Can't Thicken Outsole Of Shoe

[mrabushka]

I'm trying to create the outsole of a shoe.  I created a 0mm offset of the entire shoe (Body 96) then created an offset of the very bottom of the shoe up 10mm (Body 97) and used Body 97 to cut Body 96 to remove the upper part of the shoe; thus leaving a shell to thicken to create the outsole.

When I try to thicken the shell 0.87mm I get an error:

Does anyone know why I'm getting this error and how to fix it?  The f3d is attached.

[TrippyLighting]

I would start my investigation with the T-Spline. In the heal area, for example you removed edges, which makes that area easier to edit, but you left unnecessary N-Gons:

[mrabushka]

Thanks @TrippyLighting !  I resolved most of the N-gons as shown below, but I'm wondering what's the best way to resolve the last one circled in red below?

Should I just add a subdivision as shown circled in blue below or is there a better strategy?

[TrippyLighting]

Nope! Now you still have N-Gons and triangles. I'll create a screencast later ...

[TrippyLighting · Accepted solution]

Here is a screencast explaining two possible approaches. 

[mrabushka]

@TrippyLighting thank you, the screencast is awesome!  I think I followed your instructions and recommendations.  Please advise why I cannot offset the bottom of the shoe:

[TrippyLighting]

I downloaded your model and don't see any problems offsetting the bottom of the shoe, either from the surface model, or from the thickened solid.

[mrabushka]

@TrippyLighting thank you!  I restarted Fusion 360 and now offset is working properly from the surface.  I'm not sure what the hang up was yesterday.  Thank you very much for explaining how to better model my shoe with t-splines.  Your information is a game changer.

[mrabushka]

@TrippyLighting your screencast is golden.  I used it again to fix another shoe.