I am new to the use of Weldments and have not been able to solve this problem on my own. Hopefully someone has seen this message before. I have created several new custom profiles for 8020 structural members and the 1515 and 1530 profiles work perfectly. However the 1545, 3030, and 3060 profiles all return the same error message, "Unable to create this feature because it would result in zero-thickness geometry.", when I apply either of the End Butt corner treatments. The End Miter corner treatment works fine. When I dont' apply a corner treatment there is considerable overlap of the parts so I don't see how there could be zero-thickness geometry at all. Any ideas on what is causing this error message?