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.PDF (w/ 3D option checked)
This is very small but will serve only as a visual check, you can't re-import this into any 3d package as far as I know and won't be able to interference check it either.
.X_T
This is the native kernel extension of Solidworks, very clean geometry but without history. Will re-import just fine and should allow for interference checks and even simulations. I recommend this one, especially if you're staying in Solidworks.
.STEP
Neutral format that will translate your Solidworks model into this file format, the format holds the data though in a similar fashion as Solidworks does so it should give you clean geometry and will also allow re-import but might give a few errors or warnings that you'll need to fix, probably also interference checks and simulations will be possibly. I would recommend this if you're going to another 3d app.
.STL
Visual format, for all intents and purposes. Depending on the geometry and the options you set in the save dialog box this can be quite a small file. Perfect for looking around and will re-import into Solidworks, will not allow interference checking or simulations though if you would require that. This file makes your model faceted making editing very difficult.
There is also an old trick...draw a large circle or square sketch on the lowest most plane of your assembly and extrude it up until it completely encases all aspects of your geometry. Call this extrustion "Delete Me" and save it. The file size should go down. Send it to your vendor with instructions that they are to delete the "Delete Me" block as soon as they get the file.
This trick might still work, no guarantees. It used to work in the early days of Solidworks.
I know in ProE to reduce the file size for sendingyou can scroll back the feature tree, take it this something similar in SW....def worth a go or even scroll back the feature tree in SW and see if that works too.
I just did a little experiment with a part that has some solid features, some surface features and I'm trying to find a somewhat balanced example, this is what I got:
Normal part: 1.191MB
Feature tree rolled back: 987KB
All features suppressed: 510KB
Delete me feature added: 1.016MB
What surprised me the most, is what a difference rolling back and suppressing makes!
I guess suppressing makes an actual state change and requires a full rebuild, but gets you down to the smallest memory requirements.
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