Hello. I'm trying to create a lofted boss with solid geometry (not surfaces), but I cannot get past the zero thickness error. By all appearances it seems to be the most straightforwad loft I've ever tried to create, but the appearances are deceiving.

What I've tried:

• I've used combinations of two, one, or no guide curves.

• "Normal to Profile" Start and/or End constraints.

• Swept Boss instead of Lofted Boss with similiar results.

• Moving connectors around.

I had started with the full length of the gap including the flat area at the top, but then narrowed it down to just the radius to try to troubleshoot it better. I realize if I uncheck the [x] Merge result box I can get the error to go away, but I do not want multiple bodies.

Unfortunately I cannot upload the part. Using SolidWorks Premium 2013 x64 Edition.

Any ideas or methods that work for you to troubleshoot Zero Thickness errors?