The real question regarding this situation is at what level SHOULD these
cooling channel cuts exist - at the part level or at the assembly level?
Unless these cooling channels are actually manufactured AFTER the two halves
of the mold have been assembled together, then they should be modeled at the
part level. Of course this does not solve your problem as to how to transfer
this geometry down to the part level.
So are you saying that in the BLOCK 1 part that contains the assembly level
cooling channels, that there are additional features at the part level of
BLOCK 1 that are referencing the assembly cuts? If this is true, then you
have a real mess. If this is the case, it may be feasible to go into the
INSERT MODE in the BLOCK 1 part prior to the features which reference the
assembly cuts, recreate the cooling channels at the part level, and then
resume the features which reference the assembly cuts and reroute them to
the newly created cooling channels at the part level. I hope this helps.
If you want to send me the models (including the assembly where the cuts
were first created) I could take a look at it to give you a better idea of
Scott W. Schultz
3D Relief Inc.
3700 Willow Creek Drive
Raliegh, NC 27604