Stitch is modifying the round shape below where the two pieces should be stitched together. First pic shows the unstitched correct shape. Second pic shows the only edges to be stitched highlighted green. Third pic shows the stitched shape with unwanted added features highlighted in red. Unstitching everything and stitching everything again causes the same, but slightly smaller, unwanted features to be added.
How do i stitch these together without the unwanted features being added?
Why does Boundary Fill create the required geometry without a problem, but Stitch does not ?
the bad geometry is still there after Boundary Fill:
those tolerant vertices, IMO, are a time bomb. You are likely to have downstream problems eventually, it's just that stitch set off the bomb a bit earlier.
I will verify with the modeling team that there is not something funky going on with stitch that I am not seeing, just to get their take on it
sure enough, the first thing I tried after the Boundary Fill was a Split Body, using one of the planar faces as a tool:
and it failed with the error message that I dislike most of all:
