Offset is not working when certain face is added

[Infraredbeard2]

Good evening,

I am replicating a late 16th century Greenwich-style gauntlet, a feature of which is a series of overlapping articulating plates. I intend to achieve this by using a series of offsets derived from a base surface, with the plates cut out using boolean intersects.

I am running into an issue where the offset tool will work for the entire model, but fails in unexpected areas. The areas are generally able to be offset on their own, and only fail when neighboring geometry as added to the offset.

I would appreciate some help in solving this issue. I have attached a video of the issue, as well as the model file. Please let me know if I should add more.

[TheCADWhisperer]

@Infraredbeard2 

Can you use Shell?

[Infraredbeard2 · Accepted solution]

Thank you for the response! I examined the shell, but unfortunately it did not allow me to extend the distance past 6 mm. However, while attempting to solve this I activated rounded edges and noticed that it also failed to create the surface where the offset had failed. I experimented and was able to achieve a satisfactory result on my model using offsets by setting edges to sharp for the first 6 mm, then offsetting at 8 and 10 mm with rounded edges. I appreciate your assistance!