I can put a block of material in a milling machine and cut a hole with a slot drill which is positioned exactly the cutter radius in fom an edge. This results in zero thickness where the cutter meets at a tangent with the outside edge of the block. OK, I know that what you get at the edge is ill-defined and can look a mess but the point is that the hole is the correct size and in the correct position.

I know that most peoples first response is "why would you want to do that" - but that is not the point. From reading some of the posts in this forum, this failing of SolidWorks causes many problems in all sorts of circumstances. There is also the issue of "how does SolidWorks display zero thickness". Well, I would much rather have a peculiar display abberation than nothing.

BTW, if anybody thinks it can't be done, Inventor does it quite successfully.

Sorry if this seems a bit of a rant but it comes as a result of a series of error messages for no apparent good reasons - even the '!' OK box. It seems to me that SolidWorks is not blessed with a "can do" attitude.