This is the first time I have done this in SolidWorks and running into an issue of trimmed ends being coped even when Simple cut selected as corner treatment. I can go back and Trim the ends, but wondering if I am missing a simple step.
Interesting. If you uncheck 'Allow protrusion', you get 3 good corners and one that looks like this:
I created a new library feature file form my own 8020 model for the 1010 profile and it worked fine:
I even tweaked my sketch so that it dimensionally matched yours, and it still worked:
so I started simplifying. If you remove all of the grooves along the exterior, the problem goes away:
If you bring back the grooves closest to the outside corners, the problem returns:
Not so for the grooves away from the corners:
Now we are getting somewhere. If you make a new test profile that looks like this:
You get this:
Bad. But if you adjust the profile slightly, you get this:
Good. What's the adjustment? You have to move the groove edge away from the tangent line at the outer corner:
If it is at the tangent point or beyond, the profile won't work. Your profile is at the tangent:
The 80/20 models I have were downloaded from their website. I don't have your exact profile, but the ones that are close have grooves that are set back from the tangent point, even if only slightly:
So, the bottom line is that external features need to stay away from outside corner tangents/edges.
And corners shouldn't be asymmetrical:
Because weird things can happen:
The more I look into it the more failure cases I find.
I think you're going to need to continue to use the Trim feature if you want to cut the bodies off at a selected face. I don't have access to that profile, but I got similar results with simple Angle.
Something is off. Can you upload your weldment profile file and model?
Here are a couple of older files - I can't upload the files from image due to confidentiality.
I did notice a difference in that the sketch was on an offset plane and not at the Origin, but in my initial experimentation that did not resolve the issue.
Outstanding analysis of the issue.
I owe you a box of doughnuts.
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