Error Message - Zero Thickness Geometry
Potential Error Messages
Unable to create this feature because it would
result in zero-thickness geometry
The model could not be properly sectioned by the
section line. Please check that the section line cuts through the model.
Potential Reasons for These Error Messages
Zero-thickness geometry (also known as non-manifold geometry) exists
when edges or vertices in a solid model do not properly connect with adjacent
geometry. Every
edge of a solid body must have exactly two adjacent faces. SolidWorks
does not allow zero thickness geometry because it can lead to mathematical
problems and downstream errors in the model.
Zero-thickness Geometry Examples |

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Every edge of a solid body must have exactly two adjacent faces. |

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Edge where zero thickness geometry is located. |

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Vertices where zero thickness is located. |

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Tangent line where zero thickness is located. |

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Zero thickness occurs when you attempt to extrude a cut tangent to a
hole.
This is frequently the cause of failed section views in drawings. |
Potential Fixes
Add or remove enough solid material to the area
of the zero thickness geometry to properly connect the edges and vertices.
In the Extrude
PropertyManager, clear Merge result
in Direction. This creates a multibody
part.
Other References