Im having an issues with region difference as well as offsetting curves

Hello, I’m kind of new to grasshopper and I’m trying to create a waffle structure for laser cutting.

Example:

I’m at the stage were I’m trying to solve the intersection between two breps in order to draw the teeth that allows everything to slot together but region difference and brep | brep aren’t working plus offset is creating random lines that it shouldn’t and I have no clue why.

I’m not too sure what part of the file you would need so I’ve attached it all below.

Any help would be greatly appreciated, thanks.
Task 2.2.gh (32.6 KB)

Normally, this is done using RegionSlits component on the 2d profiles of each slice or I like the Bowerbird plugin.

If you try and do it using the solids then it will be hard to add clearances to help assemble the final piece.

Bowerbird lets you add a clearance (r) on the depth of the slits if you are cutting them with a radius (r) router bit, for example.

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I agree with martyn here, Bowerbird is going to be the easiest way to go about this solution.

Please keep in mind as martyn mentioned, you need to do some testing of the proper “slot width” for your given material thickness. You will need a to make the slots slightly wider than the material thickness. This is known as “tolerance” and without proper tolerance you either 1) wont be able to join the two members together because the slot is too narrow, causing too much friction to be able to join without members breaking or 2) members will not stay joined because the slots are too wide, not creating enough friction for the “friction joint”. This likely requires some basic prototyping based on your material.

There are a number of threads here regarding waffle grids. Coding them in native grasshopper can be a headache for a number of reasons, including what martyn has mentioned.

Here is an example for study, keeping in mind this has additional functionality to be able to adjust the intersection points of slots.

Adjustable Waffle Intersection.gh (25.4 KB)

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