Please find attached my efforts so far. I have a plastic plate(Boss-Extrude1) which requires a honeycomb(linear array) cut out whos shape is constrained by the rounded rectangle of sketch2.
I can apply an Extruded cut feature to the honeycomb(sketch6) which punches the correct hole pattern but it also holes out the polygons outside the rounded rectangle. I cant't figure out how to ignore/leave solid, those outside the rounded rectangle.
Another problem is one of 3d printing this project. Ignoring the constraint to rounded rectangle failure, I printed the part as is.It came out as expected except that the 1mm walls of the polygon were hollow. ie made up of two .5mm sides with a whisker gap between. ie the polygons are individual and held together by friction. If I push hard enough the individual polygons will fall out. I don't know much about 3d printing either but it looks like it put support material in between each polygon which has then washed out. Looking at the sketch there does not seem to be a problem with the extrusion, it looks solid. The printing is done in another dept.
would appreciate any thoughts