CAD - FAQ: What can I do if my STEP export looks incorrect in my CAD platform.

Zemax OpticStudio uses by default the 3D ACIS Modeler as a geometric modelling kernel. We have seen some cases, especially in connection with non-circular aperture shapes (e.g. rectangular aperture), in which the geometry can be flawed in the CAD environment and we are currently working on a solution. As a temporary workaround to this issue, the OpticStudio user can switch (before creating the export file) from the default ACIS Modeler to the SMS Modeler. This can be done via the Project Preferences -> General -> Untick: Use ACIS Libraries.(See image below)

OpticsBuilder - FAQ2: Import, Export and Update a .ZBD file

A .ZBD file (Zemax Builder file) is initially created in Zemax OpticStudio with the Prepare for OpticsBuilder tool, this replaces the traditional CAD Export.

The so generated .ZBD file can be imported into the CAD environment with the OpticsBuilder Add-in via the Import .ZBD file feature. After that, mechanical components can be added and an optomechanical assembly can be modelled. The mechanical components can be CAD native or any other imported solid file format. When the optomechanical system is finished the optical performances can be analysed. If the optomechanical system needs to be analysed in Zemax OpticStudio, the Export .ZBD file feature can be used to transfer the whole system back into Zemax OpticStudio. This way the mechanical parts which have been added in the CAD platform are also exported to OpticStudio and are either a STEP file format or native CAD Parts (Depending on CAD Platform). If only the optical components are edited in OpticStudio another .ZBD file can be created and then updated with the Update .ZBD file feature in the CAD environment.

This thread is now closed. Thank you @Flurin Herren for a great overview of CAD and OpticsBuilder. For any additional questions about these topics, please refer to the pinned reply!