One of PlyWiz's most powerful yet underutilized features is the MasterCut tool, which can dramatically reduce the time required to create complete composite layups. In this post, we'll explore how this tool works and how it can transform your workflow.

Understanding the MasterCut Concept

Traditional layup creation often involves designing each ply individually—a time-consuming process that can take days for complex parts. The MasterCut tool takes a different approach:

1. Start with a base cutout (the MasterCut) that typically represents the first layer of your composite part

2. Define your complete layup structure in the MasterTable, including materials, fiber orientations, allowable rotation angles, and labeling

3. Divide the MasterCut into segments and link adjacent areas

4. Let PlyWiz automatically generate all plies according to your specifications

This approach can reduce layup creation time from days to minutes while ensuring consistent, high-quality results.

Step-by-Step Guide

Step 1: Create or Import Your Base Layer Import your first layer from a 3D model, create it directly in PlyWiz, or use the Picture Wizard to extract it from an image. This will serve as your MasterCut.

Step 2: Configure Your MasterTable Create a new MasterTable by clicking on "Layup > New MasterTable". Define your layup sequence, including:

• Material type for each layer

• Fiber orientation angles

• Layer thickness

• Labeling conventions

• Allowable rotation angles for nesting

Step 3: Segment Your MasterCut Divide your MasterCut into logical segments using the Segmentation tool. These typically correspond to areas with different layup requirements or geometrical features.

Step 4: Link Adjacent Segments Use the Segment Linking tool to connect adjacent segments. This crucial step tells PlyWiz which edges should be staggered in the final layup to ensure structural integrity.

Step 5: Generate Your Complete Layup Click "Generate Layup," and watch as PlyWiz automatically creates all plies according to your MasterTable specifications, complete with properly staggered edges and correct fiber orientations.

Pro Tips for Maximum Efficiency

• Keep your segments logical: Create segments based on structural considerations rather than just geometric shapes

• Use consistent naming conventions: This makes it easier to track segments across multiple layers

• Save your MasterTables: Create templates for common layup patterns that you can reuse across projects

• Verify linking before generation: Double-check your segment links before generating the full layup to avoid errors

Real-World Success

A Formula Student racing team recently reported reducing their layup design time from two weeks to just three days by implementing the MasterCut workflow. Not only did this save valuable development time, but it also resulted in more consistent production documentation.

Ready to try it yourself? Download our free MasterCut Project Template or watch our detailed video tutorial on the Get Started page.