A user has created a cylindrical contour flange and then created a Normal Cutout onto the part. If they use the 'Thickness cut' option it results in 'notches' or 'steps' in the corners of the feature. Why?
The 'Thickness cut' option cuts each set of layer faces with the tool body, thickens them individually and then combines the two individually thickened tools. When the two sets of layer faces are not perpendicular to the profile extrusion direction, the result is "steps" or "notches" at the corners. This is a known limitation of the 'Thickness cut' option.
This is the reason why the 'Nearest face' and 'Mid-plane' options were introduced. It is recommended to use either of these other two options as a workaround to avoid this situation when this condition exists.
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