SolidWorks Tutorial 2026 – Parametric Twisted Wire / Cable with Twist Along Path

SolidWorks Tutorial 2026 – Parametric Twisted Wire / Cable with Twist Along Path (Updated & Redesigned)

Original Video Tutorial (2020) by Ivan Oblak:
Watch the step-by-step video demonstration here (Assembly context with equation table for parametric wire):

This is the **fully redesigned and updated 2026 text version** of the tutorial. It features cleaner steps, better global variables/equations setup, multi-strand options, and tips compatible with the latest SolidWorks releases. Use this as a companion guide or standalone reference.

Goal: Build a fully parametric single-wire or multi-strand twisted cable that updates instantly when you change diameter, length, twist count, or path – great for renders, animations, electrical mockups, or 3D printing.

Step 1 – Create the Path (3D Sketch or Helix)

1. Insert → 3D Sketch.
2. Draw the wire centerline using Spline (best for flexible/organic routing) or lines/arcs.
3. Add tangent relations at ends if connecting to connectors.
4. Fully define the sketch.
5. Exit.

Perfect uniform twist path alternative: Insert → Curve → Helix/Spiral (faster for straight or cylindrical routing).

Step 2 – Create the Profile (2D Sketch)

1. New 2D Sketch on Front Plane (or plane intersecting path start).
2. Draw circle(s) for wire diameter (e.g. Ø1.8 mm).
3. Add Pierce relation: circle center to path start point.
4. Dimension diameter → link to global variable (Step 4).

Multi-strand version: Draw 2–19 small circles (circular pattern in sketch), space them realistically.

Step 3 – Swept Boss with Twist

1. Features → Swept Boss/Base.
2. Profile: select circle(s).
3. Path: select 3D sketch or helix.
4. Orientation/Twist Type: Twist Along Path.
5. Define By: Revolutions → link to global variable.
6. Optional: Tangent to Path for smooth ends.
7. OK.

Step 4 – Parametrization with Equations

1. Tools → Equations.
2. Add global variables (examples):

"Wire_Dia"         = 1.80
"Twist_Revs"       = 24.0
"Path_Length"      = 450     (or link to path length dimension)
"Twist_per_meter"  = "Twist_Revs" / ("Path_Length"/1000)

3. In Sweep: link revolutions to "Twist_Revs", diameter to "Wire_Dia".
4. Save → change values in Equations → model rebuilds automatically.

Auto path length: In 3D sketch add Path Length Dimension → link "Path_Length" to it.

Step 5 – Enhancements for Realism

• Multi-body: Sweep conductors first → then outer insulation (Thin Feature).
• Appearances: Copper + rubber/plastic.
• Fillet ends (0.3–0.8 mm).
• High-twist rope: 7–19 strands + 40–80 revs.

Advanced Alternatives

• Exact length calc: Measure path + equation.
• Complex harness: Use SOLIDWORKS Routing / Electrical 3D.
• Braided: Multiple helices + pattern.

Download free part from original video: Google Drive link

Happy modeling! Questions? Drop a comment. More tutorials coming soon.

Updated: January 2026 • Original video: November 2020

The ideal time has come for SolidWorks training

Dear friends, if anyone is interested in training for the SoliWorks software package, you are in the right place.

I am a mechanical engineer with extensive practical work experience. In my work I used SolidWorks, which is an indispensable tool for every engineer.

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