Hi simba, re:

> so working with surface points doesn't work as this would change the shape of the original part.

The amount of disturbance of the original part can be reduced if you insert additional points into the surface, see the attached 3DM file for an example.





The surface retains the same overall shape, it's only changed in shape in the localized area around the moved control points.

That's probably the easiest way to get the seamless and smooth type qualities that you were asking about originally.

If you want to build something as a separate part you're probably looking at cutting away some holes in between the pieces and doing Blend, but your case here with the very tightly bent shape right in the area you want to blend from will probably make that rather difficult.

- Michael