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Face blend not completely seamless

Hello everyone,
I'm trying to do a face blend with a block to a cylinder but I keep getting this annoying bumps:
How do i change the face blend so that the block seamlessly connects to the cylinder?
Best Answer
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GregBrown Member, Onshape Employees, csevp, pcbaevp Posts: 339
Just based on what I can see in the image, this will take more than just a single face blend feature to achieve. It will need a bit of surface modeling, but not much.
See example here:
https://cad.onshape.com/documents/cc00aeaccfa37cd98094b575/w/5cc1d965e9f1477b471e4a83/e/7f64f8520e5081d654943d73
I've exaggerated the "bump" you mentioned, it is not something that the face blend is designed to conform to.But I can use some of the edges created by the face blend! I copied them, mirrored them to the other side and created a single patch (using a Fill feature) that blends in perfectly. Do this again (deleting the face blend helper faces and you'll be done. There are a ton of other ways you could do this (e.g. create the curves directly, without the face blend helper feature), but basically creating a smooth surface patch from surrounding reference feature is the way. Just be careful not to introduce any ugly noise in the curves you use for subsequent surfaces…
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Answers
You might want to share a view/copy link to an example document - then people might be able to help
Just based on what I can see in the image, this will take more than just a single face blend feature to achieve. It will need a bit of surface modeling, but not much.
See example here:
https://cad.onshape.com/documents/cc00aeaccfa37cd98094b575/w/5cc1d965e9f1477b471e4a83/e/7f64f8520e5081d654943d73
I've exaggerated the "bump" you mentioned, it is not something that the face blend is designed to conform to.
But I can use some of the edges created by the face blend! I copied them, mirrored them to the other side and created a single patch (using a Fill feature) that blends in perfectly. Do this again (deleting the face blend helper faces and you'll be done. There are a ton of other ways you could do this (e.g. create the curves directly, without the face blend helper feature), but basically creating a smooth surface patch from surrounding reference feature is the way. Just be careful not to introduce any ugly noise in the curves you use for subsequent surfaces…
Thank you, I managed to finish the design. Now I can use my loppers again!