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Jim ZwicaOct 14, 20253 min read

The Real Costs of Legacy 3D Workflows: Expertise That Doesn’t Scale

The Real Costs of Legacy 3D Workflows: Expertise That Doesn’t Scale
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In today’s global manufacturing landscape, product data is one of your most valuable assets. Yet for many organizations, that knowledge is trapped—locked behind file-based tools, complex software, or the desks of a few specialists. Whether it’s an engineer exporting static files, a buyer waiting for clarification, or a technician navigating outdated documents, the result is the same: delays, inefficiencies, and missed opportunities across the enterprise.

File-Based Workflows = Friction

Legacy 3D workflows create friction for every role that touches product data—not just engineers:

  • CAD experts spend hours creating and exporting files, instead of designing.
  • Program managers can’t make informed decisions because they lack real-time visual context.
  • Technicians prep work from outdated PDFs, leading to costly rework.
  • Supply chain teams struggle to validate parts or resolve RFQs quickly.

These aren’t isolated inefficiencies. They represent a systemic barrier to productivity and collaboration—especially for global teams that cannot access up-to-date 3D data in real-time.

A major aerospace manufacturer found that distributed design reviews were delayed by 30% simply because teams in different time zones couldn’t access CAD models. Engineers relied on screenshots while suppliers operated using 2D drawings. This reliance on workarounds led to production delays and created frustration among the teams involved.

The Cost of Trapped Knowledge

Siloed 3D data doesn’t just slow teams—it impacts core business outcomes:

  • Time-to-market suffers: Decision-making stalls when stakeholders lack context.
  • Costs rise: Rework, scrap, and inefficiencies pile up from miscommunication.
  • Talent churns: New hires struggle with legacy knowledge and complex tools.
  • Innovation slows: Experts are buried in manual repetitive tasks instead of solving real problems.

Worse yet, when knowledge lives in files or is limited to specific people, it walks out the door with employee turnover—putting business continuity at risk.

Unlocking Knowledge for All Teams

Imagine a world where everyone—not just engineers—can instantly view, explore, and collaborate on high-fidelity 3D models from any device, anywhere. No installs. No exports.

  • A sourcing lead flags a fit issue during a real-time review—before it becomes a $10,000 rework incident.
  • A technician prepares for a job with a live model—catching an error before production, saving weeks of rework.
  • A new hire explores assemblies interactively—accelerating onboarding by weeks.
  • A program manager independently navigates a design update in real-time, spotting potential delays early.

When 3D data is unlocked across the enterprise, teams stop waiting and start solving. Everyone—from engineering to the shop floor—can explore product context in real-time, without bottlenecks or back-and-forth. And your most skilled experts? They’re freed up to focus on innovation, not file prep or data wrangling. That’s how you scale expertise—and move faster as a business.

From Engineering Asset to Enterprise Advantage

With Vertex, 3D data becomes a shared strategic asset—not an engineering bottleneck:

  • Stream context-aware pixels—not files—so your IP stays protected.
  • Eliminate specialized hardware and software—intuitively view massive models on any device, anywhere.
  • Deploy in days—achieve ROI in weeks with turnkey, browser-based access.
  • Scale across teams—from design to sourcing, manufacturing, and service.

One customer manages over 50 million parts and 60,000 engineering changes daily—with no file exports. They’ve reduced CAD model access time from over 6 minutes to under 12 seconds.

By making product data a shared resource, these platforms turn experts into enablers. CAD designers drive design innovation, program managers make faster decisions, and shop floor teams execute with confidence.

Why Now?

Today’s manufacturers face unprecedented complexity: global supply chains, distributed workforces, and digital-savvy employees who expect seamless experiences. Legacy file-based 3D tools can’t keep up.

Your teams need real-time access to the most accurate product data. Your business needs the agility to respond instantly. And your customers expect flawless execution.

Knowledge Scales. Teams Thrive.

Your best people shouldn’t be the only ones who understand the product. They should be the ones leading innovation—not maintaining access.

With Vertex, you multiply the value of your experts by making product context accessible to everyone who needs it—without sacrificing control or security.

That’s how insight scales. And that’s how your organization moves faster, together.

Next up in our series on The Real Costs of Legacy 3D Workflows:

📊 Visibility Gaps on the Shop Floor by Thomas Berg – When service technicians rely on outdated drawings or static documentation, the risk of errors, delays, and incorrect parts skyrockets. His post explores how real-time access to the exact as-built 3D model enables shop floor teams to identify issues faster, order the right parts, and complete repairs with confidence—no guesswork, no rework.

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Jim Zwica

Jim Zwica is a product expert and solution architect at Vertex Software, with over 30 years of experience in PLM and supply chain collaboration. He currently serves as the voice of the customer at Vertex. Previously, he held positions at Caterpillar and Siemens and managed Ford’s initial digital prototyping process, focusing on product development, virtual design reviews, and optimizing supply chain operations. Jim combines technical expertise with a global perspective, having worked for years across Europe, Asia, and the Middle East.

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