Hello all,

I'm trying to model a bent aluminium tube of 2cm diameter. Because of the complexity, I'm using 3d Sketch Spline to define center line, and that line is defined by 4 2cm circles along that line. I made some complex sketching to make these circles perpendicular to the spline, and it seems to be ok.

Problem is, that when I try to make the actual tube with Sweep feature, using that spline as centerline, and one of these circles - as a profile, the resulting tube is a bit off. I can see it because it doesn't align with the other circles, meaning that Sweep isn't following that spline as EXACT centerline, but deviates a bit.

I need accuracy here, so how do I make Sweep follow that spline as path with no deviations?

Attaching the part. It is of large assembly, so there will be some external references, don't mind them. Some sketches are on top of each other, because Sweep needs clean sketches.

In the part:

Circle that defines sweep profile is in 3DSketch7, centerline - 3DSketch6, and the circles that are exactly 2cm and exactly perpendicular to the centerline, are in Sketch3. According to common sense, since they are perpendicular and 2cm, they should match the tube.

Just as you open up the part, it is zoomed in so that this mis-match is obvious.

How do I fix that?

P.S. Tried to use Loft instead of Sweep. Same result.