I have been working on this particular part and have been running into some issues regarding the geometry of the surface and thickening the part. I have one surface that is created from a surface revolve and another which is created from a surface sweep (using the edge of the revolve surface as the path). As the swept surfaces goes around a tight turn, the geometry gets a little strange. Ideally, the part would be symetric around this curve.
Another issue, that may be fixed when fixing this odd geometry is thickening this part. The part needs to be thickened to 0.03'' but by simply using the thicken tool I get rebuild errors (thickening to a smaller dimension of 0.01'' works). I saw in some previous posts people have created additional surfaces to make a solid part and then used the shell command. I have attempted this but it still results in errors.
Attached are the part, along with some pictures of the problem areas.
Any help with this would be greatly appreciated! Thanks a lot!