Hi, blimey a lot here for me to look through,
lost a day on this so other work to catchup on, but then brain will go cold on this,
must try and find time to study all this.
@theoutside
I set about solving the non maifolds by using chamfer 0.01 on the two crosses and infinity symbol ,
editing the base surface to the new edges.
Then made new bars dupedge and extrude surface, made new female slots by mirroring those and using a new block and boolean difference them from it, then cut out the base areas in the surface.
moved the male bars fwd by 0.01mm, so now no touching corners.
revisedd one sea urchin.
then Gijs fixed a badObject in the result.
and here is SR4
SR4 calibration sheet repaired Gijs basic.zip (3.6 MB)
is this what one envisages ?
It was my approach.
Learnt a few lessons.
Steve