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Free form construction - why perfect 3D curve turned to bad form?


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Hey Guys,

Does anyone have this similar construction issue?
I have my 3D curve scanned and the min/max are around 0.001" there. 2662_27ff4e3b67bc201e5566108da2714286.png
Then I construct a new free form by using this 3D curve 2662_d3c2ea442ec20982e218f6bb96ff336a.png
2662_a01f86ac818896e8416d53d6d0ccb4a6.png
2662_231382741c7c82e99be3ffbd21e870fd.png
There has a very large discrepancy between the constructed free form and original 3D curve. Constructed form has 0.0404" and curve has 0.0007" on the min value. It did not make difference when Re-calculated box checked.

There must be something about free form construction rules I don't know, like using 3D curve to construct, using plane feature to construct.... anyone could give me suggestion please?

All my measurement and construction based on Base alignment.

1.jpg

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And it is not always turned to be bad, something it get even better..like this one my original 3D curve 2662_3409f8e63ea89b2b0a968832e2764e32.png
After recall feature points, it turned more better. Why? 2662_6aa822bb09160ed87b8adbc744079f06.png
What is the concept behind it?
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You also need to associate the Free-Form with the surfaces. You do this by being inside of the Free-Form main window, and select the CAD surfaces that it is applied to.
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Yes I saw it. Shall I choose it first?
What I did is in the free form window, 1st choose recall feature points, then select the 3D curve, and then ok. Got free form with 0.040" deviation there.
3D curve itself has 0.0019" deviation.

When should I check " surface used " selection? what is the step? 🫣 2662_f8698b1b29b0c6a315d11acdc3fb27e4.png
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And I did another try, this time instead of checking "surface used" button at the end, I hit it first and then choose recall feature points, then in the pop out window choose target 3D curve and ok. Still got same huge deviation. Is there anything I missed during the construction?
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