"Reasonably sized cylindrical mesh", V3

grabcad

To achieve a cylindrical mesh with an optimal file size for objects featuring this design, such as flex connectors, the approach involves creating a series of surfaces rather than solids. The process entails initially constructing a 3D equation sketch and saving it as a part. This part is then imported into an assembly, rotated to create a strip with two lines encircling a circle, and saved as such. Next, this assembly is derived into another part, completing the sketch to form a boundary loop for surface creation. Finally, the resulting part is incorporated into a new assembly, allowing for recursive design and easy tweaks to the original 3D sketch that propagate throughout the final assembly. This method enables a true weave without any interference between faces. However, further edits may be required to perfect the model parameters and achieve the desired results. The problem primarily lies in the geometry of the 3D curve, placement, amplitude, number of repetitions, and arc length between copied sketches. Despite ongoing tweaking and experimentation, progress is being made towards a satisfactory outcome.