creating something to set a complex part in help

My question is, is there any way to auto create a holder to fit around an already designed part. mold tools are out of the question because the parting line would be 200 different lines and it would jump around in depth because this part is very complex containg hundreds of surfaces. i have tried to linear pattern the part up about .01 distance and pattern it 100 times so i could simply use the combine feature to place the 100 parts in a piece of foam and just subtract the parts creating exacty what i want, if the computer doesnt explode in this process it will tell be i cant do so because it would create invalid geometry. cant use swept cut because that only applies to revolved boss's. going around the edge and selecting over a hundred lines in a 3d sketch and converting entities to extrude upward will also not work. so to give you a better idea of what i want, lets say maybe there is a feature i can use to just draw my rectangle foam around my part and extrude it. but this feature would stop certain parts of this boss when it hits all the surfaces on the part and the untouched part of my foam boss would get extruded past the part. creating a holder to place this part in. or even more simple imagine shining a flashlight past an object, light that hits the object stops while the light around the object continues to shine past it. the light would be my foam boss. does anyone know of such a thing? maybe theres not but any suggestions would be helpfull because i have been stuck on this for weeks. thanks.

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2 Answers

wow. long question. do you use Combine function?

 
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Try to sketch a problem to see what we can expect?

 
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