I would say that that notch is not unexpected. The hole is too close to the outer side of the body. The way that Shell works is: All the faces in the model are offset by the shell thickness, then everything is stitched back together, and the shell is subtracted from the original body. So, when Fusion offsets those hole faces, the offset pokes through the outer wall, creating that notch. The fix is to move the hole. I turned on history in this model to make it easier to illustrate. Then I added the shell, which produced the notch. Then, I roll back before the shell, and insert a Move Faces feature to move the hole (I just picked .25mm, you can play around with different values). Then, roll forward, and: no more notch. There is another place on this body where a similar effect happens (not as bad), so the same fix would apply
model is attached.
Jeff Strater
Engineering Director