Having an issue stitching surfaces.

[SAURABH.BENDE]

Hi folks!!

I'm creating a pretty simple geometric pattern using surface. The pattern contains a small bulge at the mid surface and vanishes at the edges. The problem I'm facing is when I try to stitch them altogether. The edges get crooked when i try to stitch them (loses the straightness) causing the edges to not fillet at all. I'm attaching all the reference images and a f3d file. 

Please help me figure out why this is happening and an appropriate solution.

[TrippyLighting]

Stitching works fine and what you are seeing is a viewport tessellation artifact that should be ignored,. The geometry is fine! 

You can change the display detail control from "Adaptive" to "fixed/high" and see if that effect disaapears.

Filleting is going to be a challenge and will likely require a different modeling approach.

[johnsonshiue]

Hi! Instead of using Boundary Patch (SurfacePatch4 particularly), I would use Loft Surface to create the surface. The issue here is that though the patch surface looks nice, the edge tolerance is really loose (0.001mm). Stitching such loose geometry is going to make further modeling more difficult. It is better to tighten the tolerance at the beginning as much as possible.

Many thanks!