As shown below, I am trying to offset two semi-complex surfaces exactly 0.1 inches outward to create a protrusion from the mold:
However, using surface offsets seems to give me an offset that isn't exactly 0.1 inches from the surface, and using ruled surfaces and then a "fill surface" does not create a surface tangent to the original surfaces. Does anyone have any ideas on things I could do? The part file is attached.
Justin,,, I had some success with this by exporting your model to an iges then importing. Then offset those faces 0.. Then thicken to .1" It's not quite perfect but is close to what I believe you want. You can see by the screenshot their is still an issue but looks like something you might be able to work with. Don't know why this is so difficult to eal with but I sure did get better results than I was getting before exporting it. I tried quite a few things as it looks like you did also.