Shell Command Fails at 2mm on One Component – Molded Pulp Design for Packaging Insert

[julius_niedermeierFH8CA]

Hi everyone,

I'm currently working on a fiber mold that will be used to secure a wooden side table inside a shipping box. The mold is modeled in three separate components: "Front", "Left", and "Bottom", which will eventually be combined into one part.

My goal is to apply the Shell command with a wall thickness of 2 mm inward to each component, in order to create the thin-walled structure needed for fiber molding.

The Shell operation works perfectly fine at 2 mm on the "Left" and "Bottom" parts. However, on the "Front" part, the shell operation fails with the message:

"Shell could not be created with this thickness."

Interestingly, it does succeed when I reduce the thickness to 1.5 mm, but I really need 2 mm, not less.

I’ve narrowed the issue down to a specific fillet (highlighted in the attached screenshot). If I remove that fillet, the shell works – but I cannot remove it, as it’s required for the design. The strange thing is: a very similar geometry and fillet exists on the “Bottom” part, and there it works just fine.

I’ve attached a screenshot showing the relevant area. Has anyone experienced something similar, or can suggest a workaround to get the 2 mm shell working with the fillet in place?

Thanks a lot in advance for your help!

[CGBenner]

@julius_niedermeierFH8CA 

Hello, welcome to the Community.  I've moved your post here to the Fusion Design forum so that more of the experts might see it.  Would it be possible for you to share a part file for others to look at?

[TheCADWhisperer · Accepted solution]

@julius_niedermeierFH8CA 

Do you get acceptable results if you change the option to Rounded Shell?

[johnsonshiue · Accepted solution]

Hi! Indeed, as JD mentioned here, the Rounded Shell option seems to help. Either option should work regardless. Another more laborious workaround is to reorder the Fillet feature. Move it after the Shell. And add the fillets on the inside edges.

Many thanks!

[CGBenner]

@julius_niedermeierFH8CA 

Did the information provided answer your question? If so, please use Accept Solution so that others may find this in the future. Thank you very much!

[julius_niedermeierFH8CA]

Thank you very much, that did the trick!