I design parts for custom cast brass hardware on Solidworks. After I've finished my design, our protocal is to offset each surface of the part by .025" to account for fnishing. I use the 'Offset Surface' feature then 'Thicken' to create the solid, however quite often the 'Offset Surface' feature will give me an error message: "Unable to offset the selected surface. Please try a smaller offset distance.". This tends to happen around corners.

I would like to know why this happens, but more importantly what's the best solution. Reducing the offset size sometimes works, but it's not what I need it to be. Does anyone know how I can successfully offset my parts surface my desired distance without error everytime?