract the required surfaces which would be helpful for creating B surfaces.
7. Then untrim the surfaces to create the extracted surfaces into plan sheet kind of shape inorder to create into a sheet like structure as below
9. Now after extracting all required surfaces offset them with distance of 2.5mm which usually is the thickness of plastic components used in Automotives.
10. Extrapolate the surfaces which were extracted and offsetted previously and then start trimming out the edges of surfaces which ever are not required.
11. After getting the required shape switch on the Class A surface and use the boundaries of that surface to project the curves of the edges and make them smooth by using Curve smooth command.
12. After that use the smooth curves obtained as the guide curves for sweep option and sweep the C surface edges required.
13. Then trim out the edges whichever are in excess and join the surface bodies in order to form as the below shape.
15. After joining the bodies enter into the part work bench in order to make solid body. Below is the attached figure of the final solid part which I have created