Thickening, extruding, and push/pull commands "could not create a valid result"

[ducer101]

After completing what I figured was the end result I wanted, I found that the model was not conducive for 3D printing. Thus I went back to create a "pretty/elegant" 45 degree slope to help the 3D printer avoid overhangs. Here is what I did (which was probably not the best way to do it, since it isn't working now...)

The part of my model that needs the 45 degree additionThis is essentially the inverse of what I need to 3D print. I use this at the end as a "cut-out" of a larger block. This is also it's own piece, and will insert into the block that I will cut from.

My lofting job

To create the 45 degree "ramp", I tried using fillet, chamfer, extrude, and anything else I could find, but ended up liking this the best. I extruded a small slice from the ledge, rotated it to be flush with the wall and then created a joining loft from the ledge to the newly extruded piece. (I feel like this caused an issue, however, because of the extra lines that are showing)

The bottom removed

Later on when I am done. I want to thicken the entire model so that I can give a little "wiggle room" for the inside piece (the one I'm trying to thicken) to comfortably slide into the outer piece (the one I will cut using the thickened piece). So I cut off the bottom with patch tools and then used the thicken tool to thicken everything except downwards by 0.2mm. This results in the error...

The error message I get when trying to thicken 0.2mm:
"Error: The operation could not create a valid result.
Try adjusting the values or changing the inputs."

Expanding the error gives me the exact same message.

However, if I increase the thickening to 1mm, then the process will work again. I found that only values under something like 0.99mm will give "valid" results.

(I have also tried simply selecting the solid model, before removing the bottom with the patch tools, and simply "extruding" it thicker, or "push/pull"-ing it thicker, which also failed.)

I'm still fairly new to all of this, so please let me know if I am missing something, or how to provide extra support to help resolve my issue.

Thanks!

[davebYYPCU]

It is much easier to trouble shoot this with your file.

File > Export, then attach to another message.

Two things I am wondering, is it a Timeline or Direct model?

What happened to the sliver / slice?

Might help....

[ducer101]

Thanks for taking a look at my issue!

I have been using the Timeline a lot. (I still haven't found a good use for using direct model because I always need to go back in the timeline and modify something)

I have included the export as an attachment. (there is extra stuff in there that isn't related. Also, I tried to group the timeline to make more sense, but there appears to be a workflow issue there since I can't add an event I missed, haha)

[davebYYPCU · Accepted solution]

It's the sketched fillet / radius that causes the shell to fail.  The result of the pinched corner was where I thought it was going to fail....

So redoing the gusset with out it, worked for me, I added the fillet to the lower original shelf, but will be something for you to consider in any redesign....

What I would do, 2 fillets, the internal first, then the left edge, so that the shell still works.

Fillets with the modelling area is recommended in this scenario....

Might help.....

[ducer101]

Thank you again for helping me with this!

Although that isn't exactly the solution I wanted, it is good to know what is causing the error. It would sure be nice if the thickening algorithm could handle such intersections/curves/etc., But until then I now know how to work around the error.