Lofted Wall Missing Pieces After Using Extrude To Cut Out Interior

[labrokish]

Hi- Really hoping someone can help me because I am at a loss.  I am completely new to Fusion 360, so this absolutely may be user error.  I am trying to create a cookie cutter (I've created about 10 of them using this current process with minimal issues).  I create a sketch, offset it twice for my walls, extrude said walls to the. height I want, then I create a plane above that at the height that I want my cutter blade to be.  I project my sketch onto that plane and offset that sketch by the width I want my cutter blade to be.  I then extrude the inner body to fill the space, and from there I use the loft function to connect the surface of the cutter to the offset space of my projected image on the plan above to create a tapered edge. To finish, I use the extrude function to cut out the middle to create the cutter shape.  For this particular shape, for whatever reason, when I use the extrude function to cut the middle out, it's taking part of the lofted wall with it, but only in one particular spot.  I have tried changing my original sketch, I've tried starting over, but each time, I end up with a jagged edge right in that same spot.  I'm not sure what I'm doing wrong? I've included images of the my original sketch, the loft, and then the cutter after using the extrude function to cut out the middle.  The other cutters I have created this way have all been complex shapes with rounded edges similar to this one, but this is the only shape in which I'm running into this issue, and only on the one side, which I find strange. Thanks in advance for any help!

[jhackney1972]

Please attach the problematic model.  Open the mode in Fusion, select the File menu then  Export and save to your hard drive.  Attach to a reply post.

[labrokish]

Attached!

[jhackney1972]

You attached a STL file, please attach the native Fusion F3D file.  If you follow the instructions I gave you this will be the type.

[labrokish]

Apologies.

[TheCADWhisperer]

@labrokish 

If this were my design, I would use Tangent Arcs and Lines rather than Splines to greatly simplify the geometry.

[jhackney1972]

I believe you can get the results you desire using Surfaces.  My model is attached.  If you cannot follow the timeline, let me know and I will explain further.

[labrokish]

Thank you so much for this- I think I have it figured out, except for the "boundary fill" step.  I can figure out which aspects of the model to select to be able to use the feature.  I can see from your model that you have 3 tools selected, but I can't find a combination of 3 that allow me to click "okay." Thank you for your time and help!

[jhackney1972 · Accepted solution]

I created a video of my process.  I made it a little easier by using an Offset Plane as the third side for the Boundary Fill command.  I have re-attached my corrected model so you can follow along with the video.  

If this answers your question, please select the "Accept Solution" on my post. If you need further help, please ask.

[labrokish]

That worked, thank you so much! I really appreciate it!