@thomthom said:
I used the same method of a recent product design project. Lots of rounded edges. (and mine included an DVI plug, as oppose to your USB
)
Though I for some reason found myself making the x100 version and then make an instance that was x0.001 smaller. I did that because it seemed that I still had problems creating the small faces, even though the instance was scaled up x100, which is why I scaled the definition instead. But maybe it was another problem...
Leave the original on desired dimension and scale just the working-with instance. Use 10x 100x 1000x. The point is to have lines big enough to can create faces. If you round an edge with r=1mm and use 6 segments for 1/4circle arc, you will have each segment smaller than 0,3mm ! In this case 10x is ok. But are lots of situations when durring intersection you can't get faces because the distance between two lines is too small. In this case you will need 100x-1000x scalling.
I used up to 1.000.000x scalling Don't be shy to scale... it's free!