Based on the stock setup from MV we are using the Blum 120 hinges for our default hinge.  Under normal circumstances of ¾ Melamine and 13/16 Laminate finished end panels this works. 

      3/4 Melamine – 1/16 reveal  – 17.46 Overlay

We currently have a project running ¾ Plywood core for the cabinet parts.  This means the both finished and unfinished ends are 13/16 nominally. 

       13/16 Melamine – 1/16 reveal  – 19.05 Overlay  (This doesn’t work)

Looking at the look-up tables I understand how and why it is drawing and machining the hinges with their offsets the way they are in the drawing I have.  But the hinge specs show that its not the case. 

Would it be possible for the formulas and look-up tables have a built-in min/max range for the hinges and their overlays so that the system could then either show the 3D error hardware drawings or generate the info that a new hinge needs to be selected?  How does everyone else handle this.  Looking at the cabinets and the drawings in 3D I didn’t see any issues until we were trying to hang the doors.