The part boundaries need to be pretty exact, and your video explained precisely how to do this so thanks for taking the time to record that. Perhaps I should have explained that my whole reason for getting into IronCAD was for 3D printing as the interface seems so much easier to get to grips with from other CAD / modelling software I've experimented with. Thanks Spencer - Actually that does answer the question and your insight into weld joints is really interesting. Very vague and back and forth answer, but just my 2 cents worth. Just depends what you are doing with it really. The easiest would be to modify the cross-section of the block you have on the right side that is bridging the two halves. Now, that being said, you can either break it back to flush right before the right side seen above in your snip or you can add material and slice it off with a hole block to make it pretty and clean looking. I think most people approach these in different ways depending on the type of manufacturing they are used to and the limitations they have to live with. being used will have a square face and it is often not worth paying for special machining of the part to fit flush like you are saying. In a lot of circumstances you would fill the gap with weld so the way you have it would be fine because the stock, sheet, etc. In my personal opinion, this is more or a manufacturing limitation question.
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