I'm still on 2010 so I can't open up your part. Have you tried offseting individual faces, then sets of faces to see if you can isolate the problem? Have you checked the radius of curvature? You might also try switching Lofts to Boundary Surfaces, as they tend to cause less problems. (Although there are the rare occasions when a Loft will work better than a Boundary.)
It's not liking the fact that the loft you're pointing at is recessed 1.3mm. When I suppress Surface-Extend 64 it shells fine but then there's no recess. Before suppressing this feature the minimum radius of curvature is 0.04mm and after suppressing it's 0.4mm. Below is a band aid way to get something close to what you want. This is probably not the right way to do it but you may have to pull similar tricks to get the geometry you want.
- Shell without the recess
- Create plane and sketch above the part and convert entities of the edges of what will be the recess
- Knit surface to offset from
- Extrude, offset from surface
- Cutt extrude, offset from surface
Hi Joel it looks to me that solidworks is having a tough time with the inside lip. SW does not know what to do with the surface in dark blue. What I am trying to show is I took a section on the front plane then started to offset surfaces to the inside of the part by 2mm (shown as 3 light blue lines). The dark blue surface gets eliminated. I think that is where the error is coming from.
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