I've been having a few issues with a model I'm working on.

I have modelled a hand held applicator and trigger as one part using surfacing.

I have split them into two bodies and then turned them solid and shelled them.

The 2 components are then brought back together to add a pivot sort out clearances etc.

The trigger recesses into the handle when fully depressed.

Originally I had cut away the trigger clearance on the handle using a revolved cut for the trigger pivot area, and a cut using an offset entities sketch to give me a bit of clearance around the trigger.

This worked fine until I had to add some more drafts to the trigger. now I have several drafts meeting at the same point. I am happy with the shape of the trigger, but cutting a recess for it in the handle is no longer 2 straight forward cuts.

My plan to fix this was to create another trigger body using offest planes of 0.5mm. This would give me a trigger which is uniformally 0.5mm bigger and could be used to cut the recess in the handle using the combine feature.

Because of the drafts and surfaces on the trigger, the trigger has to complete a swing of approx 5 degrees for it to cut the handle correctly. I cannot create a swept extrude as I would need a 3D sketch to do this properly and I can't use a move/copy body as I would need an infinate number of copies to fill in the void corrctly.

I have attached an image of a dumbed down version of the trigger to act as an example.

If anyon can think of a more elegant solution please let me know. Although it is unlikely I can go back to surface stage to modify this.

Thanks

Michael