Complex Solid Union Problem

[jason907238]

Please help Augi gods!!!!

I have managed to get as far as I could. I am down to 2 solids that I need to union. Once I union them, I will then need to mirror the object and union the mirrored object to the original. I am trying to create a custom corbel (bracket). Once I have created this as one object, I then will have to export it as a lithography (.stl) file to get this to another program for machining. This is not the problem but it is the reason why I have to have it as one object. The problem is getting the object as one complete object. I have been union and subtract to create these solids which are very complex. I have tied saving as older versions; saving as dxf files, saving as older version dxf files; moving the object closer together; scaling them up and down; and selecting them in different orders. No matter what I do, I can’t get these last two objects to union together.
On a side note, if I draw a simple box, I can union it to the bigger object if I select the simple box first.

TIA
Jason

[jaberwok]

No success but the problem appears to be with the smaller part. Trying to Move or Extrude the mating face gives a message "This function is not tolerant modeling compatible."
"tolerant modeling" returns nothing in Help.
I can subtract either part from a larger solid "brick" but not both.

[jason907238]

Might this be something that one of the Inventor guys might be able to import and fix?

I did copy the smaller part from another file which I scaled down and modified the steam. When I get to the office, I will try to copy the larger object to that file, maybe it will help. I am also going to try to scale both objects larger and smaller.... see what happens.

Thanks.

[jason907238]

I have had no luck so far. I would hate to remake this but if I do, is there something that I may have did wrong in creating these objects?

The smaller one was made mainly by lofting and using union. Since I had so much trouble with the smaller one, I created the larger object from extruding the outline and then subtracting most of the details. Because of the different angles, i had to Union it to gether by only 3 pcs.

[jaberwok]

If you look at the flat, mating surface of the smaller part, you see internal edges that almost form a segment of a ring. I get the feeling that that area could be the cause of the problem. I could be wrong though. :-(

[jason907238]

Is there another way to export more than one object out to a stl file... as one object

[jaberwok]

I've exported to a SAT file and imported it in Onespace Designer. Trying to merge the two parts gives three errors - "Error: Edge doesn't lie on face but it should" - with arrows to the backs of the three areas I suggested earlier.

Edit: further checks in Onespace gives "This part is corrupt."

Sorry.