Lofting through a body - STUCK!

[cyrus.dalal8P5DW]

I am making a part which comprises of a clip and a flat mounting surface. I want the part to look nice by lofting the two together. The best way Ive found to get the shape I want is to create a 3d sketch, create a patch and loft the mounting surface to the patch. The problem is that the loft overlaps another body and causes problems where the two intersect.

Ideally I would combine these two using the combine command but in this case there are boolean errors.

My goal is to 3d print this part so if I could find a way to export it as a combined solid that would work fine.

Alternatively I could re-design the part somehow but I cant figure out how to get the shape like it is here any other way without spending hours making a ton of 3d guide rails. How would you make this part?

Any suggestions to fix this problem when combine fails? I am VERY new to 3D sketching and complex curves so any help would be greatly appreciated. Model is attached.

 

[TrippyLighting]

I would start with fully defining the sketches.

[etfrench]

Simply export both pieces in one mesh file.  You can do this by turning visibility of all other components/bodies off, then select the top node in the Browser and 'Save As Mesh'.

[cyrus.dalal8P5DW]

Thank you for the suggestions. I started by fully defining all my sketches and then tried to export using the save as mesh option from the top level. Unfortunately my output looks exactly the same once sliced there are holes in the part anywhere that the two independent bodies (body 1 and body 54) overlap. See attached updated file and screenshot of the sliced mesh.

 

[etfrench · Accepted solution]

SuperSlicer handles the two bodies with no problem:

Note: The forum software doesn't like .3mf file extension name.  Just delete the .txt.

[cyrus.dalal8P5DW]

It looks like this may be a Simplify3D issue or setting then. I will work on resolving that and post back with the solution if I find one. I thought that it was a mesh output issue simply because I thought that the two bodies should be merged in the mesh output and if Simplify3D could see them as separate then the mesh itself must be the problem.

[cyrus.dalal8P5DW]

It looks like this is a Simplify3D thing! I found this support forum post from someone else with the same issue. In Simplify3D going to Mesh>Separate Connected Surfaces resolved the issue and the part slices fine. Thank you for the guidance!!

https://forum.simplify3d.com/viewtopic.php?t=4986