Fusion Problems

[gsandy]

I have two components (wheel pant and strut) in a model (both look normal before fusion) that have been fused. After the fusion process the model looks black. Trying to change the color does not work.
On closer inspection of the wheel pant there seem to be "flaws" see arrows. This may be the problem?
A meshed fused model has been sent to a 3D printer and prints, but it is difficult to work on the black model.
I would attach the file but its 15Mb (14Mb zipped).
Any help would be appreciated.

OS: Windows 7
Word size of OS: 64-bit
Word size of FreeCAD: 64-bit
Version: 0.18.15944 (Git)
Build type: Release
Branch: master
Hash: 9d87d13dd2d356200db03a79c4cbacc89353c1b7
Python version: 2.7.14
Qt version: 4.8.7
Coin version: 4.0.0a
OCC version: 7.2.0
Locale: English/NewZealand (en_NZ)

[chrisb]

This frequently happens if you have tangent faces in boolean operations. If possible try modelling with some overlap. There is a chacker that can help finding those issues: BOP Check.

[gsandy]

Thanks Chris, used the BOP Checker and found the problem, see attached. Its the "Wheel Pant" to "Wheel Cover lip recess" fusion. Unsure how to rectify it!

[chrisb]

Can you upload the file to a publicly available fileserver, preferably one without registration, e.g. dropbox?

[gsandy]

Its here (hopefully).

https://www.dropbox.com/s/dxszypvpaz8df ... r.rtf?dl=0

[chrisb]

You seem to have published the dropbox howto and not the FreeCAD file.

I wont be able to look at it before the next 15 hours or so, but others may jump in.

[gsandy]

https://www.dropbox.com/s/9w4i66n38xee1 ... FCStd?dl=0

[gsandy]

The latest version:
https://www.dropbox.com/s/7caa2wozczyvz ... FCStd?dl=0

[openBrain]

On closer inspection of the wheel pant there seem to be "flaws" see arrows. This may be the problem?

This very probably is the problem. If you BOP check the lone Wheel Pant part, it is an invalid solid.
The issue originated in the Offset feature labeled "Spat 2mm". You have to change the parameters of it (or even find another way to get this part step) so it remains a valid solid.
Unfortunately I'm not skilled enough with these tools to give further advices.

[chrisb]

You seem to have used at least one additional workbench - which one is it? I would be glad if someone else could look at this, The MacOS version is currently not very stable and I would like to refrain from adding workbenches until this is fixed.