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tuning guide To me this actually looks plausible. In navigation the inflation value needs to be half the base_size plus margin. Collision is usualy calculated from the "center" of base_link (base_frame), not its boarders (green rectangle in picture). As I think I can see in the picture (resolution) the base_link center is actually outside the inflation layer thus this outcome is possible. It seems to use a very high path_distance_bias though. Have a look at the linked tuning guide, this should help getting better results.