I'm trying to subtract one part from one another (a thread template from a bolt). If you look at the screenshots, I have a thread template of about [80 mm] in length and a bolt about [6 in] in length. The feature works perfectly when I want to create a partially threaded bolt. However, something gets a little screwy when I try to subtract the thread template and there is leftover bolt on the bottom (see screenshots for clarification).

The first response, naturally, should be "create a longer thread template." And I've done that, but I cannot create a thread template longer than [80 mm] because, guess what, the same thing happens. Namely, the thread becomes transparent (see screenshot). So what I tried to do as a workaround was to create multiple short thread templates and place them one over the other. But that's proving to cause the same essential problem with the apparent transparency.

The thread template was created using a sweep feature of a variable diameter helix spiral.

I know the computer specs are nearly perfect so that can't be it. And I've played around with the performance/image quality as well.

If this is an inherent flaw in using the sweep helix function, maybe there's another way to go about this to create the same effect? Essentially, my thread template uses a design table to create thread templates for many different size Metric and Imperial threads along with appropriate pitch options. I prefer to have one file for Standard Hex Cap Bolt, with different configurations for different sizes. No, I do not want to use SolidWorks' built in toolbox feature for a number of reasons.

Any help is appreciated. Thanks.