This is a reference guide for designing vinyl decals to fit over a curved surface, using Solidworks or other CAD software. It demonstrates the optimal steps for fine-tuning the shape and offsets of the decal, ending with the surface flattening feature + SVG export available in Onshape. I use this procedure to design stickers for pillowed twisty puzzles.
1. Copy unique surfaces
First, use the Offset Surface tool in Solidworks (or equivalent in your CAD software) to copy each curved surface that gets a sticker. Set the offset to 0 so that the new surface is exactly the same as the original.
