Surface Thicken Issue

[Jimmyfabs]

Im trying to thicken a surface loft shape to .25" but the most I can get it to thicken is .19".  Ive tried several different methods and nothing seems to work.  Is there a reason why I cant thicken to the required size?  The geometry doesnt seem too complicated.  Ive attached a screen shot and the file.  I rolled back the file to the point in history where the loft is (hopefully it saved it correctly)

[innovatenate]

It's definitely the top corner giving you troubles.

There's some pretty interesting curvature that's causing problems.

Is this supposed to be mirrored geometry? If it is, I can see you're crossing the mirror plane as you thicken.

Do you have an image of some similar geometry you're trying to create?

[Jimmyfabs]

Thanks for your help, this body does get mirrored further along the way.  Ive attached a screen shot of what the almost finished product looks like.  Ive gotten this far and realized I need to have a thicker wall.  Playing around a bit its actually the curved end that's causing the problem.  If I try to thicken each face individually the top corner and center section have no issues going to .25" thick, the opposite end actually fails.  See attached screen shots.

[innovatenate · Accepted solution]

I took a swing at recreating this with much simplified sketch geometry and I didn't run across as many issues. 

The big things I did differently were:

• I eliminated the straight lines on the guide curves. I move the control points for the centerline spline to intersect with the guide curves.
• I also made sure that the straight line and spline for the centerline curve had a tangent constraint applied between them.

Result: I get a nice smooth result that thickens well beyond .25 in.

Please see the attached sample file and let me know if you have any questions.

Thanks,

[Jimmyfabs]

Thank you for taking the time to help.  I ended up recreating the model a bit and got everything to work but your solution will help me on future parts which will be similar.