Hello,

I am trying to pattern a lofted boss/base that has a twist value of 360° and have it follow the contours of a revolved boss/base, but can't seem to get it right. Eventually I want to take all the pattered bodies and do a Boolean subtraction from the main body. The closer the spacing between each body the better as I am trying to approximate the shape that would result from one large continuous sweep (which can't be done directly as far as I can tell). Here's a video of the machining process I am trying to reproduce, only with a different cutting insert: https://www.youtube.com/watch?v=xWR-LvynFZ4&t=114s. Both the cutting insert and the stock rotate in sync at a 1:1 ratio.

I tried using the vary sketch option on a linear pattern, but the feature patterns at an angle without advancing along the X-axis:

If I instead select it as a solid body to pattern, then the preview shows it being patterned without vary sketch having an effect, but it fails nonetheless because "a pattern with variable sketch option is not suitable for geometry pattern" even though geometry pattern no longer shows as an option:

Something else that's strange is if I change the instance count or spacing from the default, then it fails due to "self-intersecting geometry" not matter how wide the spacing. I also looks like the sketch profile (see red arrow) defining the lofted boss/base moves itself after trying this. After I exit the pattern are rebuild, the sketch goes back to where it should be:

Using a lofted cut has it's own issues:

Please see my file attached below. Any ideas?

Thanks for the help,

Jack