Hi dodeqaa,
re:
> Could you explain the step involving the SAT in detail please?
That's the part that's pretty tricky - a side effect of exporting a joined curve out to SAT format is that in the SAT file it will be curve made up of just one segment, multiple segments will be fused together. When you then import it back in, it will get broken into separate segments at any tangent discontinuities but areas that are tangent will remain as a long segment.
When you do an extrude you'll get a separate face for each segment in the input curve, so to eliminate edges between faces you want to get this curve to be composed of just one segment instead of multiple segments which is what you get currently with the Join command.
> Next I would need to trim it with (b) ?
Yes, I trimmed it with the naked edges of the main object.
> If the points of the curve profile (y) are out of alignment in (b), wouldn’t that make union with the trimmed surface impossible?
If it's a small enough change then it can still get joined. If it's too large of a shift then yes some other reconstruction steps would be needed.
- Michael
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