I encounter some weird problem with an array modifier.
I’m trying to make a rim for a wheel but it renders an ugly thing.
This artifact exists twice on the rim at the top and bottom (like picture).
I tried with a curve modifier, with or without subsurf or smooth but nothing changes.
The model is repeated 96 times around an empty and its dimensions were refined a lot of time without success.
You want 96 objects arrayed around a circle. Therefore the empty used to create the array needs to be rotated 360/96 = 3.75 degrees. In your scene you have rotated it 3.833 degrees. You therefore have overlapping geometry given the size of your base mesh
Before you model anything further you need to fix the mesh that you are arraying so its the correct width that allows it to be arrayed 96 times and fit an exact circle and the adjacent vertices merged together
Also have the subsurf modifier below the array modifier so you subsurf and arrayed mesh and not array a subsurfed mesh
I listened carefully to your advices and have still some/same problems:
In front view
A/
1/ selected the left side (alt+RMB) and then S+X+0 (scale X 0.0).
2/ selected the right side (alt+RMB) and then S+X+0 (scale X 0.0).
It makes the object squared. All L/R points have the same X coordinate.
B/ Put the Empty rotation to 3.75° as asked.
C/
1/changed the merge distance to 0.0025 (first value where the bottom point merges) but it messes the mesh with the subsurf because;
2/ the object is not enough large at bottom. There is a little space between replications.
3/ the top is now too large as previewed (there is an overlapping in the array replication).
Options;
1/ move the object in top direction until the bottom issue is solved (reduction of the rim diameter) or enlarge the X value of the piece.
2/ reduce the top length of the object by applying a rotation on both sides.
Here is how I did it before without success:
a/ create a plane guide with 3.75° of rotation.
b/ In object mode, put back the pivot point to center of geometry.
c/ Apply a rotation on Y so a side sticks to the plane.
d/ make the same thing with other side.
e/ In object mode, put back the pivot point to 0,0,0.