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Use the seed surface and boundary tool to copy/paste all of the surfaces. You can then pattern the resulting copied surface feature without any merge. Create a solidify cut and reference pattern that cut. (Can be accomplished with protrusions also) In Creo Elements/Pro 5.0 and Creo 1.0 this is now all inclusive in the Geometry Pattern command.
Doug,
With this method, do you select the solid part surfacesbefore the first cut is placed or after? If after, is the cut hole's surfaces the only surfaces selected?
Does this method work well on flowing surfaces as well?
I haven't done those type of pattern cuts that way. A couple months back I had to create some expandedmetal guards and through a lot of trials I found the best and quickest (for file size and regenerations) was to create a single line consisting of a number of the diamond shaped cuts per row in one feature and then do a second cut forthe next line and so on for a few rows then group those and pattern the group.