Hi Jack, here's a fixed version of the booleaned pan object, I separated out the bad surface, selected its edges and hit delete to untrim them, then used Edit > Join to glue it back together.

- Michael

thx Michael, but that misalignment face was created by Blend method.

Hi Jack, I've tried to recreate the misaligned blend but it doesn't seem to be happening here. Do you possibly have a version saved off just before you did the blend so I could test that step?

When you make a closed blend in the blend options stage of the command there will be 2 points in the viewport that you can drag to adjust the seam location. if it's off you can fix it there but if it's making it off by just that slight amount in the starting default seam location that could be something I could probably tune up if I could repeat it happening.

- Michael

Hi, Michael , I attached a step file before blend, you can try it, I just tried, it will be missalignment.

Thanks Jack, I can repeat it now. I'll investigate it to see if I can improve Blend for v5 to avoid it.

- Michael

Hi Jack, I've got a fix for this so this case should be improved in the first v5 beta.

Thanks, - Michael

Thx, Michael.