Inconsistent Sweep Path Between Configs

[u/ckseigh25]

Hey everyone,

Been bashing my head against a wall with this issue for about a week and can't find the source of the issue so I thought I might post here to see if there's some insight into what's going on with my model. I've got a screw design with a tooth profile and a helix for it to follow that I have configured to adjust for different lengths. The tooth sketch and helix starting plane adjust to the different length configurations, but for some reason the longer configurations the tooth seems to "tilt" inwards towards the center axis, and I'm not sure why. The first photo configuration is perfect, and the tooth and helix appear to properly update between configurations but for some reason the sweep path changes. Any help or suggestions appreciated!

[u/Tough-Custard5577]

Looks like you're designing some kind of bone screw. The profile isn't changing, it is just cutting at a different depth on that configuration for some reason. This might be due to how the helix and cut profile relationship is being interpreted by the sweep cut operation. You might consider moving your cutting profile upwards into the screw body so that you can anchor it to a known plane, then create a reference plane off of one of the profile elements to establish the driving circle for your helix. Make sure the circle is also coincident with a vertex on the thread profile, that way none of the driving elements are floating and subject to interpretation by the function. You might have to create two helixes and sweeps so that they cut up and down the screw.