Hello,

In my - now famous on the forum - model, I am trying to combine two solid bodies, but I get the "Unable to create feature because ... zero thickness geometry". From another post, I understand that this is due to merging two solid bodies that have surfaces lying against each other. I think the problem does come from the surfaces where the bodies should join, and this is probably induced by the way I built the second body. I believed I was using the right worklow for surface modeling but apparently not.. :

1. cut back part of the main body to have some room to work with and make a nice transition with the "front-support"

2. make 3D sketches to shape the new solid

3. use filled surfaces to form the new solid

Note: I tried using boundary surfaces, but didn't succeed.. it always selects an entire sketch and won't let me pick just a single edge, even if I used the "plit entities" tool. So I always end up having billions of sketches where 99% of them contain converted entities from other sketches...

4. knit them together with "try to form solid body" checked

5. combine the main solid body with the newly created one

The error happen on step 5. When zooming in, I can definitely see that both bodies don't match perfectly (see "here-is-the-problem.jpg"), though they were created with the exact same lines ! I think this is a tolerance problem as discussed in another thread I created a few days back.

As I read on the thread mentioned above, I could directly merge the surfaces with the main body and form a solid body all at once, without the need of step 5. Is that really possible ?

Thanks for your help !

All the best,

J.