Originally I designed a vacuum mold tray comprising of three parts (see Pic1). The main tray with two end pieces. After prototyping it was decided to make one complete tray with the ends connected to the main tray. I managed to model up the complete one piece tray, but can't achieve the same dimensions as before. This I know is down to the 'Swept Cut' feature (see Pic2). The profile used is fine along the 'long side' of the rectangular shape but doesn't work along the short side as a different profile is required (see Pic3). The distance of 185mm should be 150mm. I played around with guide curves and options without any success. I just need some direction how to sweep cut with different profile shapes?

Cheers,

Ray