@PolyDoge Looks like there should be more than enough geometry in the existing model to get a passable result. The key is to use the existing geometry as support by offsetting the edges in the intersecting shapes so there's room for the subdivision smoothing to average things out. It's also important to preserve the…
@Udjani You're on the right track. Sacboi is right about working through some additional block-outs to analyze the shape. There's a few distinct features that appear to be in conflict: the oblong boss appears to have a fixed width, the pattern draft appears to be relatively uniform and the complex profile appears to have…
@Daf57 The base geometry that's controlling the subdivision isn't dense enough to support the perforations. For that to work the mesh would have to be subdivided to an appropriate level before the perforations are added. There are several alternatives that will look better, work better and require less effort. If the model…