Joining 3D Shapes

[Glen]

I have mirrored my design. How can i attach the two images by a web of material to help reduce costs. It wil be made of aluminum on the three axis mill. I nudged the mirrored images apart to allow space for machining the facing edges , however i am unable to connect them by adding two bridges of material that i can remove later.

Thanks, Glen

[Tech2]

In milled parts it is not generally a good idea to link parts as the link becomes a weak spot which can create work-holding complications during machining. Such orders might be declined. Nevertheless there are some cases where it will work. "That being said" (as the overused phrase goes) the trick is that you need a single line shape that encompasses the full size and shape of the overall joined parts including the small link - very roughly like the side view of an hour-glass. From that base you build up the sub parts. (Just adding a small shape between the sub parts will not work as you apparently experienced.)

Here's a trick to build the encompassing shape.

* Create two 3D models that are separated by a small gap.
* Go to the Top view usually.
* Select everything.
* Edit | Copy ... Edit | Paste.
* Nudge the dupe away from the original.
* Draw the link in the dupe.
* Select all lines in the dupe including the link.
* Line | Intersect
* Delete all line segments inside the outer contour of the dupe, leaving only the outer shape.
* Group the remaining lines of the outer contour of the dupe.
* Set a Z value (e.g. 0.1").
* Nudge the encompassing shape back into position on the original lines.
* Make final adjustments to compensate for the added "base" material.