MultiBody Parts in SOLIDWORKS

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One of our customers brought up a very interesting problem recently. What he wanted to create was some structural reinforcement inside of a sheetmetal fabricated arm. He wanted to have a toothed shaped feature that would interact with and be welded to the sheet metal as an internal reinforcement, but creating the part interface manually could be quite time consuming. Rather than do it manually, we tried out creating it as a multibody part that we split up after the fact.

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Cylindrical Sheet Metal

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You can generate cylindrical sheet metal geometry pretty easily within SolidWorks. The key though is to design it in place. The first step is to define a sketch that is a single arc, as shown below. Make sure to split the arc somewhere. In my case I

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