How to fix irregular cross section and shape-stretching while curving a mesh? I am trying to create a finger ring made of connected hexagons. The steps I followed were:
1. Create a mesh of 7 connected hexagons lying side to side
2. Bend that mesh using simple deform around a central point
3. Convert that mesh into a curve
4. Use another bezier circle curve as the bevel object to create a cross section for the hexagon curve
5. Convert the hexagon curve into a mesh again

There are 2 issues I am facing here:
1. My hitherto, regular, equal length-sided hexagons have now got stretched after the simple deform modifier, so 4 sides are much longer than the 2 sides
2. The cross section of the mesh is not uniformly circular (and looks a bit twisted)
3. The mesh at the junctions is protruding

Is there a relatively easy way to fix this or should I consider a completely different approach? If the latter, would be great if you can explain the new approach. I have lost a fair amount of hair in trying to figure this out so would greatly appreciate your help.

Thanks in advance!

Ayan
You could do it this way:


Create a torus with 6 Major Segments. Rotate it 90° on the X axis and 30° on the Y axis. Apply the rotation with ctrlA.
Duplicate it and keep a half somewhere.
Cut the 2 extremities with the knife (K to activate, Z to cut through, C to cut perpendicularly), separate in the middle with V, move one half and create an X.
Give your shape an Array modifier with a Count of 7, activate the Merge and First Last options.
Give it a Simple Deform modifier / Bend mode, with the angle you want, for example 280° if your final shape is not closed.
As you will want to smooth it with a Subdivision Surface modifier, add some edge loops to your mesh to sharp the edges.
Give it a Subdivision Surface modifier, smooth it.
Keep a copy of your object somewhere. Apply the Array and Simple Deform modifiers on the original.
Bring back the half torus you've created at the beginning and stick it to each extremity of the shape with the help of the Snap option / Vertex mode and Automatically Merge Vertices option.
Go in Edit mode, select all and W > Remove Doubles.