Trouble extruding to surface

[K_Baker_89]

Hi,

I'm struggling to get a sketch to extrude to a surface. It's probably easiest to show via a couple of images, so basically Image 1 shows a successful extrude to the surface, however, Image 2 shows this fails once the sketch profile is extended to the match that of the surface (or slightly inset). I suspect the issue is to do with the circular sections at either end of the surface (as this seems to be the point at which the extrusion doesn't work).

I've also attached the IPT.

Any assistance in getting the extrusion to work would be much appreciated.

Thanks,

Kurt

[PaulMunford · Accepted solution]

I'm Guessing that the tolerance between the sketch outline and the surface is too tight.

Extrude > (ALL) works, either as a solid, or as a surface.

Always click on the red text for a hint on the problem...

Extrude > (All) worked this time...

[johnsonshiue · Accepted solution]

Hi! This case is highly doable. Please take a look at attached part. I did not create one single sketch but I can get it done. Boundary Patch is not a good choice here. You already have the imported faces. The faces are fine. You don't need to add approximated faces on top of precise faces. The projected edges in the sketch introduce yet another level of complication.

The key is to preserve the geometry as much as possible. For imported geometry, unless you have the original wires or sketches, try to reuse existing geometry. Only create construction geometry like sketches when you don't have other options. Or, the model is very bad and you have to recreate it.

Please let me know if more information is needed.

Many thanks!