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How can I add seam allowances in duct designs without collisions?

I am designing a bunch of ductwork parts for 24ga sheet metal for hand assembly (not welded), and I can't figure out how to add seam allowances for something like a Pittsburgh seam. In a flat layout, I'd just add 1" on one side of the rip joint for the pitt and 1/4" on the other side of the rip for the flange. But when the duct is designed in 3D, I can't add these allowances because it will cause collisions.

For example, in this model, the seam highlighted in yellow is a rip. They are free ends when flattened and will be joined after folding. I need to add 1/4" 90 deg. flange on one vertex and a 1" allowance for the pittsburgh on the mating vertex. Similar for the slip & drive seam between the light blue lofted taper and the dark blue enclosure faces.

Any suggestions?

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Answers

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