Hi All,

I have a design problem for all of you SolidWorks professionals out there :)

I am designing a broach for a hip stem model. I have modelled these before and the process is extremely long because it involved creating 40 - 50 Cut-sweeps around the profile of the stem. This uses a large amount of processing power, and normally close to the end of the design Solidworks starts to crash because there are so many sketches, planes, and features involved in making the teeth of the broach.. I have attached a quick mock model with a few teeth to illustrate what I mean. These teeth are to repeat along the length of the stem.

If there are 50 teeth, this will be normally 50 planes, 50 sweep paths sketches, 50 tooth profile sketches, and 50 cut-sweep profiles..

Therefore, I am looking for an optimised solution that can create teeth along a hip stem model without needing all of these sketches and features. Hopefully one of you Solidworks Geniuses can figure this out :)

The following solution was nearly there, but the chamfer feature does not great teeth:

- Split the stem at each tooth level into seperate bodies, then apply a chamfer to the edge of each sub body. (This doesnt work optimally)

Any cool, out of the box, solutions are welcome ! Lets see what you guys got :)

Kind Regards

Scott