Extrude Creates new face on continuous edge

[charlieV9LYD]

Hello ,

I have been using fusion360 for years and this problem has only been showing up recently, when I extrude a face it will not join the face but create a new face where there should not be one. 

I have confirmed that the two faces are parallel and that they are the same body.

I have attached the latest file that has shown this error but I have had it on many designs (Both curved and flat faces).

The pictures are of a cylinder with a d-slot where it must be removed, when extruding the face to the top face it creates a split face at the top.after extrudeBefore extrude 

[davebYYPCU]

You have imported 2 bodies that don't have a timeline.  They are known as Base Features.

Your first external extrude is cutting the thread off, can be done editing the Base Feature or as you have done it..

The "Unusual" is that you are extruding the dflat while not editing the Base Feature.

Edit the shaft Base feature, and select / delete the large flat face.

Finish the edit and

delete the last extrude from the timeline.

Might help.....

[charlieV9LYD]

With this example I have to then extrude the cylinder out by ~50mm and that still creates that split face(on the cylinder). I do not want to edit the base feature as this is a variant design, I do feel that this shouldn't be happening. And with more complex designs it has caused some very time consuming errors.

Is there another way around this?

[davebYYPCU]

Base Feature has no tie backwards to anywhere. 

Different for Linked or Derived Components.

If this variant is not similar to the required, why not make it in the timeline?

[charlieV9LYD]

This variant that is an option for, but I have not always got that as an option. Is there another way of redefining the object or merging the two faces?

[sanjana.shankar.goli · Accepted solution]

Hi @charlieV9LYD ,

The extrude cut you made is not leaving a circular surface on the top from what I see. (Check the file to see how a distance of 6mm from the other end is used to make the extrude cut alternatively)

You can also use extent type "to object" instead of "distance" in the extrude cut definition to avoid the split face with the same timeline you have set up.

  

[davebYYPCU]

You want to Edit a base feature outside the base feature,

I believe that the body is "locked" within the Base Feature, I get it, edits inside a base feature are not parametric.

Seems a lot of (recent) trouble that can be avoided for a body imported you can't use.

Might help....