We implemented an automated CAD to BOM synchronization solution using CAD Connector that cut our engineering cycle time by 40%. Previously, our engineers manually created BOMs from SolidWorks assemblies, taking 2-3 hours per product and introducing frequent attribute errors.
The automation handles multi-level assembly structures with scheduled overnight syncs. We mapped 15 critical CAD attributes (material, mass, supplier code, finish) directly to BOM item properties. The system processes assemblies up to 8 levels deep, maintaining parent-child relationships automatically.
Key implementation included custom attribute mapping rules, conflict resolution logic for changed components, and automated notifications when sync issues occur. Engineers now spend 20 minutes reviewing auto-generated BOMs instead of hours building them manually.
How did you tackle multi-level assemblies? That’s typically the trickiest part. Did you flatten the structure or maintain the full hierarchy? Any issues with circular references or shared components across multiple assemblies?
Very interesting approach. What about your attribute mapping strategy? Did you create custom item types or extend standard Part items? We struggle with maintaining mappings when CAD properties change or new properties get added by design teams.
We extended standard Part with custom properties for CAD-specific attributes. Created a configuration ItemType that stores mapping rules as XML - makes it easy for admins to update mappings without code changes. When new CAD properties appear, system flags them in a review queue rather than failing silently. This gave us flexibility while maintaining data integrity.
We maintain full hierarchy using Part BOM relationships. The sync algorithm processes assemblies top-down, creating or updating BOM structure items at each level. For shared components, we implemented reference counting to detect when a part appears in multiple assemblies - it creates the part once and links it appropriately. Circular references are caught during validation phase before BOM creation starts.
Comprehensive implementation that addresses all critical aspects of CAD-BOM automation. Let me break down the key success factors:
Automated Sync Scheduling: The overnight batch processing approach is optimal. Running at 2 AM with 50-file batching prevents production impact while handling typical daily change volumes. The throttling mechanism is crucial for large assemblies. Consider adding incremental sync for urgent changes - a manual trigger for specific assemblies when engineers need immediate BOM updates during critical design phases.
Attribute Mapping: The configuration-driven mapping using XML storage is excellent architecture. This separates mapping logic from code, enabling business users to manage mappings. The review queue for unmapped properties prevents data loss while maintaining process integrity. Recommend adding version control for mapping configurations to track changes over time and enable rollback if needed.
Multi-Level Assembly Handling: Top-down processing with reference counting for shared components is the correct approach. Your circular reference detection in validation phase prevents corrupt BOM structures. For complex products with 8+ levels, consider implementing progress tracking so engineers can monitor sync status for large assemblies.
Additional Recommendations:
- Implement delta sync to process only changed components rather than full assemblies
- Add metrics dashboard showing sync success rates, processing times, and error patterns
- Create rollback capability for syncs that introduce unexpected changes
- Consider conflict resolution rules when CAD and BOM are both modified between syncs
Your 40% cycle time reduction demonstrates significant ROI. The combination of scheduled automation, flexible mapping, and robust hierarchy handling creates a scalable solution. This architecture can extend to other CAD systems beyond SolidWorks with minimal modification to the core sync engine.
This is excellent work. How did you handle the scheduling aspect? We’re looking at similar automation but concerned about server load during business hours. Did you use standard Aras scheduled methods or implement custom scheduling logic?
We used Aras scheduled server methods triggered at 2 AM daily. The method queries for modified CAD files in the vault, processes them in batches of 50, and generates sync reports. Average processing time is 45 minutes for our 300-400 daily file changes. We added throttling to prevent overwhelming the database during large assembly imports.