Error Message - Zero Thickness Geometry
Potential Error Messages
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Unable to create this feature because it would result in zero-thickness geometry
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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.
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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.
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Potential Fixes
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Add or remove enough solid material to the area of the zero thickness geometry to properly connect the edges and vertices.
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In the Extrude PropertyManager, clear Merge result in Direction. This creates a multibody part.
Other References