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How to shell when floating body is possible

Question asked by Chris Pratt on Aug 4, 2017
Latest reply on Aug 7, 2017 by Chris Pratt

I want to Shell the 10mm diameter part in Figure 1 shown below (attached file "Initial Part.SLDPRT"). But if I try to Shell, to any thickness (between .1mm and 2mm for example), the highlighted face I get the error "The shell operation failed to complete. One of the faces may offset into an adjacent face, a small face may need to be eliminated, or one of the faces may ..."

Initial Part.png

     Figure 1


My desired result for this shell is show in Figure 2 for a thin shell where 2 separate bodies are created (attached file "Thin Shell.SLDPRT"), and Figure 3 for a thick shell (attached file "Thick Shell.SLDPRT").

Thin Shell.png    Thick Shell.png

     Figure 2                                                                                               Figure 3


I believe the root cause of the Shell's error is the potential to create 2 separate bodies, such as in Figure 2, even when the Shell's thickness wont separate the bodies, such as in Figure 3. Does anyone have a solution for this? This problem originated on a much more complex part where its not feasible to use anything other than the Shell command.


I am running: SolidWorks 2017, Windows 10, on a laptop, 8GB ram, HD Graphics 530 Graphics card, Intel Core i7-6700HQ CPU, with a know SolidWorks - graphics card incompatibility.