Processes and tools for 'gutting' products for marketing and other external vendors

I have tried shrinkwrap(model>shrinkwrap). I make a new ASM add my complete product ASM then create a shrinkwrap from the product inside the new ASM. I was hoping that with the product as a reference anytime the model updated the shrinkwrap would update and then after a checkin to windchill the windchill publisher would make a step file for me.
That shrinkwrap always needed  touch up of surfaces to include and exclude. It would update though. Depending on how complex your parts are this can be a no go because too many little things need to be fixed every update and its easy to miss stuff. I probably just don't know what I'm doing but I never liked the result of the shrinkwrap. The shrinkwrap from model>shrinkwrap is a surface model, I probably could develop further to make a solid but I'm already past my fixing limit for how mediocre the result is.

Solid model shrinkwrap from a save-as operation. I need some holes filled others not. I have a lot of product with conical high pressure connections to customer lines. The fill holes option goes too far. So I need to go about doing it without fill holes and then get to fixing it. This model has no association and no autoupdate with model changes.

No matter what I do I have to fiddle with it. A lot. So I make a new ASM put my product in ASM then make a quick and dirty part in the ASM that fills all the space inside the product. Extrudes and revolves galore as fast as I can putting the ends of the new parts geometry just were I want the holes of the product geometry cut off. Then I merge everything into that new part. Now I have a filled solid inside, the exact exterior, and holes geometry shown to the depth I specified. Windchill will publish a step file. The model will update with the product changes, sometimes fail and need some touch up. The advantage to the touch up(IMO) is its normal sketching of the base geometry for your merge part. Or, its delete all merge features and then merge all again. Still manual, still a pain I know. This gives the exact result I need and I can edit and update edit this type faster as its "normal" modeling in my workflow.

If anybody has the magic of how to make customer models automated that show just what you want. Nothing more, nothing less. I'm interested.

My process is "specific" to sending to customers who want/need our product in their overall layout. Usually they are looking for the major interface areas.

It takes out as much internal information as I can reasonably remove. 

Below is a copy of how I documented it so others within our group could follow the same recipe:

See below for the steps I used. The kicker on my process is I end up cutting away some surfaces and then re-adding back in some models that I consider “major interface components”. 

It’s the fastest process I have come up with. Is the least prone to failure with respect to save as and export within creo. Also, it gives away the least amount of information that I have seen.

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The purpose of this is to provide a customer with a “reasonable” 3D model without giving them (or whoever they may send the file to) too much information on internal components.

This procedure will produce a single part file surface model that includes dimensionally accurate interface geometry but will only be a “shell” file with almost no internal geometry.

1. Open the LMRP or Lower stack, preferably in the stack layout rep. It may be wise to remove major interface components, examples include connectors, mandrels etc.

1. Create a shrinkwrap of the assembly using the following options (file – save as – shrinkwrap)
1. Surface Subset
2. Level 10
3. Fill holes
4. Do not ignore quilts
5. Ignore small surfaces - 1%

Always open the shrinkwrap and verify what you are left with. It should be mostly just an outer “shell” of surfaces with few or no internal details.

1. Once the shrinkwrap is created, you will notice the fill holes option has “covered” some of the interfaces. You will need to cut away those surface to be able to re-add the major interface components.

1. Make a new assembly, add the shrinkwrap at the default coordinate system. Assemble the major interface components back. It may be necessary to go back to the master creo assembly to get appropriate dimensions for re-assembling.

1. Create a new shrinkwrap of this new assembly using the following options
1. Surface subset
2. No fill holes
3. No ignore quilts
4. No ignore small surfaces

1. Save as a step file. Make sure you the step options include quilts and in the advance settings, the “export solids and quilts as” SURFACES.

Here is another idea. Let me know what you think. 

What is the process requires the engineer to create a 'gutted' simplified rep of the product before release. The Windchill generates an iges file of that simplified rep (where it exists). The iges format automatically can create a 'flat' state which mimics the process of merging everything together into 1 part. Does anyone know if Windchill can use certain simplified reps for some of its representations?