Help removing ugly edges

[nielswitlox]

Hey guys, I'm new to this form. I am looking for some superior Sollidworkers advice.

I have been struggling for hours to make an ugly edge smooth. But instead of continuing like this I thought I would seek some help.

So this is the problem: I basically want to make a recessed part in a surface. I started by copying the surface to a part, and then thickening it, and then use it to make a cavity in the original part. But the thickened surface has some ugly edges. Do you guys have a suggestion on how to make these edges smooth/merge?

Here are (I hope) some pictures of what I'm doing:

Image of the ugly edges:
https://ibb.co/BG8jbqz

Image of the cavity part:
https://ibb.co/ZSKH4XK

Image of the part that receives the cavity:
https://ibb.co/Pt6Xhst

Thanks for your help in advance!!!

Niels

[len_1962]

Have you tried delete face and patch, it is the surfacing tools. I use this alot

Too Tall Toby!

[SPerman]

I think you need to reconsider how you model this part/assembly. With the lack of information provided, I can't make a suggestion.

[nielswitlox]

Have you tried delete face and patch, it is the surfacing tools. I use this alot

Too Tall Toby!

Yeah I tried this, but then I get: "The faces cannot be patched due to geometric condition"

[nielswitlox]

I think you need to reconsider how you model this part/assembly. With the lack of information provided, I can't make a suggestion.

This could be a solution yes. I already thought about maybe making a swept boss base, but I would have no idea how I could then make it tapered towards the back.

[Frederick_Law]

What are you making?
A cover?
Side panel?
Retaining wall?

[SPerman]

I would probably make the panels oversize, and then trim them as needed. But if the goal is a cavity, the cutter part may be unnecessary.

Again, I'm speculating because all we have to work from is a few screen shots. Are you able to share the models?

[DanPihlaja]

Is this going to end up as a piece of sheet metal that is going to be bent into shape?

[DLZ_SWX_User]

I saw this post on Monday but because I was not able to get a good visual of what the part was & I do very little with surfacing I never responded. If it is a bent sheet metal part I think I would use lofted bend.

If you can share the Solidworks part, it might give us a better idea as to what is trying to be accomplished.

[len_1962]

can you show the part you are going to resess this into as maybe some of the other faces can help develope what you need.

As others have asked can you send the files of this and the part to resess into so we can help.

I do alot of things like this for 3D printing when students want different colors or adding aluminum or other materials.
Model Maker tricks I have done for 40 years for ID parts. just need to see the overall picture.

could use multiple bodies, copy original save as new part and slice and dice with maybe a shell or or or and then other things to get there.