I have a user that wants to have a variable section sweep that creates a “cup” geometry to mimic what is seen on LEDs. However in Creo I can’t get the section to be perpendicular to the axis and trajectory. See below. I want a cup like what is shown in the blue lines, but all I can seem to get is interference in the corners as shown with the red lines. He can do a rotated cup, but that wont include the corners of the square in the “cup”. Any ideas for us?
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You know, i always say its simple and it rarely is 
Indeed, there are a few tricks you must be aware of when using sweep.
In this case, the Sweep acts normal to the trajectory. In order to make the sweep revolve around the axis, you need a circular trajectory (Origin). The periphery is a "guide chain" (Chain 1; rule bases tangent). Further more, the endpoint of Chain 1 needs to be in line with the endpoint of the trajectory circle (Origin). If you divide the midpoint of the line in the Extrude sketch, you will have an endpoint there to align with the circle. Orienting the sketch for the circle will also let the circle align properly (without adding an additional Divide).
For the sweep sketch, note that you don't even have to touch the selected Origin. Inn the example attached, the arc is attached to the edge and to the axis reference.
So what happens now is that the circle defines the normal direction, but the section sketch follows its references.
Hope all that makes sense.
The attached file is Creo 2.0 full version.
