Welding PowerCopies – Fillet & Butt Joints (with gap / chamfer cases)

Hi everyone,

I’m working on PowerCopies / User Features in 3DEXPERIENCE to model different welding situations:

  •  Fillet welds
  •  Butt welds
  •  Planar, cylindrical or complex surfaces
  •  Assemblies with or without mounting gap
  •  With or without weld prep (chamfer / bevel / sharp edge)

Progress so far

Fillet weld version: ✅
Working well. I handle gaps using a Boundary → Near → Extrapolate approach.
I can share a quick 3DXML sample.

Butt weld version: ❌
I’m struggling with cases where weld prep (chamfer or not) changes the intersection logic.

Have you already tackled this in PowerCopies or User Features?

How do you handle:

  • Gaps between parts,
  • Non-planar / non-coplanar surfaces,
  • Presence or absence of chamfer / bevel?

Happy to share what I’ve done and learn from your ideas.

Thanks in advance! 🙌