I am a placement student working for an action sports company in the UK and I am working on a new helmet for the company. I have produced the vast majority of the helmet on Solid Works and I am stuck on a final detail.
The helmet is made of two parts the outer shell and the EPS. The EPS holes need to be slightly bigger than the holes in the shell to prevent the EPS from being seen through the shell.
These holes in the EPS are also chamfered inwards. I have created these holes using a lofted cut however I am struggling to get the outer dimension of the hole to be the correct dimensions but the interior hole dimensions are correct.
I have attached a picture with the the sketch highlighted on where it should be intersecting the EPS.