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SolidWorks Boundary Cut Feature Tool_SolidWorks Tutorial 3

Hi friends, Welcome to Solidworks tutorials for beginners and in this tutorial you are going to see how to use Solidworks boundary cut feature tool for creating complex product designs. Boundary cut feature tool is just like Boundary boss or base tool, but function just opposite to it. Boundary boss helps to add materials between two profiles; instead of adding boundary cut removes the materials from in two directions. You have to specify the two boundaries and apply cut feature tool to remove material even in complex manner.

What is SolidWorks Boundary Cut Feature?

SolidWorks boundary cut is a cut feature tool which helps to cut a solid model by removing material between profiles in two directions. You have to create sketch profiles in two boundaries of the solid model. Boundary cut tool is located in features command manager or cut feature from insert menu. Using the this tool, you can cut solid model design in very complex manner through curves, normal to sketch profiles, apply curvy feature to holes, tangent to faces, using direction vector etc. Solidworks boundary cut applications are creating different cross-section curved holes, mold design, complex shape face material removal etc.

Note: This is just tutorial showing how to use Boundary cut tool, not showing any product drawing or designing in it. If you are advanced SolidWorks user please avoid it. This Solidworks tutorial is for beginners, students or people likes to learn about SolidWorks.

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Other tutorials of cut feature tools such as Extrude cut, Swept cut, Revolve cut and Loft cut are available on

Watch SolidWorks boundary Cut Step by Step Video Tutorial:-

Let us see the step-by-step guide for using boundary cut feature tool in SolidWorks CAD software.

 How to Use SolidWorks Boundary Cut Tutorial?

In this tutorial, I am going to create a rectangular plate having dimension “500 x 250 x 50 mm” and create curve hole (diameter 40 mm and 80 mm) on the one of the flat face between two edges.

solidworks boundary cut tutorial_boundary cut final image

Step 1: Create a Part File

Open SolidWorks CAD software. Click on the ‘New’ button from the quick access toolbar or from file menubar. From that, select ‘Part’ and click ‘OK’. Then you can see the Main user interface of SolidWorks modeling software.

File -> New -> Part -> OK

solidworks boundary cut tutorial_create deafult right plane

Select the default “Right Plane” from the Features DesignTree manager. Go to Heads-up toolbar and click on “View Orientation” and click on “NormalTo”. Then you can see the Top plane view changes from isometric to XY plane.

Step 2: Sketch the Profile

Go to sketch command manager and click on ‘center rectangle sketch tool’. Then draw a rectangle by setting the center on origin and drag outward direction.

solidworks boundary cut tutorial_create recatngular profile on right plane sketch

Using the smart dimension tool, you can adjust the dimension of the rectangle by 500 x 50 mm.

solidworks boundary cut tutorial_apply smart dimesion tool to set diemsion as 500 length and 50 thickness

solidworks boundary cut tutorial_created rectangular plate

Click on “Exit the sketch” button form sketch toolbar.

Related SolidWorks Features Tools Tutorials:-

Step 3: Apply Extrude Boss to Create Rectangular Plate

Go to Features commandmanager, select the ‘sketch 1’ and select Extrude boss or base tool. Extrude it any one of the direction normal to profile to create rectangular plate by setting extrude length ‘250mm’.

solidworks boundary cut tutorial_extrude boss or base application to create 3d rectangular platesolidworks boundary cut tutorial_rectangular plate created using extrude boss feature tool

Step 4: Sketch Two Circle Profiles on Opposite Faces

Again, select one of the faces of rectangular plate and go to sketch toolbar to select the ‘circle sketch tool’. And draw a circle on the face by setting the center on the top edge 200 mm away from the origin. Using Smart dimension, you can set the circle diameter as ‘40 mm’ and distance from the center of the circle and origin is ‘200 mm’. It is shown in the below figure:-

solidworks boundary cut tutorial_create first circle on the top edge of the face

Click on the “Exit the sketch” button and select opposite face and apply ‘NormalTo’. Then draw another circle profile having diameter ‘80 mm’ and 200 mm away from the origin as shown in the below screenshot.

solidworks boundary cut tutorial_create second circle sketch on the opposite face and side

solidworks boundary cut tutorial_two cicrcular sketch profiles showned

Click on the ‘Exit the sketch’ from the sketch toolbar.

Step 4: Select SolidWorks Boundary Cut Feature Tool

From Features Command Manager

solidworks boundary cut tutorial select boundary cut from the solidworks features commanad managerGo to Features Command Manager, click on the ‘Boundary cut’ feature tool.

From Menubar

solidworks boundary cut tutorial_select boundary cut feature from the cut feature menu from insert menubar

Click on “Insert Menu” and from drop down menu, select “Cut” feature. Again you can see side drop down menu and select “Boundary cut” from it.

Then, you can see the Boundary cut property manager.

Step 5: Apply SoildWorks Boundary Cut Feature

You can see the two direction boxes in Boundary cut property manager such as “Direction 1 and Direction 2”. In “Display” tab, you can see the mesh preview and mesh density. Adjust the mesh density to get smooth curve or boundary cutting using this tool. In the “Direction 1 or Direction 2” tab, you can see the draft angle and tangent length setting box and setup the draft angle and tangent length to get proper boundary cut between the profiles as you created. Let us see how to apply this between two circular profiles.

Open the “Direction 1” tab and first click on the sketch 2.

solidworks boundary cut tutorial_select sketch 2 on the dierction 1 tab

Then select the ‘sketch 3’ and you can see the boundary cut preview here.

solidworks boundary cut tutorial_remove material from two icrcle sketch profile preview

Click and hold on the green point using mouse pointer and make it is same direction for getting smooth profiles. If you set green points between the profiles in different angle to get twisted or irregular boundary cut. Here I am making to same direction to get smooth curve.

solidworks boundary cut tutorial_adjust the two green points to get smooth boundary cutting

Then on each sketch apply “Normal to profile” option which is shown in the screenshot.

solidworks boundary cut tutorial_apply normal to profile option from boundary cut property manager

After that, apply draft angle as ‘1 degree’ and tangent length as ‘1.2 mm’.

solidworks boundary cut tutorial_set draft angle and tanagent length

Step 6: Click OK

Click on green tick button on the Boundary cut property manager to make it ‘ok’. Then you can see the final image like seen on the below screenshot.

solidworks boundary cut tutorial_final boundary cutted model or design create surface curved path

This way you can apply Solidworks boundary cut feature tool to create complex surface cutting. There are lot of applications for this cut feature tool and you will see each one of the in the upcoming Solidworks tutorials.

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