This seems pretty absurd as an example of high face complexity with regards to a simple Circular Pattern. File attached. If the existing pattern in the file attached is changed to Faces (with the same bits selected - 13 in total) it fails as shown.
Circular Pattern Failing
the complexity here is these two non-manifold edges:
Which is why pattern Faces (or Feature pattern set to "optimized", which is the same thing) fails. This is because face patterning uses a kernel algorithm where faces are unstitched from the body, copied, repositioned, and attempted to be stitched back into the body. These non-manifold edges prevent those faces back into the body. Just the limitation of the algorithm/geometry involved.
This pattern does succeed using Feature/Identical, which is a faster algorithm than Feature/Adjust.
Jeff Strater
Engineering Director
