Unknown error when making a taper angle

[silverryu]

Hello! I'm working on making some clay cutters and I've been doing ok with most of my shapes but one is giving me issues when I'm trying to make a tapered angle for the outer blade part of the design. The inner part of the design works without issue, but the outer part gives me an "Unknown error" after I confirm the extrusion with a negative taper angle when I try to extrude it by 3mm and a -7°taper angle despite the preview of the extrusion showing a success.

When I try to extrude 7mm without the taper angle, then add 3mm with a -7°taper angle it doesn't work at all so I'm guessing something isn't right with the model itself but I can't figure out what it could be the cause. I'm pretty new to this program, only used it to make a few dozen clay cutters so I'm not sure what to pay attention to. Any help or tips are very welcome!

I'm attaching a video of the error when I try to extrude it by 3mm and a -7°taper angle, and the .3fd file that I was working with.

[jhackney1972]

You are exceeding the taper angle for the body faces due to the complex curvature of the profile.  I sure you noticed all the "yellow"warnings in your timeline plus the fact you do not have any Bodies showing in your Browser.

[silverryu]

The yellow warnings were added when I tried to extrude at different taper angles so there are multiple because of that. I tried to make the bodies but deleted them after the extrusion of the blade part didn't work so I could just test the blade taper angle.

I did suspect that the curvature might be too complex for the taper angle, but I didn't have that problem until now on any of the other models I made so I wasn't sure if it was that or something else.

Is the only way I can fix this to make the modle simpler? I.e. to have a less complex curvature?

[jhackney1972 · Accepted solution]

You could possibly get away with using Sweep cuts on both sides to give you the taper you want but the curvature still is too tight to get easy results.  Attached is a model with two Sweep cuts but as you can see the path ends up giving you some material that is not easy to get rid off with the current sketch curves. 

[silverryu]

Thank you for that examlpe! I'll check it out, it might work for me since I could just remove those parts post 3D printing since they would be very thin and easy to remove.

And I'll try to simplify the curvature and see how that goes just to test it out and find a better balance.

Thank you for the help!

[johnsonshiue · Accepted solution]

Hi! Another solution is to utilize Ruled Surface to create the tapered faces. Then use Boundary Fill to solidify the bodies.

Many thanks!

[silverryu]

Thank you for that suggestion and the fix to the file!

I will note down this solution if I get the same issue again cause that is the perfect solution.