NIST GCR 15-1009

Investigating the Impact of Standards-Based 

Interoperability for Design to Manufacturing and 

Quality in the Supply Chain

Kevin Fischer

Rockwell Collins

Phil Rosche

Advanced Collaboration Consulting Resources

Asa Trainer

International TechneGroup Incorporated

This publication is available free of charge from:

http:// dx.doi.org/10.6028/NIST.GCR.15-1009
NIST GCR 15-1009

Investigating the Impact of Standards-Based 

Interoperability for Design to Manufacturing and 

Quality in the Supply Chain

Prepared for 

U.S. Department of Commerce

Engineering Laboratory 

National Institute of Standards and Technology 

Gaithersburg, MD 20899 

By

Kevin Fischer 

Rockwell Collins 

Phil Rosche 

Advanced Collaboration Consulting Resources 

Asa Trainer 

International TechneGroup Incorporated 

This publication is available free of charge from: 

http:// dx.doi.org/10.6028/NIST.GCR.15-1009 

December 2015

U.S. Department of Commerce 

Penny Pritzker, Secretary 

National Institute of Standards and Technology 

Willie May, Under Secretary of Commerce for Standards and Technology and Director 
Disclaimers

This report was prepared for the Engineering Laboratory of the National Institute of Standards and 

Technology (NIST) under the following cooperative agreement:

 70NANB14H314, International TechneGroup Incorporated, “Investigating the Impact of 

Standards-Based Interoperability for Design to Manufacturing and Quality in the Supply Chain”

Any opinions, findings, conclusions, or recommendations expressed in this publication do not necessarily 

reflect the views of NIST. Additionally, neither NIST nor any of its employees make any warranty, 

expressed or implied, nor assume any legal liability or responsibility for the accuracy, completeness, or 

usefulness of any information, product, or process included in this publication.

This paper may identify certain commercial systems. Such identification does not imply 

recommendation or endorsement by NIST. Nor does it imply that the products identified are necessarily 

the best available for the purpose.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

ii

Table of Contents

Executive Summary...................................................................................................................................... iv

Project Team................................................................................................................................................. v

Introduction ..................................................................................................................................................1

The Model Based Enterprise.....................................................................................................................1

A Reliance on Drawings.............................................................................................................................1

The Promise of STEP .................................................................................................................................2

An Impact to Cycle Time and Quality........................................................................................................2

Barriers to Model-Centric Data Interoperability.......................................................................................3

Opportunity for a Standards-Based Solution............................................................................................3

Motivation for the Study...............................................................................................................................4

Method .........................................................................................................................................................5

Approach Outline......................................................................................................................................5

Considering Use Cases..............................................................................................................................5

OEM Use Case.......................................................................................................................................5

Supplier Use Cases................................................................................................................................6

Defining Metrics........................................................................................................................................6

OEM Metrics.........................................................................................................................................7

Supplier Metrics....................................................................................................................................8

Create the Test Models and Data Sets......................................................................................................8

Map the PMI into STEP and ACIS ............................................................................................................13

Demonstrate Standards-Based Interoperability.....................................................................................14

CAD Process ........................................................................................................................................15

CAM Process .......................................................................................................................................15

CMM Process......................................................................................................................................16

Data Exchange Issue Resolution .........................................................................................................17

Results.........................................................................................................................................................18

Results from Mapping PMI between STEP and ACIS ..............................................................................18

Results from Embedded PMI Data Exchange..........................................................................................19

Results from CAD Model Creation ..........................................................................................................19
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

iii

Results from CAM Model Creation .........................................................................................................20

Results from CMM Model Creation and Inspection ...............................................................................21

Discussion and Recommendations.............................................................................................................22

Model Validation and Verification..........................................................................................................22

ACIS and Embedded PMI Gaps ...............................................................................................................22

CAD Process Observations......................................................................................................................23

CAM Process Observations.....................................................................................................................25

CMM Process Observations....................................................................................................................26

Conclusions.................................................................................................................................................27

Tools........................................................................................................................................................27

Standards................................................................................................................................................28

Processes.................................................................................................................................................28

Summary .................................................................................................................................................29

Acknowledgements.....................................................................................................................................30

Works Cited.................................................................................................................................................32

Appendices..................................................................................................................................................33

Appendix A: Use Cases............................................................................................................................33

Visualization and Collaboration Use Cases.........................................................................................33

OEM Use Cases ...................................................................................................................................33

Supplier Use Cases..............................................................................................................................35

Appendix B: Mapping PMI into STEP and ACIS .......................................................................................36

Appendix B.1: Mapping GD&T into STEP and ACIS .............................................................................36

Appendix B.2: Mapping Other MBD-related Items into STEP and ACIS .............................................42

Appendix C: Technology Readiness Levels (TRL) ....................................................................................43
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

iv

Executive Summary

To achieve the industry vision of a Model-Based Enterprise (MBE), the MBE strategy must include 

model-centric data interoperability for design to manufacturing and quality in the supply chain. Even 

though there has been a move in industry to become model-centric, today there is still significant 

manual intervention in the supply chain to go from product design to manufacturing and quality 

inspection. The ISO 10303 Standard for the Exchange of Product Model Data (STEP) data standard can 

minimize much of the manual intervention. The majority of STEP implementations have been primarily 

focused on CAD-to-CAD and long-term data archival. Significant opportunity exists for STEP-based CADto-CAM and CAD-to-CMM data exchange.

The vision for this project was developed following a survey of small and medium enterprise (SME)

suppliers. Despite being in the digital age, a large percentage of SME suppliers still receive OEM designs 

as full-detail-2-dimensional (2D) drawings or as a combination of 3-dimensional (3D)-shape-geometry 

models plus 2D drawings containing the product and manufacturing information (PMI). A large 

percentage of suppliers must either completely remodel the part or manually add the PMI to the 

imported shape-geometry model. Much of the CAD industry has implemented STEP AP242 with 

embedded PMI, reducing the need for drawings. The same degree of implementation has not occurred 

in the CAM and CMM industries. This project demonstrates the value of improved CAD-to-CAM and 

CAD-to-CMM data interoperability using STEP AP242 with embedded PMI. 

This project was developed to investigate high-payback use cases in the supply chain and identify 

opportunities of model-centric standards-based data exchange to:

• Eliminate or reduce significantly the need to re-create downstream models,

• Reduce cycle time and cost,

• Reduce the risk of introducing downstream errors,

• Increase part yield, and 

• Produce higher quality parts.

The project team consisted of an OEM, supplier, system integrators, as well as CAM and CMM system 

providers. The NIST Engineering Laboratory provided direction and guidance for this standards-based 

data exchange demonstration. Three data exchange scenarios were compared in the investigation:

• Full-detail-2D drawing

• 3D-shape-geometry model and a 2D drawing containing the PMI

• 3D model with embedded PMI

Metrics were established to assess the cycle time for CAD, CAM, and CMM model creation and the ease 

of data interoperability in each data exchange scenario. The results were compared and observations 

shared by the project team. There was clear cycle time advantage demonstrated with the use of a 3D 

model with embedded PMI for CAD-to-CMM data interoperability. Gaps were identified in tools, 

standards and interfaces, PMI-feature coverage, modeling knowledge, and best practices.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

v

This project demonstrates the benefits of standards-based product-data interoperability in the supply 

chain for CAD-to-CAM and CAD-to-CMM. It also identifies gaps to be addressed to enable industry to 

achieve its MBE vision of becoming model-centric. This project can help industry push for 

commercialization of the demonstrated capability and achievement of the MBE vision.

Project Team

Project Coordination

Phil Rosche, Advanced Collaboration Consulting Resources

Asa Trainer, International TechneGroup Incorporated

OEM

Kevin Fischer, Rockwell Collins

Tom Matuska, Rockwell Collins

Jesse Pisarik, Rockwell Collins

Scott Wegener, Rockwell Collins

Supplier

Derrick Hess, Geater Machining & Manufacturing

Greg Sondag, Geater Machining & Manufacturing

System Integrators

Guillaume Blanchard, CT CoreTechnologie

David Selliman, CT CoreTechnologie

Gauthier Wahu, CT CoreTechnologie

Ed Paff, International TechneGroup Incorporated

CAM System

Pete Rimkus, CNC Software, Inc.

CMM System

Larry Maggiano, Mitutoyo America

Research Advisors

Allison Barnard Feeney, National Institute of Standards and Technology

Thomas Hedberg, Jr., National Institute of Standards and Technology
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

1

Introduction

The Model Based Enterprise

To achieve the industry vision of the model-based enterprise (MBE), the MBE strategy must include 

model-centric data interoperability for design to manufacturing and quality in the supply chain. The 

model-based definition (MBD) is created by the OEM using computer-aided-design (CAD) tools. This 

information is then shared with the supplier so that they can manufacture and inspect the physical 

parts. Much of the supply base consists of small and medium enterprise (SME) manufacturers. Today, 

almost all suppliers use computer-aided-manufacturing (CAM) and coordinate-measuring-machine 

(CMM) models respectively for these tasks. Traditionally, design data is provided by the OEM to 

supplier in the form of full-detail-2-dimensional (2D) drawings. More recently the data has also included

a 3-dimensional (3D)-shape-geometry model. This shape-geometry model is often provided in a 

standards-based format, STEP AP203 is most prevalent. In addition to shape-geometry, the CAM and 

CMM processes require product and manufacturing information (PMI) to fabricate and inspect the part.

A Reliance on Drawings

Model-based exchange has primarily focused on CAD-to-CAD data interoperability and long term data 

archival. Even with the drive for industry to become increasingly model-centric, there is still significant 

manual intervention when going from OEM to supplier with product design for manufacturing and 

quality inspection. In part, this is due to the fact that the STEP AP203 model provides only shape 

geometry and does not contain the PMI necessary for CAM and CMM models and machine programs.

Despite the industry MBE vision to become model-centric and the model-based hype from major CAD 

suppliers, there is still a reliance on 2D drawings. A survey

1 of SME suppliers shows that many of those 

surveyed still receive design data from their OEM customer in the form of full-detail-2D drawings. 

Another large group receives a 3D-shape-geometry model combined with a 2D drawing containing the 

PMI. Only a small percentage of the SME manufacturers receive just a 3D model with embedded PMI. 

The design to manufacturing process is still very much drawing-centric. The very few data exchanges 

that are model-centric with embedded PMI use proprietary, not standards-based models.2

 

1 Hartman, N., Fischer, K., & Rosche, P. (May 21-23, 2012). Successfully Engaging Small and Medium Enterprises.

3D Collaboration and Interoperability Congress. Englewood, CO.

2 NIST MEP. (November 22, 2009). Phase One Final Report - Assessment of Supplier Capabilities to Operate in a 

Model‐Based Enterprise Environment.

The challenge: Given industry’s vision of MBE, why is model-centric data 

interoperability not more prevalent for design to manufacturing and quality 

inspection?
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

2

The Promise of STEP

Development of ISO 10303 Standard for the Exchange of Product Model Data (STEP) started in 1984. Its 

objective is to provide a mechanism that is capable of describing product data throughout the life cycle 

of a product, independent from any particular system. The nature of this description makes it suitable 

not only for neutral file exchange, but also as a basis for implementing and sharing product databases 

and archiving.3

STEP is developed with a series of integrated data models known as application protocols (AP’s). There 

are dozens of STEP AP’s, which can be roughly grouped into the three main areas design, manufacturing 

and life cycle support. 

Today STEP AP203 Configuration Controlled 3D Design is still one of the most important parts of ISO 

10303 and is supported by many CAD systems for import and export. According to another survey of 

SME suppliers, STEP AP203 is the most commonly used format for CAD-to-CAD data interoperability.4 

But, the STEP AP203 model contains only shape geometry, and not the PMI necessary for downstream 

processes.

In December 2014 ISO published the first edition of a new major application protocol, STEP AP242 

Managed Model Based 3D Engineering, which combined and replaced the following previous AP’s in an 

upward compatible way:

• AP201 Explicit Draughting (simple 2D drawing geometry related to a product with no association 

and no assembly hierarchy)

• AP202 Associative Draughting (2D/3D drawing with association but no product structure)

• AP203 Configuration Controlled 3D Designs of Mechanical Parts and Assemblies

• AP204 Mechanical Design Using Boundary Representation

• AP214 Core Data for Automotive Mechanical Design Processes

In addition, STEP AP242 edition 1 contains extensions and significant updates for geometric dimensions 

and tolerances, kinematics, and tessellation. In other words, STEP AP242 offers standards-based models 

with embedded PMI – exactly what is needed for model-centric downstream CAM and CMM processes.

An Impact to Cycle Time and Quality

With the continued reliance on full-detail-2D drawings or even 3D-shape-geometry models, a significant 

amount of time is spent recreating the product model or adding PMI data to an existing shape model. 

This significantly affects cycle time. Furthermore, there is an increased risk of error from incorrect or 

missing data when recreating or enhancing models for downstream purpose, potentially affecting model 

and part quality.

 

3

ISO/TC 184/SC 4. (1994, December 15). ISO 10303-1:1994. Industrial automation systems and integration --

Product data representation and exchange -- Part 1: Overview and fundamental principles. International 

Organization for Standardization.

4 Hartman, N., Fischer, K., & Rosche, P. (May 21-23, 2012). Successfully Engaging Small and Medium Enterprises.

3D Collaboration and Interoperability Congress. Englewood, CO.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

3

In the survey mentioned earlier, SME manufacturers reported spending 2-4 hours adding PMI to a 

simple CAM model. They also reported spending twice that time, 4-8 hours, adding PMI to the CMM 

model.5 For more complex parts, an automotive engine block for example, the recreation of 

information for CAM and CMM might take weeks after receiving the OEM 2D drawing or 3D-shapegeometry model.

Barriers to Model-Centric Data Interoperability

Even with the introduction of STEP AP242, what keeps industry from moving toward the MBE vision? 

Especially, why can’t industry achieve a vision that includes model-centric data interoperability when 

going from design to manufacturing and inspection across the supply chain? In the team’s opinion, 

some of the barriers that keep industry from being more model-centric include:

 The 2D drawing is still considered the master versus the 3D model by many in industry.

 There is a significant learning curve to effectively embed PMI into a 3D CAD model.

 Many application program interfaces (API’s) do not adequately support downstream processes 

due to lack of PMI.

 Major product lifecycle management (PLM) tool providers are concerned with losing market 

share due to easy data exchange through standards-based implementations.

 The CAM and CMM markets are distributed across many SME manufacturers and there is no 

significant aggregation of industry that drives CAM and CMM providers to implement standardsbased solutions.

Opportunity for a Standards-Based Solution

This project team composed of Aerospace and Defense industry members, along with several CAD, CAM,

and CMM solution providers, discussed possible approaches to more effectively enable model-centric 

data exchange for CAD-to-CAM and CAD-to-CMM. Many CAM and CMM systems are based on the 

ACIS®

6 modeling kernel and can already ingest model geometry and PMI data through their respective 

API’s. They also ingest standards-based model geometry via STEP AP203. So, why can’t they ingest 

standards-based PMI data now that STEP AP242 is available? Wouldn’t this model-centric data 

exchange offer significant improvement in cycle time, model quality, and part quality? Can it be 

demonstrated that STEP AP242 minimizes much of the manual intervention and provides significant 

opportunity for standards-based CAD-to-CAM and CAD-to-CMM data interoperability? Lastly, could this 

 

5 Hartman, N., Fischer, K., & Rosche, P. (May 21-23, 2012). Successfully Engaging Small and Medium Enterprises.

3D Collaboration and Interoperability Congress. Englewood, CO.

6 ACIS is a registered Trademark of Spatial Corporation.

The hypothesis: The ACIS and Parasolid modeling kernel can support CAD-to-CAM 

and CAD-to-CMM using STEP AP242 to exchange model-based definition with 

embedded PMI, reducing cycle time while improving model and part quality.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

4

demonstration plant a seed with the CAM and CMM industries to further commercialize STEP AP242 

implementations?

This project will test the hypothesis that model-based data interoperability from CAD-to-CAM and CADto-CMM is practical and that there is significant value in implementation of STEP AP242 as a standardsbased solution. The project will answer the questions of feasibility and value through demonstration 

and measured results. It will also provide for discussion and recommendations based upon the findings

and observations. Finally, the project will draw conclusions toward the pursuit of industry’s vision of the 

Model Based Enterprise and the feasibility of standards-based model-centric data interoperability.

Motivation for the Study

With a supported hypothesis, the team believes this project will motivate industry in its drive to achieve 

the vision of the Model Based Enterprise. The goal of this project was to demonstrate the value of 

model-centric CAD-to-CAM and CAD-to-CMM data interoperability when using STEP AP242 with 

embedded PMI. The anticipated benefits from this standards-based approach between the systems and 

across the supply chain include:

• Eliminating or reducing significantly the need to re-create part models,

• Reducing cycle time and cost,

• Reducing the risk of introducing downstream errors,

• Increasing part yield, and 

• Producing higher quality parts.

The technology developed by this project is extensible to include PMI-data items beyond those used in 

the project test models. The CAD, CAM, and CMM applications can successfully exchange more complex 

parts than the test models used in this project. 

This project demonstrates the applications have achieved Technology Readiness Level (TRL) 6 and 

industry is pushing for further technology maturity. The current TRL scale runs from level 1 to 9. TRL 1, 

the least mature technology readiness level, is the state when basic research ideas are taking the first 

steps toward practical application. TRL 9 is the most mature technology readiness level and the product 

is in full production use. TRL 6 is the maturity level where a prototype capability is represented in a 

simulated operational environment. Organizations will typically begin to adopt technology as it achieves 

TRL 7 or higher. A full list of the TRL definitions is given in Appendix C. 

Demonstrating the technology readiness for CAD-to-CAM and CAD-to-CMM data-interoperability 

provides motivation to commercialize tools that provide standards-based 3D models with embedded 

The motivation: Demonstrate the value of model-centric CAD-to-CAM and CAD-to-CMM 

data interoperability using STEP AP242 with embedded PMI.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

5

PMI to the CAM and CMM industry. Likewise, the CAM and CMM tools providers should be motivated 

to commercialize the ability to receive and utilize the standards-based 3D models with embedded PMI.

As the identified gaps in current tools and standards are addressed to achieve this level of 

commercialization, and the process and skill gaps are overcome by industry users, the opportunity to 

improve efficiency and effectiveness across the product lifecycle will be provided in design, bidding and 

quoting, manufacturing, inspection, and collaboration across the supply chain.

Method

Approach Outline

To test the hypothesis, the following approach was used:

• Consider the use cases creating or utilizing CAD, CAM, and CMM data.

• Develop metrics to compare results of current versus future model-centric processes,

• Map model-based PMI requirements to STEP AP242, map STEP AP242 to ACIS geometric 

modeling kernel, and identify gaps that hinder broad solution deployment, 

• Develop prototype software to demonstrate data interoperability between CAD, CAM, and 

CMM tools using standards-based STEP AP242 models with embedded PMI,

• Test the current and future model-centric processes using representative industry part designs, 

• Validate the CAM and CMM models against the original CAD model for any data loss during 

transformation and any missing CAM or CMM information, 

• Refine the test cases and software following an analysis of the initial results, and

• Collect and analyze the metrics data to determine benefits associated with the process change.

Considering Use Cases

Various product lifecycle use cases were investigated as the project team explored how the benefits 

described earlier might manifest across the product lifecycle. The use cases were organized into two 

categories: (1) use cases that affect the OEM and (2) use cases that affect the supplier. Ultimately, a 

partial set of the use cases (those best aligned to the scope of this project) were used to define the 

project metrics and demonstrate the differences between current-state and future-state processes. 

Below is a description of the use cases that define and affect the metrics for this project. Appendix A

includes the broader set of product lifecycle use cases discussed by the team, including those beyond 

the scope of this project.

OEM Use Case

CAD Model Creation

This use case centers on the creation or authoring of the CAD model. Traditionally, the 3D-shapegeometry model is created without embedded PMI. Once the shape-geometry model is generated, a 

drawing is created, and typically presented in 2D PDF format. It includes the PMI that is not part of the 

3D-shape-geometry model. In the past, the 2D drawing was fully detailed and could be used by itself to 
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

6

manufacture the part. In more recent practice, a 3D-shape-geometry model and a 2D-partial-dimension

drawing are required. The partial-dimension drawing contains only the PMI that is not embedded in the 

shape model. In the current-state scenarios either the full-detail drawing or the combination of the 

shape model and the partial-detail drawing is required for manufacturing processes. In the future-state

process designers will create a 3D model with embedded PMI such that the model will completely 

support the manufacturing and inspection processes. 

CAD Validation and Verification

This use case involves validation and verification of design intent, model correctness, and producibility. 

Persons with the appropriate subject matter expertise review the design at points in the lifecycle to 

determine that it meets design intent, follows best drawing or modeling practices, and meets desirable

producibility expectations. The traditional way of visually inspecting drawings, and more recently 

models, does not always work. With model-based design it is not possible for a human (visual) 

inspection of the model to detect all issues. As a result, rules-based systems have been introduced to 

automate the process, especially for model and producibility analysis. In addition to analyzing the 

construct of a unique model, it is also necessary to compare two different models when data exchange 

occurs. This ensures the original design intent is correctly transferred to the downstream model, such as 

when a model is exchanged between design and manufacturing or inspection.

Supplier Use Cases

CAM Model Creation

The CAM-programming use case focuses on the import of a STEP AP203 model for the shape-geometry. 

The 2D drawing is referenced for the PMI not embedded in the model. In addition, the manufacturing 

specifications that are referenced in the drawing are also reviewed to determine additional machine 

programming and secondary operations.

CMM Model Creation

The CMM-model use case utilizes the 2D drawing and the STEP AP203 model to create the CMM model. 

All the PMI is manually entered into the CMM application. The demonstrated future-state directly 

imports the embedded PMI from a STEP AP242 model.

CMM Inspection

The CMM-inspection use case requires a significantly manual and time-consuming process to generate 

the first article inspection report. The inspector must review the CMM results and manually input the 

information into a spreadsheet that conforms to AS9102 FAI report standards.

Defining Metrics

The project team defined a set of metrics to understand the impact of more comprehensive modelbased interoperability. The metrics for the use cases provide a way to compare the current state and 

future state of part design, manufacture, and inspection. The metrics support the investigation of the 

benefits and challenges of data interoperability when using 3D models with embedded PMI for 

downstream purpose. These metrics include cycle time, model quality, part quality, and cost. Table 1

provides the target metrics for each use case.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

7

Table 1: Project use case and defined metrics

Use Cases

Metrics

Cycle

Time

Model

Quality

Part

Quality Cost

at OEM

CAD model creation X X

CAD validation and verification (design intent; model correctness; producibility) X X X

at Supplier

CAM programming X X

CMM programming X X

CMM inspection X X

Cycle Time Metrics

The cycle-time metric measures the time to complete each use-case step and is a key to the project 

investigation. The use cases were divided into a discrete set of steps for the operator to record the time 

it took to complete the step.

Model Quality Metrics

Model quality includes completeness as well as comprehensiveness. One metric compares the number 

of PMI elements found in the models. The PMI data types are broken down by dimension, tolerance, 

datum feature, and notes (with no semantic data). This metric provides visibility into model quality and 

how well the data is translated from native CAD to STEP AP242, to ACIS, and ultimately to the CAM and 

CMM models. As each data model exchange occurs, the PMI elements for the models were compared 

for completeness and comprehensiveness.

Part Quality Metrics

Part quality metrics indicate when the part does not match the design intent. They are found through

CMM inspection and documented in the FAI report. The metrics indicate the clarity of information, 

report generation, etc.

Cost Metrics

While cost is a derivative metric for many use cases, the actual base metric in most of those cases is the 

cycle-time to complete the process. Thus, cycle-time is the metric of focus. Cost is, however, the base 

metric directly affected in part validation, procurement and bidding processes. Cost is identified as a 

metric with direct impact on the accuracy of the bidding process. It also comes into play during a 

producibility reviews when considering design aspects that actually drive an increase or decrease in part 

fabrication costs.

OEM Metrics

The OEM metrics captured for part design include CAD modeling and validation as shown in Table 2.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

8

Table 2: OEM metrics

OEM Process Current-State Process (Metrics) Future-State Process (Metrics)

CAD model creation Create geometry model and PMI drawing

(cycle time, model quality)

Create fully constrained model with 

embedded PMI (cycle time, model quality)

CAD model validation Semi-manual validation (cycle time, model 

quality, cost)

Automated validation (cycle time, model 

quality, cost)

In particular, cycle time metrics were captured during the creation of the 3D model, 2D drawing, and 

embedded PMI. For this project, metrics were also captured and observations recorded for model issue 

resolution and designer education with regard to embedded PMI practices. Lastly, metrics were 

captured for the time required to understand and resolve issues discovered about 3D models with

embedded PMI as the data was imported into the CMM system.

Supplier Metrics

The supplier metrics for part manufacture and inspection involves CAM and CMM programming, 

machining, and inspection as shown in Table 3.

Table 3: Supplier metrics

Supplier Process Current-State Process (Metrics) Future-State Process (Metrics)

CAM programming Import part shape into CAM, manual 

addition of PMI (cycle time, model quality)

Import part shape and embedded PMI into 

CAM (cycle time, model quality)

CMM programming (input) Import part shape into CMM, manual 

addition of PMI (cycle time, model quality)

Import part shape and embedded PMI into 

CMM (cycle time, model quality)

CMM Inspection (output) Manually create inspection programming

(cycle time, part quality)

Automate CMM inspection programming 

(cycle time, part quality)

The metrics captured for part manufacture includes cycle-time to import the shape-geometry data into 

the CAM system. The current-state process also captured the metrics for the manual addition of PMI, 

while the future-state process used embedded PMI directly from the 3D-model import.

The metrics captured for part inspection includes cycle-time to import the shape-geometry data into the 

CMM system. The current-state process also captured the metrics for the manual addition of PMI, while 

the future-state process used embedded PMI directly from the 3D-model import. Metrics and insight 

were captured during the learning curve and issue resolution for importing embedded-PMI models into 

the CMM system.

Create the Test Models and Data Sets

The project team reviewed five part designs submitted by Rockwell Collins as candidates for the test 

models. The team selected two of the parts as the test cases for this project. These were based upon 

the model features and also considered how each part would be machined and inspected given the 

geometric dimension and tolerance (GD&T) callouts. Furthermore, the team added new features to the 

models to test additional machining and inspection criteria. 
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

9

The first part chosen was a rolled standoff shown in Figure 1. The design was altered to create a generic 

part using industry GD&T practices. Modifications were made to the part length. There were no 

additional features added to this part.

Figure 1: Rolled Standoff

The second part chosen was a heat sink shown in Figure 2. The design was altered to create a generic 

part using industry GD&T practices. The heat-sink-fin feature was changed to incorporate a chamfer on 

one end. A heat-sink-pin array with a spherical radius on each pin tip was added near the fins. There 

were standoffs, bosses, and a flatness callout added to the bottom side to drive additional machining 

and inspection elements. Material attributes were added to the models to support downstream system 

input requirements. These attributes included the thermal expansion coefficient, thermal expansion 

coefficient units, and material name.

Figure 2: Heat Sink

The PMI data types included in the project models are shown in Table 4.

Table 4: PMI data types used in the models

PMI data types used in the models
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

10

Datums

Dimensions

Angular

Diameter 

Linear 

Radius

Spherical Radius

Thickness

Dimension Origin Symbol

Tolerances

All Around

Cylindricity 

Total Runout

Flatness

Perpendicularity

Position

Profile Surface

Angularity

After the shape-geometry modifications were incorporated into the models, three different data sets 

were created to investigate how part information is exchanged with a supplier. The first data sets (827-

9999-905 and 827-9999-906) contain only the full-dimension-2D drawing with all of the GD&T callouts, 

per ASME Y14.5, and all other necessary PMI data types. The parts can be manufactured and inspected 

using just the drawings. The drawings are shown in Figure 3 and Figure 4.

Figure 3: Rolled Standoff 827-9999-905

full-dimension-2D drawing
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

11

Figure 4: Heat Sink 827-9999-906

full-dimension-2D drawing

The second data sets (827-9999-907 and 827-999-908) align with ASME Y14.41 practices for creating 

digital-product-definition data. These data sets include a partial-dimension 2D drawing along with a 3Dshape-geometry model without embedded PMI (using the STEP AP203 format). Both the model and the 

drawing are necessary to manufacture and inspect the parts as shown in Figure 5 and Figure 6.

Figure 5: Rolled Standoff 827-9999-907

3D- shape-geometry model (STEP AP203) with partial-dimension-2D drawing
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

12

Figure 6: Heat Sink 827-9999-908

3D-shape-geometry model (STEP AP203) with partially dimensioned 2D drawing

The final data sets (827-9999-903 and 827-9999-904) contain a full-dimension-3D model with embedded 

PMI (using the STEP AP242 format). These parts can be manufactured and inspected completely with 

the 3D model, without the need of a supporting 2D drawing. These data sets are shown in Figure 7 and

Figure 8. The schema aligns with the MIL-STD-31000AAppendix B data structure for PMI presentation. 7 

Once the native CAD model with embedded PMI was created, it was then delivered to the project team 

for translation into the STEP AP242 model used by the downstream CAM and CMM systems.

 

7 United States Department of Defense. (2013, 26 February). MIL-STD-31000A. Department of Defense Standard 

Practice: Technical Data Packages.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

13

Figure 7: Rolled Standoff 827-9999-903

full-dimension-3D model (STEP AP242) with embedded PMI

Figure 8: Heat Sink 827-9999-904

full-dimensioned-3D model (STEP AP242) with embedded PMI

Map the PMI into STEP and ACIS

According to Spatial Corporation, the 3D ACIS® Modeler geometric modeling kernel is used by many 

software developers, including the CAD, CAM, and CMM industries, to provide underlying 3D modeling 

functionality.8 One project research task was to analyze the PMI elements in STEP AP242 and ACIS® to 

determine where gaps exist and what enhancements are needed to address those gaps. This analysis 

was performed and delivered to NIST as an early deliverable for this project. The mapping tables used 

as the basis for the analysis are included as Appendices B.1 and B.2. The gaps and subsequent issues are 

reviewed further in the results and discussion sections.

 

8

Spatial Corp. 3D ACIS Modeling. Retrieved October 09, 2015, from Spatial Products: 

http://www.spatial.com/products/3d-acis-modeling.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

14

Demonstrate Standards-Based Interoperability

The flow diagram shown in Figure 9 demonstrates the data-exchange process from CAD-to-CAM and 

CAD-to-CMM, using commercially viable solutions. Rockwell Collins performed as the OEM. Rockwell 

Collins designed the test parts using Siemens NXTM CAD software. Geater Machining and Manufacturing 

performed as the supplier. Geater used CNC Software Mastercam® for numerical control programming 

for the manufacture (CNC machining and turning) of the test parts. Geater used Mitutoyo MiCATTM 

Planner automatic measurement program generation software to enable inspection of the test parts. 

The data exchange process required the use of CoreTechnologie 3D_Evolution© to convert data from the 

native NXTM CAD shape, metadata, and PMI into standards-based STEP AP242 format. ITI PDElib® data 

exchange library was used to complete the import from STEP AP242 into Mastercam®. ITI eACIS utility 

library was used to complete the import from STEP AP242 into the ACIS® kernel used by MiCATTM 

Planner.

Figure 9: Data exchange process flow diagram

The software tools used for model conversion from CAD to CAM and CMM required algorithm 

enhancements to the currently available commercial versions to enable and fine-tune the exchange of

the semantic PMI data. Issues were identified and resolved in order to successfully exchange the data. 

The project used an iterative approach in the issue resolution process:

 Perform data exchange for each process step,

 Evaluate the output for the required model entities at each process step,

 Identify errors encountered in the individual PMI elements,

 Modify each sub-process algorithm to address the issue, and

 Re-evaluate the updated output until each sub-process converged to a viable end-to-end data 

exchange solution.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

15

CAD Process

The OEM use case process steps, referenced in Table 5, represent the activity most likely affected by the 

inclusion of embedded PMI in the CAD model necessary for downstream manufacturing and inspection. 

The OEM metrics captured for this project focus primarily on the CAD-model creation process steps, but 

also provide some insight into CAD-model validation and verification process. The project also provided

anecdotal observations for the part-receiving-inspection use case, but those come mostly as a result of 

metrics captured for the CMM inspection and reporting use cases.

Table 5: CAD model creation process

Process Steps OEM Steps

CAD

Model Creation

CAD 3D model creation 

Model-embedded PMI

2D PDF drawing creation

CAD tool issue resolution and designer education *

CAD model resolution to address CMM issues *

* CAD model issues and designer education demonstrate the need to overcome gaps in current state of tools and knowledge

CAM Process

The supplier CAM use case process steps represent the activity involved in CAM model creation. The 

project focused on the most useful metrics to record for the supplier for CAM-related process steps. 

The metrics demonstrate the difference between the current-state and the future-state process steps. 

They must provide enough detail to demonstrate the process areas most significantly affected when 

ingesting models with embedded PMI for CAM programming. Finally, the metrics need to align with the 

supplier process steps such that they could be easily recorded. It was determined that cycle-time 

metrics would be most useful to compare current-state to future-state for the CAM process. The 

supplier completed the CAM model creation process steps using the three technical data exchange 

scenarios and manually recorded the cycle-time for the steps. 

The project reviewed the manufacturing process steps identified in the NIST Testing the Digital Thread 

project.

9

 The research compared these process steps to the manufacturing check-list steps used by the 

supplier. In the comparison, four general process step segments were identified. These became the 

segments for recording cycle-time measurement results for the project. Table 6 shows the comparison 

of steps for the CAM process.

Table 6: CAM model creation process

NIST Steps Process Steps Supplier Steps

 

9 Hedberg, Jr. T., Lubell, J., Fischer, L., Maggiano, L., & Barnard Feeney, A. Testing the Digital Thread in Support of 

Model-Based Manufacturing and Inspection. Submitted for publication, 2015.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

16

Gather product definition

Generate 3D model, if needed

Gather manufacturing requirements

Gather specification and standards requirements

Digest the eBOM

Generate mBOM

Determine required manufacturing processes

Determine required manufacturing resources

Interrogate product definition

Conduct manufacturing stacking process

Determine form features and process requirements

Determine manufacturing resource availability

Adjust proposed manufacturing process based on 

resource availability

CAM

Process

Preparation

Manufacturing process preparation

Generate in-process 3D model for tooling and 

programming

Determine and add manufacturing notes

CAM

Setup

Draw a solid of the stock, fixture and tabstock

Select correct machine post

Set revision level in properties page

Set tool settings

Select stock model

Save Mastercam file as part number and 

revision level less decimal points (xxx-xxxxxxx, REVA)

Create tooling models (fixtures and gauges)

Create tooling documentation

Create CAM / NC program

Add tooling to CAM / NC program

CAM

Programming

Check material type

Program part

Program fixtures

Check that coolant is on for all tools

Add number of shifts and distance to macro 

programs

Turn on shift cancel for any tools that run the 

full length of a strip (if applicable)

Create manufacturing work instructions

Generate additional process documentation, as needed

Create CAM and NC documentation

Process review: verify final product definition (all 

dimensions, etc. covered by manufacturing process)

Process review: verify all manufacturing, process, and 

engineering notes requirements are achieved

Final process sign-off

CAM

Verification

Make sure rapid retract is being used on all 

tiles

Create VERICUT for fixture programs

Create VERICUT for part programs and 

make sure all hardware is in place

Run auto-diff in VERICUT and take time to 

ensure all excess and gouges are correct

Double check all drill and tap tooling against 

print for correct sizes

CMM Process

The CMM process steps were identified in a similar way as the CAM process steps. Inspection steps 

previously defined in the NIST Testing the Digital Thread project were compared to the steps in the 

supplier check-list for inspection. In the comparison, five general process step segments were 

identified. These became the segments for recording cycle-time measurement results for the project. 

Table 7 shows the comparison of steps for the CAM process.

Table 7: CMM model creation process

NIST Steps Project Steps Supplier Steps

Gather product definition

Generate 3D model if needed

Gather inspection requirements

Gather specification and standards requirements

CMM

Process

Preparation

Import model into CMM software
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

17

Determine required inspection processes

Determine required inspection resources

Interrogate product definition

Balloon and identify characteristics from product 

definition

Populate reporting documentation (e.g. AS9102, 

etc.) with characteristics

Determine inspection resource availability

Adjust proposed inspection process based on 

resource availability

Generate in-process 3D models, if in-process 

inspection will occur

CMM

Setup Establish datum features

Create CMM measurement program

Create CMM measurement work instructions

Create CMM measurement documentation

CMM

Programming

Measure all features on the model per print 

specifications

Verify final product definition (all characteristics 

are covered by Inspection process)

Verify all inspection, process, and engineering 

notes requirements have been met

Final process sign-off

CMM

Verification Verify for collisions

Populate reporting documentation (e.g. AS9102, 

etc.) with characteristic measurement results

Compare and analyze conformance of product 

against product definition (capture deviation)

CMM

Data Analysis Run report

Data Exchange Issue Resolution

With the iterative data exchange approach, numerous issues were discovered and the majority resolved 

for the final demonstration of the CAD-to-CAM and CAD-to-CMM data exchange using models with 

embedded PMI. Examples of resolved issues for CAM and CMM are shown in Figure 10 and Figure 11.

Figure 10 is a snapshot of the in-development Mastercam environment with imported PMI data. Note 

the STEP geometric tolerance anomaly in the upper right of the image. This was corrected in a 

subsequent iteration.

Figure 10: Snapshot of in-development Mastercam environment

Figure 11 is a snapshot of the in-development NX CAD and MiCAT CMM environments with PMI data. 

Note the items identified in the CAD data tree on the left. The common annotation is a complex feature 

that is presented in a human-readable format on the drawing. It is actually a combination of several 
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

18

features and characteristics presented in a non-semantic way, which is not machine-interpretable. The 

imported PMI with machine-interpretable representation is shown in the MiCAT view on the right.

Figure 11: Snapshot of in-development NX CAD and MiCAT CMM environments

Note there were other identified issues that could not be addressed within the scope of this project. 

Those issues are reviewed further in the results and discussion sections.

Results

Results from Mapping PMI between STEP and ACIS

The following PMI gaps were identified when mapping PMI between STEP AP242 and ACIS:

• Spherical dimension types (RADIUS, DIAMETER) are missing from ACIS

• Oriented and curved dimensions are missing from ACIS

• ACIS does not support angle selection (SMALL, LARGE, EQUAL) in an angular dimension

• Tolerance principal (ENVELOPE, INDEPENDENCY) is not supported by ACIS

• Dimension value with plus/minus bounds is not supported by ACIS

• Dimension value with qualifier (MAXIMUM, MINIMUM) is not supported by ACIS

• Very limited support for dimension modifiers (BASIC, REFERENCE, STATISTICAL) by ACIS, many 

are missing (CONTROLLED RADIUS, FREE STATE, ANY CROSS SECTION, etc.)

• Movable datum target is not supported by ACIS

• Geometric tolerance type (COAXIALITY) is missing from ACIS

• Limited support for tolerance zone types (DIAMETER, SPERICAL DIAMETER, PROJECTED) by ACIS, 

some are missing (NON-UNIFORM, RUNOUT, WITHIN A CIRCLE, etc.)

• Very limited support for tolerance modifiers (FREE STATE, LMC, MMC, RFS, STATISTICAL, 

TANGENT PLANE) by ACIS, many are missing (ANY CROSS SECTION, COMMON ZONE, etc.)

• Very limited support for datum reference modifiers (LMC, MMC) by ACIS, many are missing 

(FREE STATE, BASIC, TRANSLATION, etc.)

• ACIS does not directly support POLYLINE presentation

The results: STEP AP242 with embedded PMI can successfully exchange modelcentric data from design (CAD) to manufacturing (CAM) and inspection (CMM).
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

19

Results from Embedded PMI Data Exchange

Development and demonstration of a process to exchange standards-based models with embedded PMI 

from design to downstream systems was successful within the scope of the limited test models used in

this project. The validation results, as defined by PMI element counts, for the downstream models are 

provided in Table 8. The validation shows that all dimensions, tolerances, and datum features were 

properly transformed and exchanged.

Table 8: Validation of model transformations using embedded PMI entity count

PMI Elements 

(by format)

NX STEP ACIS Mastercam MiCAT

Model (827-9999) -903 -904 -903 -904 -903 -904 -903 -904 -903 -904

Dimension 8 54 8 54 8 54 8 54 8 54

Tolerance 6 13 6 13 6 13 6 13 6 13

Datum Feature 2 3 2 3 2 3 2 3 2 3

Notes 

(not semantic data) 7 8 7 8 0 0 7 8 0 0

Total 23 78 23 78 16 70 23 78 13 68

Automated validation of the downstream models using analysis software during algorithm development 

was performed using techniques described in a separate NIST project.10 As indicated in Table 8, general 

notes could not be mapped to ACIS and were not transferable to the MiCAT Planner. Other 

development roadblocks are discussed later.

Results from CAD Model Creation

Results for CAD model creation are shown in Table 9. For each part, three data sets were generated. 

The future-state data set (-903 and -904) included the 3D model (STEP AP242) with embedded PMI. The 

current-state had two significant data sets to compare against the future-state. The first current-state 

data set (-905 and -906) provided a full-annotated-2D drawing with dimensions and PMI. The part is 

represented fully and can be manufactured from the drawing. The second current-state data set (-907 

and -908) contains the 3D-shape-geometry model (STEP AP203) and a 2D drawing with the PMI. This 

data set requires both the model and the drawing together to manufacture the part.

Table 9: CAD model creation metrics

CAD Metrics Rolled Standoff Heat Sink 

827-9999 -903 -905 -907 -904 -906 -908

 

10 NIST Collaborative Agreement: 70NANB14H256. (2015). Validation for Downstream Computer Aided 

Manufacturing and Coordinate Metrology Processes.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

20

2D PDF drawing ---

full dimension

with 2D PMI 

annotation

key 2D PMI 

annotation 

only (PDD)

---

full dimension

with 2D PMI 

annotation

key 2D PMI 

annotation 

only (PDD)

3D model

includes 

embedded 

PMI

not provided

with no 

embedded 

PMI

includes 

embedded 

PMI

not provided

with no 

embedded 

PMI

Number of PMI entities 23 (24*) --- --- 78 (90*) --- ---

CAD model creation

(modified existing part) 0.5 hours 0.5 hours 0.5 hours 0.5 hours 0.5 hours 0.5 hours

Model-embedded PMI 3.0 hours --- --- 6.0 hours --- ---

2D PDF drawing creation 0.5 hours 1.0 hours 0.7 hours 0.5 hours 2.4 hours 1.3 hours

CAD tool issue resolution 

and designer education 9.0 hours 0.5 hours 0.1 hours 4.9 hours 0.5 hours 0.1 hours

CAD model resolution

to address downstream 

issues

 2.3 hours 

+ 4.5 hours 

to learn NX

--- ---

 3.0 hours 

+ 1.3 hours 

to learn NX

original dwg 

missing dim –

required ECO

---

* Original PMI entity count based on objects found in the NX Part navigator – eventually reduced count by issue resolution

Results from CAM Model Creation

The supplier steps defined earlier were the basis for the four general project steps that condensed into 

recordable metrics in Table 10. These metrics show the difference between the current-state processes 

and the future-state process. Recall that two current-state processes were demonstrated. The first data 

set (-905 and -906) contained a full-dimension-2D drawing including all PMI. The second data set (-907 

and -908) contained a 3D-shape-geometry model (STEP AP203) and a 2D drawing with the key PMI 

annotations. The future-state data set (-903 and -904) contained a full-defined-3D model with 

embedded PMI (STEP AP242).

Regardless of the data exchange scenario, the CAM process preparation steps were the same for each 

and the cycle-time did not show any difference. Likewise, due to the simplicity of the rolled standoff, no 

significant cycle-time difference was recorded for the CAM programming and verification steps.

Table 10: CAM model creation metrics

CAM Metrics Rolled Standoff Heat Sink 

827-9999 -903

3D model with 

embedded PMI

-905

2D drawing 

fully annotated

-907

2D PMI drawing 

and 3D model

-904

3D model with 

embedded PMI

-906

2D drawing 

fully annotated

-908

2D PMI drawing 

and 3D model

CAM Process Preparation

a) Gather information

b) Analyze job

c) Determine approach

3.25 hours

a) 0.25 hours

b) 0.50 hours

c) 2.50 hours

3.25 hours

a) 0.25 hours

b) 0.50 hours

c) 2.50 hours

3.25 hours

a) 0.25 hours

b) 0.50 hours

c) 2.50 hours

3.83 hours

a) 0.33 hours

b) 0.50 hours

c) 3.00 hours

3.83 hours

a) 0.33 hours

b) 0.50 hours

c) 3.00 hours

3.83 hours

a) 0.33 hours

b) 0.50 hours

c) 3.00 hours
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

21

CAM Setup

a) Model preparation

b) Pre-program setup

0.45 hours

a) 0.00 hours

b) 0.45 hours

0.52 hours

a) 0.07 hours

b) 0.45 hours

0.45 hours

a) 0.00 hours

b) 0.45 hours

0.68 hours

a) 0.45 hours

b) 0.23 hours

0.64 hours

a) 0.52 hours

b) 0.12 hours

0.40 Hours

a) 0.28 hours

b) 0.12 hours

CAM Programming

a) Part programming

b) Tooling preparation

1.00 hours

a) 0.50 hours

b) 0.50 hours

1.00 hours

a) 0.50 hours

b) 0.50 hours

1.00 hour

a) 0.50 hours

b) 0.50 hours

3.23 hours

a) 3.01 hours

b) 0.22 hours

3.13 hours

a) 2.75 hours

b) 0.38 hours

2.30 hours

a) 2.08 hours

b) 0.22 hours

CAM Verification

a) Create work

instructions

(setup sheets)

b) Review process 

(Run VERICUT)

0.15 hours

a) 0.10 hours

b) 0.05 hours

0.15 hours

a) 0.10 hours

b) 0.05 hours

0.15 hours

a) 0.10 hours

b) 0.05 hours

0.42 hours

a) 0.32 hours

b) 0.10 hours

0.50 hours

a) 0.35 hours

b) 0.15 hours

0.53 hours

a) 0.35 hours

b) 0.18 hours

Total 4.85 hours 4.92 hours 4.85 hours 8.16 hours 8.10 hours 7.06 hours

Results from CMM Model Creation and Inspection

Once again, the cycle-time metrics show the difference between the current-state processes and the 

future-state process. Recall that the first data set (-905 and -906) started with only a full-dimension-2D 

drawing including all PMI. But in this case, the supplier was able to take advantage of the model that 

was already created for the CAM process and re-use it in the CMM process. The same occurred for the 

second data set (-907 and -908), which contained a 3D-shape-geometry model (STEP AP203) and a 2D 

drawing with the key PMI annotation. The future-state data set (-903 and -904) contained a fulldefinition-3D model with embedded PMI (STEP AP242). The metrics for CMM model creation are shown 

in Table 11.

Table 11: CMM model creation and part inspection process

CMM Metrics Rolled Standoff Heat Sink 

827-9999 -903

3D model with 

embedded PMI

-905

2D drawing 

fully annotated

-907

2D PMI 

drawing and 3D 

model

-904

3D model with 

embedded PMI

-906

2D drawing 

fully annotated

-908

2D PMI 

drawing and 3D 

model

CMM Process 

Preparation

Unable to perform automated inspection process due 

to physical size limits of the available CMM equipment. 

The part features were too small for the CMM probe to 

measure. These test parts were inspected manually.

0.10 hours 0.50 hours 0.75 hours

CMM Setup 0.10 hours 0.75 hours 1.00 hour

CMM Programming 0.50 hours 4.76 hours 4.75 hours

CMM Verification

a) Verify information

b) Verify for collisions

0.30 hours

a) 0.15 hours

b) 0.15 hours

1.00 hours

a) 0.50 hours

b) 0.50 hours

1.00 hour

a) 0.50 hours

b) 0.50 hours

Inspection

a) CMM inspection

b) Manual inspection

0.50 hours

a) 0.00 hours

b) 0.50 hours

0.25 hours

a) 0.00 hours

b) 0.25 hours

0.25 hours

a) 0.00 hours

b) 0.25 hours

0.70 hours

a) 0.20 hours

b) 0.50 hours

0.40 hours

a) 0.20 hours

b) 0.20 hours

0.40 hours

a) 0.20 hours

b) 0.20 hours

CMM Data Analysis 0.50 Hours 0.50 hours 0.50 hours

Total Time 0.50 hours 0.25 hours 0.25 hours 2.20 hours 7.91 hours 8.40 hours
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

22

Discussion and Recommendations

Model Validation and Verification

Standards-based workflow for design to manufacturing and inspection involves exchange of CAD-toAP242-to-CAM-and-CMM models. Validation and verification of this translation process is important, 

especially for regulated industries. An important part of quality assurance is traceability back to the 

design definition. To assure compliance at any point in the manufacturing or inspection process, it is 

essential to have validation and verification of the models throughout the data exchange process. A

draft of ASME Y14.41.1 3D Model Data Organization Schema 11 is currently defining Critical Metadata 

Elements based upon MIL-STD 31000A Department of Defense Standard Practice: Technical Data 

Packages, Appendix B MBD Model Organizational Schema.

12

 Once complete, these metadata elements 

will need to be supported by the STEP AP242 Model-Based Definition. Similar to ensuring coverage of 

GD&T elements defined by AMSE Y.14.5, the 3D metadata elements being defined by ASME Y14.41.1 

are necessary in the AP242 model to fully support data interoperability for 3D models with embedded 

PMI.

ACIS and Embedded PMI Gaps

The PMI-element count was used as a metric to determine that the model was imported correctly as it 

moved from the native-CAD model through STEP AP242, ACIS, and ultimately into the CAM and CMM 

models. Several iterations and changes to the CAD-model-embedded PMI were required to achieve 

acceptable transformation into the downstream formats for CAM and CMM. Several iterations of the 

application algorithms were also required to enable the transformation.

Verification and validation tools are available to identify model-based data quality issues that impact 

downstream reuse for tooling, simulation, and data exchange. Repair tools also offer diagnostics, 

translation, healing, and repair of CAD geometry for downstream model use. Types of model quality 

issues include:

• Geometry that impedes model translation or downstream reuse of CAD models

• Unrealistic features that require changes during CAM modeling

• Unrealistic or ambiguous PMI features that require changes during CMM modeling

• Undocumented changes caused by revisions or engineering changes

• Unintended changes caused by complex parametric relationships unknown to CAD users

Additional work is needed to overcome some deficiencies in ACIS to enable embedded-PMI-data 

exchange. One potential solution might involve using ACIS attributes as a mechanism to provide the 

missing or incomplete information. However, since this method would not be a semantic 

 

11 American Society of Mechanical Engineers. Y14.41.1. 3D Model Data Organization Schema (in development). 

ASME.

12 United States Department of Defense. (2013, 26 February). MIL-STD-31000A. Department of Defense Standard 

Practice: Technical Data Packages.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

23

representation, an agreed upon specification between the sender and the receiver would be required to 

interpret the augmented data correctly.

Likewise, with the polyline presentation in STEP, ACIS wire bodies could be created and associated to 

the PMI data using attributes. But again, the sender and receiver would need to agree upon a common 

specification to successfully exchange the data and its semantic meaning. ACIS does support 

presentation information in a more semantic form, but this is not the preferred (or implemented) 

method in STEP.

CAD Process Observations

One unexpected but not un-common issue occurred. The original heat sink data set with the full 

dimension 2D drawing (-906), and without a 3D model, was provided to the supplier with two missing 

dimensions. The supplier discovered the missing dimensions while the model for the CAM and CMM 

processes was being created. The supplier had to request an updated drawing from the OEM for the 

missing dimensional information. This required an ECO, which had significant impact on cycle time and 

delivery schedule for the part. Figure 12 shows the missing dimensions. Only when you rely on 2D 

drawings for information does a missing dimension become relevant. Missing dimensions are not 

possible when using 3D model with embedded PMI. 

There are anticipated benefits in the part validation, procurement, and receiving inspection, as well as 

for the ECO process. These areas would be good candidates for a future, more definitive ROI study of 

the digital thread.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

24

Figure 12: CAD model creation - missing dimensions

Several observations were made about the creation of the 3D CAD model with embedded PMI. During 

the time of CAD-model creation, some learning curve was required for the designer to become familiar 

with methods to both present and represent PMI annotations. User training on embedded PMI with the 

CAD system is absolutely necessary. There are challenges to create embedded PMI that is both human 

interpretable and machine readable. The inherited 3D-annotation views do not necessarily transfer to a 

2D-visualization format. The 2D-GD&T presentation within the CAD software is not always easily 

transferred to the 3D-model representation. Critical for the support of downstream model usage is the 

understanding and use of a model schema that organizes data elements and standardizes how the data 

elements relate to one another. Edge versus face or surface selection for PMI annotation is especially 

important for machine-readable-downstream use. Even though human interpretation appears straight 

forward; there can easily be redundant association with the model that creates issues with the 

downstream manufacturing and inspection systems. 

It was observed that for the data sets containing a 2D drawing, the drawing includes a non-semantic 

presentation note stating, “Unless otherwise specified, all basic dimensions (as found in the 3D model) 

shall comply with: .” Only the key GD&T (PMI) items are annotated in the 2D drawing, 

all unspecified GD&T is implied in the note. Currently, there is no recommended practice to incorporate 

this UOS functionality in 3D models with embedded-PMI representation. Industry recognizes value in 

the cycle-time efficiency from the use of blanket tolerances. Many features share the same tolerance 

and if each required explicit tolerance definition it would be too time-consuming. If a blanket tolerance 
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

25

is not possible with embedded-PMI representation, then the time required for CAD model creation will 

be prohibitive for industry to move toward acceptance of full-dimension-model-based definition.

CAM Process Observations

Observations from the supplier indicate that shape-geometry imported using the STEP AP242 format

was as readily imported as it was from the STEP AP203 format. The AP242 model also provided access 

to the semantic representation of PMI data. The ITI library used by Mastercam to support import of 

STEP AP242 models provides an API to set up PMI-to-geometry associations, display the associations,

and allow the associations to be saved within the Mastercam file. 

The supplier was able to generate toolpath data using the imported STEP files but with a slight loss of 

efficiency. This efficiency loss was due to the time the operator took to manually validate the CAM 

model to the CAD model with embedded PMI. As the confidence level in the model-based process

grows, it is expected that this inefficiency with the operator will be eliminated. Model-based validation 

tools could help reduce the cycle-time, while ensuring data exchange continuity and model quality.

There would be reduced risk of error between CAD and CAM models and there would be more 

opportunity to automate validation of the CAD model to the CAM model.

There were issues with the method Mastercam chose to display the PMI. For human-readable 

visualization the CAM model presentation looked like a “fur-ball” of information with no organization, as 

shown in Figure 13. 

Figure 13: Dimensions imported as a "fur-ball" in CAM presentation

The imported annotations rebuilt in Mastercam using the semantic-representation data did not exactly 

match the original presentation data. This resulted in missing or difficult to interpret visual information. 

Figure 14 is an example of presentation in the original view which did not meaningfully present in 

another 3D view.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

26

Figure 14: Difficult to interpret visual presentation

As shown in the results, there was no significant improvement in cycle time from the current-state to 

the future-state CAM model creation using embedded PMI. It actually took more cycle time to process 

models with the embedded PMI than it did with the 3D-shape-geometry model because the supplier 

spent additional time to validate the embedded information. No quality advantage was seen in the CAM 

model creation and part manufacture as a result of embedded PMI. It may be that no significant 

improvement in cycle time or quality was measured due to the simplicity of the test models. The team 

expects that there would be improvement in CAM model creation when applied to more complex 

models. 

CMM Process Observations

Similar observations of the results for CMM-model creation indicate that shape-geometry is imported 

the same as the STEP AP203 model when using the STEP AP242 to eACIS converter. Furthermore, STEP

AP242 model import using this intermediate exchange provides access to the semantic PMI data 

originally in the STEP file. This provides significant automation of data entry into the CMM system. The

PMI data was usable for CMM programming by the MiCAT Planner application.

CMM-model creation demonstrated the most significant improvements from importing an embedded 

PMI model. Importing the model with embedded PMI required just 1.70 hours for CMM process 

preparation, set-up, programming, verification and inspection. When using the full-dimension-2D

drawing the same activity required 7.40 hours and when using the 3D-shape-geometry model with a 

partial-dimension-2D drawing required 7.90 hours. In all, exchanging a 3Dmodel with embedded PMI 

demonstrates more than 4-times improvement in cycle-time over drawing-based or shape-geometrymodel-based practices.

Upon delivery of the physical parts for inspection, an unexpected issue was encountered. The supplier 

was unable to inspect some features on the heat sink, and none of the features of the rolled standoff 

using the CMM process as originally planned. This issue was due to the physical-size limits of the 

available CMM equipment. As shown in Figure 15, the part features were too small for the CMM probe 
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

27

to measure even with successful model import. The manual inspection cycle-time was recorded to 

cover the areas not able to be measured using the CMM system. The manual-inspection metric 

demonstrates that even with full-model-based definition, a human-in-the-loop will sometimes still have

significant process impact.

Figure 15: Physical measurement limitation even with successful model import

Conclusions

Tools

It was demonstrated that there is benefit from the CMM-system ability to interpret embedded-PMI 

information versus using nominal shape-geometry-model dimensions. It is anticipated that the same 

benefit could be gained by CAM software as well. While the basic ability to receive the embedded PMI 

was achieved, the CAM tools require further development to fully leverage the benefit of receiving that 

data.

In a number of instances, embedded PMI created by the designer does not align well to the needs of 

downstream-machine consumption. Since PMI-authoring capabilities of CAD systems have evolved from 

origins where 2D visualization of PMI was the requirement, current CAD systems allow designers to 

create PMI content that is, at best, partially useable for downstream consumption. Embedded-PMI 

rules should be implemented in CAD systems to better align model creation with the downstreammachine-interpretable expectations.

The conclusion: Model-centric CAD-to-CAM and CAD-to-CMM data exchange using 

STEP AP242 is a viable part of the MBE vision, but there are still gaps to address.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

28

CAD-model structures are not optimized for downstream consumption. The ability to capture 

groupings of design features that represent geometric sets that correspond to equivalent manufacturing 

features is needed for downstream use and no method exists currently to achieve this functionality.

Standards

The project team recommends certain gaps be addressed by the STEP community (standards 

development and implementer forum). During the course of the project, it was observed that there is 

incomplete PMI coverage and recommended practices for the standards. Two examples illustrate the

need for more coverage. There is the industry practice to use an unless-otherwise-specified tolerance 

callout as a general note. Although a workaround was achieved, a recommended practice is needed for 

this often-used callout to properly account for the required geometry associations. The second example 

is that surface-texture or surface-finish PMI are not yet implemented by the STEP community. A 

development activity to support this construct is necessary. This also necessitates a recommended 

practice document and the introduction of a test case into future test rounds of the STEP CAx 

Implementer Forum.13

Processes

The project demonstrated the cycle-time benefits of the future-state process. This is based upon a 

small-sample-size demonstration, but the authors believe the results are potentially scalable for

increased model complexity and PMI-element counts. Significant reduction in cycle time for CMM 

model creation and characteristic analysis was observed. Cycle-time reduction was not conclusive for 

CAM-model creation however, and additional research is required to better understand the 

implications. It is recommended that additional testing of the process be completed over a broader 

sample size. Future research could seek out opportunities to increase the participants in the testing 

activity. This would result in a broader range of example data to work from and provide an opportunity 

to better assess the impact of variation in both design and processes.

It was clear that designer education is not aligned with requirements for downstream-PMI consumption, 

especially for machine-interpretable expectations. Industry needs recommended practices for proper 

association of PMI to geometry elements. There would also be value in a post-process to repair PMI 

geometry associations so they are complete and consistent. CAD systems should be augmented to 

provide design rules for creation of embedded PMI with downstream machine consumption in mind or, 

at a minimum, recommended practice documents need to be developed to guide designers as they 

annotate 3D models with PMI data. Verification tools are needed to ensure that recommended 

practices have been followed prior to the release of models for downstream consumption.

There are anticipated benefits in the part validation, procurement, and receiving inspection, as well as 

for the ECO process. These areas would be good candidates for a future, more definitive ROI study of 

the digital thread.

 

13 PDES, Inc. and ProSTEP iViP. CAx Implementor Forum. Retrieved October, 09, 2015, from 

https://cax-if.org/index.html.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

29

The latest version of AS910214, the aerospace standard for reporting FAI results, suggests the potential 

exists to improve FAI reporting, particularly through automation. There is also potential for developing 

a visual presentation that ties metrology results and MBD. Lastly, there is potential mechanism to 

provide metrology results feedback to upstream users for analysis and prediction to better consider 

design decisions and manufacturing technologies for future products. 

Summary

In summary, motivation exists for industry to continue its drive for the MBE vision through modelcentric data interoperability for design to manufacturing and quality inspection. A number of 

conclusions have been drawn from the research performed under this project. An attempt has been 

made to organize them broadly into categories of tools, standards, and processes. Fundamentally, the 

project successfully demonstrated the value of standards-based CAD-to-CAM and CAD-to-CMM data 

interoperability when using STEP AP242 with embedded PMI. In doing so, there were many issues 

uncovered, some we were able to address within the project and others require further effort to 

overcome. Some significant gaps were identified as well. These gaps will need to be addressed through 

changes in the tools, standards, and processes used currently to share information from design to 

manufacturing and inspection across the supply chain.

 

14 International Aerospace Quality Group. (2014, October 06). AS9102B. Aerospace First Article Inspection 

Requirements. SAE International.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

30

Acknowledgements

The team would first like to recognize the NIST System Integration Division, Engineering Laboratory, for 

providing this project opportunity. The Digital Thread is an important concept for industry. NIST focus 

and investment in product lifecycle capabilities and standards is truly recognized. Especially, we thank 

Allison Barnard Feeney and Thomas Hedberg, Jr. who have provided the leadership in establishing the 

Digital Thread for Smart Manufacturing. The project team fully supports the drive to investigate the 

product lifecycle holistically and extend the digital thread of information with easy implementation into 

manufacturing systems. NIST has provided a significant seed opportunity for commercialization of 

standards-based model-centric data interoperability – enabling industry’s vision of the Model-Based 

Enterprise.

A project like this would not be possible without the commitment and contributions from a number

people. The project team would like to acknowledge the following companies and individuals who 

participated in various elements of the grant.

ACCR, Inc., Summerville, SC, provided consulting and project management services for the program. Phil 

Rosche of ACCR contributed to project planning, insights into the current and expected near-term states 

of the ISO10303 STEP standard, and assisted in keeping project work on track. Phil contributed 

significantly to authoring of the final report.

Rockwell Collins, Cedar Rapids, IA, provided the industry OEM perspective for the project. Rockwell 

Collins was the principal host for the kick-off and planning meeting as well as the final demonstration 

meeting. Tom Matuska and Jesse Pisarik were responsible for selection of representative Rockwell 

Collins parts, transformation of the Rockwell Collins designs from traditional model and drawing sets

into 3D models with embedded PMI. Tom and Jesse also collected metrics data for the current-state

and future-state design processes. They helped write and edit the sections on model selection. Scott 

Wegener supported the supply chain process discussions and provided insight into the issues associated 

with aerospace and defense supply chain traceability and practices. Kevin Fischer led the Rockwell 

Collins team and was responsible for metrics definition and data analysis. He contributed valuable 

insight into design for manufacture and manufacturing processes. Kevin contributed significantly to 

authoring of the final report.

Geater Machining and Manufacturing, Independence, IA, a manufacturing supplier to Rockwell Collins, 

was responsible for manufacturing operations and downstream manufacturing and inspection processes 

for the selected test parts. They were the secondary host for the kick-off and planning meeting as well 

as the final demonstration meeting. Geater collected the downstream metrics data. Greg Sondag, 

Programming Engineer Supervisor, was the project lead for Geater. He was responsible for 

manufacturing planning and execution as well as manufacturing metrics data collection and analysis for 

CAM processes. Derrick Hess, Quality Working Supervisor, was responsible for manufacturing 

inspection processes as well as metrics data collection and analysis for those processes. Greg and 

Derrick helped write the sections on CAM and CMM processes.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

31

CT CoreTechnologie, Southfield, MI, and Lyon, France, was responsible for writing algorithms to extract

PMI presentation and representation data from the CAD models and the output of the data into STEP 

AP242 format. David Selliman led the US team and Guillaume Blanchard led the algorithm development 

in Europe.

CNC Software, Inc, Tolland, CT, provided the Mastercam manufacturing planning and execution software 

for the project. Pete Rimkus, Product Owner, CAD Interfaces, was responsible for developing algorithms 

to load semantic PMI content into the Mastercam manufacturing planning software.

Mitutoyo America Corporation, Aurora, IL, provided the MiCAT metrology planning software for the 

project. Larry Maggiano, Senior Systems Analyst, was responsible for analyzing the consumption of 

eACIS data structures converted from STEP AP242 data by the MiCAT Planner and leveraging those 

characteristics in the metrology planning process. Larry provided CMM subject matter expertise and

guidance on metrology standards and processes. Larry also provided metrology-focused requirements 

for future systems.

International TechneGroup Incorporated, Milford, OH, provided overall program execution and grant 

administration as well as technical development of translation components. Ed Paff was responsible for 

translation component development. Asa Trainer, VP of Product Operations, was responsible for 

program execution administration. Asa contributed significantly to authoring of the final report.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

32

Works Cited

American Society of Mechanical Engineers. (n.d.). Y14.41.1. 3D Model Data Organization Schema (in 

development). ASME.

Hartman, N., Fischer, K., & Rosche, P. (May 21-23, 2012). Successfully Engaging Small and Medium 

Enterprises. 3D Collaboration and Interoperability Congress. Englewood, CO.

Hedberg, Jr., T., Lubell, J., Fischer, L., Maggiano, L., & Barnard Feeney, A. (2015). Testing the Digital 

Thread in Support of Model-Based Manufacturing and Inspection. Submitted for publication.

International Aerospace Quality Group . (2014, October 06). AS9102B. Aerospace First Article Inspection 

Requirements. SAE International.

ISO/TC 184/SC 4. (1994, December 15). ISO 10303-1:1994. Industrial automation systems and 

integration -- Product data representation and exchange -- Part 1: Overview and fundamental 

principles. International Organization for Standardization.

NIST Collaborative Agreement: 70NANB14H256. (2105). Validation for Downstream Computer Aided 

Manufacturing and Coordinate Metrology Processes.

NIST MEP. (November 22, 2009). Phase One Final Report - Assessment of Supplier Capabilities to Operate 

in a Model-Based Environment.

PDES, Inc. and ProSTEP iViP. (n.d.). CAx Implementor Forum. Retrieved October 09, 2015, from 

https://cax-if.org/index.html

Spatial Corp. (n.d.). 3D ACIS Modeling. Retrieved October 09, 2015, from Spatial Products: 

http://www.spatial.com/products/3d-acis-modeling

United States Department of Defense. (2011, April). Technology Readiness Review Assessment (TRA) 

Guidance. Retrieved October 09, 2015, from 

http://www.acq.osd.mil/chieftechnologist/publications/docs/TRA2011.pdf

United States Department of Defense. (2013, February 26). MIL-STD-31000A. Department of Defense 

Standard Practice: Technical Data Packages.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

33

Appendices

Appendix A: Use Cases

Visualization and Collaboration Use Cases

Two use cases that will require significant change from current state to the future state processes 

following the introduction of embedded-PMI models are visualization (human-interpretable 

presentation) and collaboration. The need to visualize and collaborate is prevalent for both the OEM 

and Supplier with many of the identified use cases. For instance, it is anticipated that 3D PDF (or a 

similar format) will serve as a likely visualization tool to capture and display embedded information 

within a model. Likewise, how the OEM and supplier collaborate, whether for bidding and quoting, 

addressing discrepancies, or incorporating engineering changes will need to be different than how it is 

done today when using 2D drawings and mark-ups. These use cases are out of scope with this project.

OEM Use Cases

CAD Model Creation

This use case centers on the creation or authoring of the CAD model. Traditionally, the 3D-shapegeometry model is created without embedded PMI. Once the shape-geometry model is generated, a 2D 

drawing is created, and typically presented in 2D PDF format. It includes the PMI that is not part of the 

3D-shape-geometry model. In the past, the 2D drawing was fully detailed and could be used by itself to 

manufacture the part. In more recent practice, a 3D-shape-geometry model and a 2D-partial-dimension 

drawing are required. The partial-dimension drawing contains only the PMI that is not embedded in the 

shape model. In the current-state scenarios either the full-detail drawing or the combination of the 

shape model and the partial-detail drawing is required for manufacturing processes. In the future-state 

process designers will create a 3D model with embedded PMI such that the model will completely 

support the manufacturing and inspection processes. This use case was used in the scope of this 

project.

CAD Model Validation

In this use case the current process is to manually inspect the 2D drawing and the 3D model separately 

when providing a producibility review or performing a check in preparation of design release into the 

PDM system. This relies entirely on the experience and ability of the operator to review the drawing or 

visually interpret the model. With embedded PMI the reviewer will need the capability to visualize and 

inspect the information in the 3D model. In the future, 3D models with the embedded PMI will lend 

themselves to more automated producibility and check (validation) tools. This automation, in turn, 

could enable in-process reviews to occur sooner and with more frequency than just when a designer 

submits work to a producibility engineer or checker near the release point for a design. This future state 

use case was not directly investigated as part of this project. But, during the project, metrics were 

captured that indicate gaps in tools and knowledge that must be overcome in order to properly embed 

PMI in a design model so that it is ready for consumption by downstream systems. This also amplifies 

the need for and importance of a model validation capability and tools.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

34

Part Procurement (Bid Request; Supplier Portal)

The current practice is to provide the supplier with a 3D model (typically native CAD or STEP AP203 

format) and a 2D drawing (PDF format) with the PMI not embedded in model. The information may be 

accessible through a supply chain portal at the OEM that allows the supplier to directly access both 

models and drawings. In the future, the 3D model with embedded PMI will be available through the 

same supply chain portal process. A 3D PDF (or equivalent) could also be provided for visualization as 

well as provide an integrated STEP file attachment for the supplier to access through the portal. This 

use case is out of scope for this project but should be explored in future work.

Engineering Changes (Request/Mark-up; Validation; Documentation)

Currently a change request requires the mark-up of a 2D drawing. Once the change is accepted and an 

ECO completed, the model and drawing updates are validated against the mark-up and the change 

order is provided to the supplier for implementation. This process creates opportunity for error in 

correctly converting the mark-up into the model. In the future, a process to address mark-up as well as 

convey the approved change in a full model-based approach will need to be determined. Several 

approaches have been demonstrated or discussed. This use case is out of scope for this project but 

should be addressed as industry moves to a complete model based enterprise.

Part Receiving Inspection

Today receiving inspection is completed using the 2D drawing. Parts are received from the supplier, 

along with the First Article Inspection Report (FAIR), which is typically provided in spreadsheet format. 

Receiving inspectors verify the report and check a portion of the part dimensions for consistency. In the 

future, when PMI is fully embedded in the 3D model, the receiving inspection process will require ability 

to utilize a format such as 3D PDF for visualization during part receiving inspection. This use case is out 

of scope for this project. There is opportunity to couple the development from this project with that of 

another ongoing NIST project to demonstrate the impact of model-centric data interoperability with first 

article inspection reporting and receiving inspection using the Quality Information Framework (QIF).

15

Assembly Work Instructions

When a design is transformed into assembly work instructions, the 2D drawing is often used in the 

construction of those instructions. Assembly and manufacturing resource information associated with a 

particular route step is added alongside the 2D drawing for operators to follow the correct assembly 

process steps. In the future, a 3D visualization will replace the 2D drawing as part of the work 

instruction construct. This offers a more immersive experience as well as introduces other technologies 

to provide work instruction aids to the operators. This use case is out of scope for this project.

Technical Data Package Delivery (from OEM to Customer)

Today TDP delivery from an OEM to a customer is typically satisfied with 2D drawings. These may be 

augmented upon contract request with native CAD or STEP AP203 3D models. In the future, 3D models 

 

15 NIST Collaborative Agreement: 70NANB14H256. (2015). Validation for Downstream Computer Aided 

Manufacturing and Coordinate Metrology Processes.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

35

and 3D visualization artifacts are expected to be the primary basis for TDP delivery per MIL-STD-31000A. 

This use case is out of scope for this project but should be explored in related and future work.

Supplier Use Cases

Bid or Quote Process

Currently a supplier will use 2D drawings to provide a bid or quote. There is more estimation involved in 

the process when only a drawing is available. The opportunity to use a 3D model and associated 3D 

visualization file provides much more information and could even allow for some automated bidding 

tools. This use case is out of scope for this project, but some anecdotal insight may be provided as part 

of the findings.

CAM Model Creation

The CAM-programming use case focuses on the import of a STEP AP203 model for the shape-geometry. 

The 2D drawing is referenced for the PMI not embedded in the model. In addition, the manufacturing 

specifications that are referenced in the drawing are also reviewed to determine additional machine 

programming and secondary operations. It is difficult to envision what changes in the CAM modeling 

process will be introduced with the use of models with embedded PMI. There should be reduced risk of 

error between CAD and CAM models, and there may be improved ability to automate the validation of 

CAD model to CAM model. This use case is within scope of the project.

CAM Work Instruction Creation

Currently the 3D CAD model, usually in STEP AP203 format, and the manufacturing specifications 

referenced in the 2D drawing are used by the supplier to create part manufacturing work instructions. 

Starting with these artifacts, the actual instructions and graphics for each route step is created. It is 

anticipated that the future use case will remain similar but, it will require less reference to drawing 

specifications. This use case is out of scope for this project, but some anecdotal insight may be provided 

as part of the findings.

In-Process Part Inspection

Currently, the supplier will perform in-process inspection of a part to determine that certain 

dimensional aspects are correct before proceeding with the next steps of part manufacturing. This is 

accomplished by referencing the 2D drawing as well as the STEP AP203 model for information against 

which to inspect the part. Sometimes discrepancies between the CAD model and the drawing are 

discovered at this point. The future state with embedded PMI should offer less risk of discrepancy than 

might occur between the model and drawing. This use case will be out of scope for the project, but 

some anecdotal insight may be provided as part of the findings.

CMM Model Creation

The CMM-model use case utilizes the 2D drawing and the STEP AP203 model to create the CMM model. 

All the PMI is manually entered into the CMM application. The future state will directly import the 

embedded PMI from a STEP AP242 model, providing significant automation of data entry into the CMM 

system. Like the CAM programming, CMM model creation and machine programming provides a basis 

of measurement for the project. 
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

36

CMM Inspection and First Article Inspection Report

The CMM-inspection use case involves a significantly manual process to generate the First Article 

Inspection Report. The anticipated future state enables a much more automated process. The 

inspection metrics will be captured in the project and will provide insight into the benefits possible for 

automating first article reporting. This use case is also explored in another NIST project involving the 

Quality Information Framework (QIF).

16

Engineering Changes (Request/Mark-up; Validation; Documentation)

Today a change request requires the mark-up of a 2D drawing. Once the change is accepted and an ECO 

completed, the model and drawing changes are validated against the mark-up and the change order is 

provided to the supplier for implementation. This process creates opportunity for error in correctly 

converting the mark-up into the model. In the future, a method to address mark-up as well as convey 

the change in a model based approach will need to be determined. Several approaches have been 

demonstrated or discussed. This use case is out of scope for this project but should be addressed for 

industry to move to a complete model based enterprise.

Table 12: Product lifecycle use case metrics

Use Cases

Metrics

Cycle Relative to Project Scope

Time

Model

Quality

Part

Quality Cost

at OEM

CAD Model Creation X X will be demonstrated

Model Validation (Producibility; Check; Release) X X X will be demonstrated

Part Procurement (Bid Request; Supplier Portal) X X out of scope

Receiving Inspection X X out of scope / possible anecdotal insight

Assembly Work Instructions out of scope

Technical Data Package Delivery (to Customer) out of scope

Engineering Change X X X out of scope

at Supplier

Bid or Quote Process X X out of scope / possible anecdotal insight

CAM Programming X X will be demonstrated

Work Instruction Creation X X may be out of scope

In-Process Inspection X X out of scope / possible anecdotal insight

CMM Programming X X will be demonstrated

CMM Inspection and FAI Report X X will be demonstrated

Engineering Change X X X out of scope

Appendix B: Mapping PMI into STEP and ACIS

Appendix B.1: Mapping GD&T into STEP and ACIS

PMI STEP AP242 ACIS

dimension types

linear dimension dimensional_location spaxpmi_dimension

angular dimension angular_location/angular_size spaxpmi_dimension 

(no way to specify which angle)

 

16 NIST Collaborative Agreement: 70NANB14H256. (2015). Validation for Downstream Computer Aided 

Manufacturing and Coordinate Metrology Processes.
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

37

PMI STEP AP242 ACIS

radius dimension dimensional_size.name = "radius" spaxpmi_dimension

spherical radius 

dimension dimensional_size.name = "spherical radius" not covered

diameter dimension dimensional_size.name = "diameter" spaxpmi_dimension

spherical diameter 

dimension dimensional_size.name = "spherical diameter" not covered

oriented dimension oriented_dimensional_location not covered

curved dimension dimensional_location_with_path / dimensional_size_with_path not covered

dimension 

tolerance principle

independency shape_dimension_representation.name = "independency" not covered

envelope shape_dimension_representation.name = "envelope" not covered

dimension values

nominal value measure_representation_item.name = "nominal value" dimension value

nominal value with 

qualifier qualified_representation_item not covered

nominal value with plus / 

minus bounds plus_minus_tolerance not covered

value range measure_representation_item.name = "upper limit" / "lower 

limit"

dimtol lower limit

dimtol upper limit

tolerance class limits_and_fits not covered

dimension 

modifiers

basic / theoretical descriptive_representation_item.description = "theoretical" dimension_type 

(dimtype_basic)

reference / auxiliary descriptive_representation_item.description = "auxiliary" dimension_type 

(dimtype_reference)

controlled radius descriptive_representation_item.description = "controlled 

radius" not covered

square descriptive_representation_item.description = "square" not covered

statistical tolerance

descriptive_representation_item.description = "statistical 

tolerance"

dimension_type 

(dimtype_tolerance)

continuous feature descriptive_representation_item.description = "continuous 

feature" not covered

two point size descriptive_representation_item.description = "two point size" not covered

local size defined by a 

sphere

descriptive_representation_item.description = "local size defined 

by sphere" not covered

least-squares association 

criterion

descriptive_representation_item.description = "least-squares 

association criterion" not covered

maximum inscribed 

association criterion

descriptive_representation_item.description = "maximum 

inscribed association criterion" not covered

minimum inscribed 

association criterion

descriptive_representation_item.description = "minimum 

inscribed association criterion" not covered

circumference diameter descriptive_representation_item.description = "circumference 

diameter" not covered

area diameter descriptive_representation_item.description = "area diameter" not covered

volume diameter descriptive_representation_item.description = "volume 

diameter" not covered

maximum size descriptive_representation_item.description = "maximum size" not covered
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

38

PMI STEP AP242 ACIS

minimum size descriptive_representation_item.description = "minimum size" not covered

average size descriptive_representation_item.description = "average size" not covered

median size descriptive_representation_item.description = "median size" not covered

mid-range size descriptive_representation_item.description = "mid-range size" not covered

range of sizes descriptive_representation_item.description = "range of sizes" not covered

any restricted portion of 

feature

descriptive_representation_item.description = "any restricted 

portion of feature" not covered

any cross section descriptive_representation_item.description = "any cross 

section" not covered

specific fixed cross 

section

descriptive_representation_item.description = "specific fixed 

cross section" not covered

common tolerance descriptive_representation_item.description = "common 

tolerance" not covered

free-state condition descriptive_representation_item.description = "free-state 

condition" not covered

dimension decimal 

places value_format_type_qualifier dimtol precision

datum datum spaxpmi_datum

datum feature datum_feature attrib_spaxpmi_datum

datum target placed_datum_target_feature spaxpmi_datumtgt

point axis2_placement_3d.name = "orientation" datum_target_type (dt_point)

line axis2_placement_3d / length_measure_with_unit.name = "target 

length" datum_target_type (dt_line)

rectangle axis2_placement_3d / length_measure_with_unit.name = "target 

width"

datum_target_type 

(dt_area_rect)

circle axis2_placement_3d/length_measure_with_unit.name = "target 

diameter"

datum_target_type 

(dt_area_circ)

area advanced_face datum_target_type 

(dt_area_face)

movable datum target Direction not covered

tolerance geometric_tolerance attrib_spaxpmi_geom_tol

tolerance types

angularity angularity_tolerance tol_type (toltype_angularity)

circular runout circular_runout_tolerance tol_type 

(toltype_runout_circular)

circularity / roundness roundness_tolerance tol_type (toltype_circularity)

coaxiality coaxiality_tolerance not covered

concentricity concentricity_tolerance tol_type 

(toltype_concentricity)

cylindricity cylindricity_tolerance tol_type (toltype_cylindricity)

flatness flatness_tolerance tol_type (toltype_flatness)

parallelism parallelism_tolerance tol_type (toltype_parallelism)

perpendicularity perpendicularity_tolerance tol_type 

(toltype_perpendicularity)

position position_tolerance tol_type (toltype_position)

profile of a line line_profile_tolerance tol_type (toltype_profile_line)

profile of a surface surface_profile_tolerance tol_type (toltype_profile_surf)
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

39

PMI STEP AP242 ACIS

straightness straightness_tolerance tol_type (toltype_straightness)

symmetry symmetry_tolerance tol_type (toltype_symmetry)

total runout total_runout_tolerance tol_type 

(toltype_runout_total)

tolerance zone

diameter tolerance_zone_form.name = "cylindrical or circular" mod_dia_type (dm_dia)

spherical diameter tolerance_zone_form.name = "spherical" mod_dia_type 

(dm_spherical_dia)

within a circle tolerance_zone_form.name = "within a circle" not covered

between two concentric 

circles tolerance_zone_form.name = "between two concentric circles" not covered

between two equidistant 

curves

tolerance_zone_form.name = "between two equidistant curves" not covered

within a cylinder tolerance_zone_form.name = "within a cylinder" not covered

between two coaxial 

cylinders tolerance_zone_form.name = "between two coaxial cylinders" not covered

between two equidistant 

surfaces

tolerance_zone_form.name = "between two equidistant 

surfaces" not covered

runout runout_zone_definition not covered

projected projected_zone_definition p_mag

non-uniform non_uniform_zone_definition not covered

tolerance modifiers

any cross section geometric_tolerance_with_modifiers.modifiers = 

.ANY_CROSS_SECTION. not covered

common zone

geometric_tolerance_with_modifiers.modifiers = 

.COMMON_ZONE. not covered

each radial element

geometric_tolerance_with_modifiers.modifiers = 

.EACH_RADIAL_ELEMENT. not covered

free state geometric_tolerance_with_modifiers.modifiers = .FREE_STATE. zone_modifier_type (zm_fs)

least material 

requirement

geometric_tolerance_with_modifiers.modifiers =

.LEAST_MATERIAL_REQUIREMENT. zone_modifier_type (zm_lmc)

line element geometric_tolerance_with_modifiers.modifiers = 

.LINE_ELEMENT. not covered

major diameter geometric_tolerance_with_modifiers.modifiers = 

.MAJOR_DIAMETER. not covered

maximum material 

requirement

geometric_tolerance_with_modifiers.modifiers = 

.MAXIMUM_MATERIAL_REQUIREMENT. zone_modifier_type (zm_mmc)

minor diameter geometric_tolerance_with_modifiers.modifiers = 

.MINOR_DIAMETER. not covered

not convex geometric_tolerance_with_modifiers.modifiers = .NOT_CONVEX. not covered

pitch diameter geometric_tolerance_with_modifiers.modifiers = 

.PITCH_DIAMETER. not covered

reciprocity requirement geometric_tolerance_with_modifiers.modifiers = 

.RECIPROCITY_REQUIREMENT. zone_modifier_type (zm_rfs)

separate requirement geometric_tolerance_with_modifiers.modifiers = 

.SEPARATE_REQUIREMENT. not covered

statistical tolerance geometric_tolerance_with_modifiers.modifiers = 

.STATISTICAL_TOLERANCE. zone_modifier_type (zm_st)

tangent plane geometric_tolerance_with_modifiers.modifiers = 

.TANGENT_PLANE. zone_modifier_type (zm_tp)
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

40

PMI STEP AP242 ACIS

unequally-disposed 

tolerance unequally_disposed_geometric_tolerance p_shift

tolerance with maximum 

value geometric_tolerance_with_maximum_tolerance not covered

unit-basis tolerance

length geometric_tolerance_with_defined_unit runit1

circular geometric_tolerance_with_defined_area_unit.area_type = 

.CIRCULAR. runit1

rectangular geometric_tolerance_with_defined_area_unit.area_type = 

.RECTANGULAR. runit1,runit2

square

geometric_tolerance_with_defined_area_unit.area_type = 

.SQUARE. runit1

composite tolerance geometric_tolerance_relationship attrib_spaxpmi_geom_tol

tolerance with datum 

references geometric_tolerance_with_datum_reference spaxpmi_drf

datum reference datum_reference_compartment spaxpmi_dref

datum reference 

modifiers

free state simple_datum_reference_modifier.modifiers = .FREE_STATE. not covered

basic simple_datum_reference_modifier.modifiers = .BASIC. not covered

translation simple_datum_reference_modifier.modifiers = .TRANSLATION. not covered

least material 

requirement

simple_datum_reference_modifier.modifiers = 

.LEAST_MATERIAL_REQUIREMENT.

datum_modifier_type 

(datum_modifier_lmc)

maximum material 

requirement

simple_datum_reference_modifier.modifiers = 

.MAXIMUM_MATERIAL_REQUIREMENT.

datum_modifier_type 

(datum_modifier_mmc)

point simple_datum_reference_modifier.modifiers = .POINT. not covered

line simple_datum_reference_modifier.modifiers = .LINE. not covered

plane simple_datum_reference_modifier.modifiers = .PLANE. not covered

orientation simple_datum_reference_modifier.modifiers = .ORIENTATION. not covered

any cross section simple_datum_reference_modifier.modifiers = 

.ANY_CROSS_SECTION. not covered

any longitudinal section simple_datum_reference_modifier.modifiers = 

.ANY_LONGITUDINAL_SECTION. not covered

contacting feature simple_datum_reference_modifier.modifiers = 

.CONTACTING_FEATURE. not covered

distance variable simple_datum_reference_modifier.modifiers = 

.DISTANCE_VARIABLE. not covered

degree of freedom 

constraint x

simple_datum_reference_modifier.modifiers = 

.DEGREE_OF_FREEDOM_CONSTRAINT_X. not covered

degree of freedom 

constraint y

simple_datum_reference_modifier.modifiers = 

.DEGREE_OF_FREEDOM_CONSTRAINT_Y. not covered

degree of freedom 

constraint z

simple_datum_reference_modifier.modifiers = 

.DEGREE_OF_FREEDOM_CONSTRAINT_Z. not covered

degree of freedom 

constraint u

simple_datum_reference_modifier.modifiers = 

.DEGREE_OF_FREEDOM_CONSTRAINT_U. not covered

degree of freedom 

constraint v

simple_datum_reference_modifier.modifiers = 

.DEGREE_OF_FREEDOM_CONSTRAINT_V. not covered

degree of freedom 

constraint w

simple_datum_reference_modifier.modifiers = 

.DEGREE_OF_FREEDOM_CONSTRAINT_W. not covered
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

41

PMI STEP AP242 ACIS

minor diameter simple_datum_reference_modifier.modifiers = 

.MINOR_DIAMETER. not covered

major diameter simple_datum_reference_modifier.modifiers = 

.MAJOR_DIAMETER. not covered

pitch diameter simple_datum_reference_modifier.modifiers = 

.PITCH_DIAMETER. not covered

with value datum_reference_modifier_with_value not covered

common datum/multiple 

datum features datum_reference_element spaxpmi_dref

polyline presentation

annotation_curve_occurrence / annotation_fill_area_occurrence 

/ annotation_symbol_occurrence / 

annotation_text_occurrence/tessellated_annotation_occurrence

body/wire

BREP

topology

solid manifold_solid_brep body/lump

shell closed_shell / open_shell shell

face advanced_face face

loop face_bound / face_outer_bound / edge_loop / vertex_loop loop

edge oriented_edge / edge_curve edge/coedge

vertex vertex_point / cartesian_point vertex

surface geometry

cone conical_surface cone

cylinder cylindrical_surface cone

extruded surface surface_of_linear_extrusion spline

nurbs

b_spline_surface / b_spline_surface_with_knots / 

rational_b_spline_surface / uniform_surface / 

quasi_uniform_surface / bezier_surface

spline

offset surface offset_surface off_spl_sur

plane planar_surface plane

revolved surface surface_of_revolution rot_spl_sur

sphere spherical_surface sphere

torus toroidal_surface torus

curve geometry

circle circle ellipse

ellipse ellipse ellipse

parabola parabola bs3_curve

hyperbola hyperbola bs3_curve

nurbs

b_spline_curve / b_spline_curve_with_knots / 

rational_b_spline_curve / uniform_curve / quasi_uniform_curve / 

bezier_curve

bs3_curve

offset curve offset_curve_3d bs3_curve

line line straight

linkages

PMI<->BREP BREP<-geometric_item_specific_usage->shape_aspect<-PMI spacollection / entity

PMI<->polyline 

presentation

PMI<-draughting_model_item_association-

>annotation_occurrence / draughting_callout not covered
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

42

Appendix B.2: Mapping Other MBD-related Items into STEP and ACIS

PMI STEP AP242 ACIS

Notes text_literal not supported

Flag Notes not supported attrib_spaxpmi_flagnote

Surface Finish (roughness) not supported attrib_spaxpmi_roughness

Tables not supported not supported

Global or General Tolerances not supported not supported

Views draughting_model / camera_model spaxpmi_capture
Investigating the Impact of Standards-Based Interoperability for Design to Manufacturing and Quality

43

Appendix C: Technology Readiness Levels (TRL)17

TRL 1: Lowest level of technology readiness. Scientific research begins to be translated into applied 

research and development (R&D). Examples might include paper studies of a technology’s basic 

properties.

TRL 2: Invention begins. Once basic principles are observed, practical applications can be invented. 

Applications are speculative, and there may be no proof or detailed analysis to support the assumptions. 

Examples are limited to analytic studies.

TRL 3: Active R&D is initiated. This includes analytical studies and laboratory studies to physically 

validate the analytical predictions of separate elements of the technology. Examples include 

components that are not yet integrated or representative.

TRL 4: Basic technological components are integrated to establish that they will work together. This is 

relatively “low fidelity” compared with the eventual system. Examples include integration of “ad hoc” 

hardware in the laboratory.

TRL 5: Fidelity of breadboard technology increases significantly. The basic technological components are 

integrated with reasonably realistic supporting elements so they can be tested in a simulated 

environment. Examples include “high-fidelity” laboratory integration of components.

TRL 6: Representative model or prototype system, which is well beyond that of TRL 5, is tested in a 

relevant environment. Represents a major step up in a technology’s demonstrated readiness. Examples 

include testing a prototype in a simulated operational environment.

TRL 7: Prototype near or at planned operational system. Represents a major step up from TRL 6 by 

requiring demonstration of an actual system prototype in an operational environment.

TRL 8: Technology has been proven to work in its final form and under expected conditions. In almost all 

cases, this TRL represents the end of true system development.

TRL 9: Actual application of the technology in its final form and under mission conditions, such as those 

encountered in operational test and evaluation (OT&E).

 

17 United States Department of Defense. (2011, April). Technology Readiness Assessment (TRA) Guidance. 

Retrieved from http://www.acq.osd.mil/chieftechnologist/publications/docs/TRA2011.pdf.