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Re: holes using extrude cut
Please think what would happen when you drill in an actual piece. There would be no material where the two holes would touch other.
SW is trying to create the same scenario and hence you get the error. So best option is too either overlap them (like Chris suggested) or move the hole slightly away from other hole.
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Re: holes using extrude cut
They need to either overlap slightly over have a slight gap. If two cylinders on different axes touch at a single point the software cannot complete the operation. At the point of contact it has 2 surfaces touching with no solid in between - hence the zero thickness error.
Can you live with an overlap of 0.0000001" or something similarly small? it becomes a rounding error in most situations that won't show up in your dimensions.
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