Getting extra lines in drawings that are not showing up until the file is sent out to be produced

[tomHKD9J]

Good morning,

I have a laser cut and folded part that is showing additional lines creating an open or nested pattern for the laser cut. When I zoom in on the exported DXF file from the flat pattern, you can see these lines int he small relief cut radius that I created for the bend and for welding. On the laser cut end they show up as a hidden line layer that I cannot find on my end. I am hoping someone can see the error in my design so I can learn not to do that again... As always thanks for the help. I have included the native file, a copy of the DXF as well as a PDF of the effected area so you know where to look.  @jhackney1972 

[jhackney1972]

I am thinking you can get by your issue by unchecking the "Hidden" layer when you insert your DXF file.

[tomHKD9J]

I am not sure where you are inserting it.  Where are you finding this stage? I would like to figure out what it is I am doing that is causing these extra lines here. The method I am using I have used many times, it has just recently created this issue and I would like to figure out what not to do so I can avoid it in the future. For example, how are these hidden items being created in the first place.

[laughingcreek]

the modeling problem starts at extrude 10.  because your extruding into a curved face, when flattened that edge won't be normal to the face.  

you can see this when you do extrude 11-

and also at fillet3-

[tomHKD9J]

So I would need to perform these cuts prior to the bend? I assumed when it was flat it would treat it as such. A lot of these changes are made as I am taking something from a thought and bringing it to reality when it is modeled and going through it. Changes and reliefs are made to aid in folding, welding etc. as well as tabs added for fit up aid and so forth. Is it safe to say that when I design like this, when finished, I should recreate it from scratch using the first model as a template? I do a lot of work as I go designing for my products, first and foremost I don't want to create issues for others who have to deal with them down the line but I also don't want to create a bunch of extra work if it can be avoided.

[laughingcreek]

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@tomHKD9J wrote:

So I would need to perform these cuts prior to the bend? I assumed when it was flat it would treat it as such....

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I'm not sure what your asking here.  when you did extrude 10, it wasn't flattened.  I made sure the history was visible in the screen shots so you could roll back to the same spot and look at what I'm talking about.  Have you done that?  this discussion will be easier after you do that.

[laughingcreek · Accepted solution]

here's an over exaggeration of what you did with extrude10.  if you where to flatten this ring, face A won't be normal, but face B will be.

[tomHKD9J]

Duplicate

[tomHKD9J]

Now I am following along. So in extrude 10, I started to separate the shell so it could be flattened, using the extrusion feature to slice and remove material. I have to do this step in order separate the edges so it can be flattened. I tried to just slice the edges but it would not flatten until I cut in reliefs. Should I cut smaller reliefs to get it to flatten then clean it up as shown?

[tomHKD9J]

Now I figured it out and know what I did. Thanks for the help!