From surface to solid
The problem is the geometry created by Loft2:
In this version, I created a 3D sketch and added a couple of rail curves. I just left them linear, but you can play with the spline handles to get different results.
This produces somewhat nicer geometry:
next, 2mm is REALLY thick for this model. That depression is not much more than 2mm itself. I was able to thicken to 2mm, but I'm not sure this is the result you want. Anyway, you have the info you need, now to work on it on your own. Use curvature analysis. Areas of high curvature will always make Thicken fail.
my model is attached
Jeff Strater
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@g-andresen you are correct that the OP should be making sure his curves are "harmonious".
I observe that your curves aren't harmonious either.
The code in Fusion 360 (or the geometric modeling kernel, not really sure which) that creates the intersection curve is inadequate to create smooth curves suitable for creating further geometry. I've provided samples of that to the Fusion 360 team for many, many years!
The same applies to the offset spline the OP created.
In fact, Fusion 360 has significant problems to create good lofts, even with better input.
Instead of offsetting the spline I would offset the surface and then use that for splitting faces or trimming.
Edit:
Attached is my version, mostly without curvature issues.
