Hi Brandroid, currently the way Blend works is that it makes the cross-section shapes of the blend to be coming off perpendicular to the edges. In areas that are more tightly curved that can lead to this kind of bunching, basically the sections are running into each other like this:




Notice in Burr's example above that he's made a cut shape that does not have quite as tight of a bend in it, that then helps to avoid this kind of bunching.

In the future I also want to add in a different mode for blending that will make more of a straight-line connection between the edges rather than having things be perpendicular to the edges, that should also help for these kinds of things.

- Michael