Funny, I never used the connect curve tool, never knew what it was for.
I think you can't stress enough never to join curves that meet at an angle. Coming from Adobe Illustrator it's easy to have this idea that a square should be joined at the corners. It took me some time to get this thought out of my head.
All splines have a start and an end, even a circle. Sometimes it's hard to tell where the start and ends meet if you have a closed shape and even if you see it there may be an issue with several points overlaying each other. What I often do is to cut a spline into smaller bits. I may delete the area where the spline ends meet if the shape is closed and join the two parts that are the closest - this way they will connect and while the outline stays the same the point where start and end meet is effectively moved. Sorry if my explanation is difficult to understand.
Seeing your project in this and other threads you gave yourself a challenge that requires much discipline in keeping the outlines clean and understanding what will work with the tool and what will fail. Often you need to work around some issue, make a larger geometry and cut your part out of it, sometimes I go to Rhino to ajust a surface because it's easier than doing it the hard way. And sometimes, I have to admit, I change my design to something I know can make in 3d.
Claus
PS. it may help to understand how these surfaces are created, very often they consist of a larger surface that is masked by a boundry. You can see the untrimmed surface by using the "untrim" command. Sometimes it's useful to see what goes on behind the scene...
Edited by user Monday, February 22, 2016 3:40:00 PM(UTC)
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