When I apply it to my curved surface, part of the pattern works fine, but a portion of the interlocking part breaks, resulting in stray lines everywhere.
This unit pattern has overlapping parts, which is predictable when distributed over a flat grid. Let me spend more time to see if you can reconfigure the pattern to have more control over the overlap, and distribute more predictably. I’ll get back to you soon.
I redid your example with new module that is more modular (and has no thickness for simplicity), but you should get the idea of a workflow that might work for you. Custom kerf_RI.3dm (449.1 KB)