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Boolean Operation failed to return a valid part.

craig_18craig_18 Member Posts: 4
edited May 2015 in Community Support
Hi all,

I'm trying to remove material to make a cool pattern on this conic shape I'm modeling.  I have a sketch with a circle pattern, and I'm trying to extrude it all the way through the part, but my extrude feature breaks and gives me "Boolean Operation failed to return a valid part" when I try it. Please see link below for the part.

I have tried converting the sketch and extruding from the flat side of the part, to no avail.  

One interesting note is that if I choose "symmetric" for the extrude depth, I can get it to work, but only for short distances before it breaks (~0.75" max)  

Ref. Sketch 3, Extrude 2.

https://cad.onshape.com/documents/3338e1277be14b95a9c8321e/w/553c69327fbb4d78914dcb02

Thanks in advance.

Best Answers

  • jakeramsleyjakeramsley Posts: 595
    Accepted Answer
    Because your quadrangles share vertices, when extruded you are going to be creating a non-manifold edge at these points.  This is why you can extrude part of the way, but once a second profile starts intersecting with your cone, you create an infinitely thin edge which is rejected by our solver.  

    If you change your extrude from Remove to New, you'll notice that each profile comes in as a different color indicating a different part.  This is how the solver wants to handle infinitely thin edges, but can't be done when subtracting from the same part.
    Jake Ramsley

    Director of Quality Engineering              onshape.com
  • colemancoleman Posts: 242 PRO
    Accepted Answer
    @Craig Wheeler  I figured out the problem.  The sketch you are using to execute the extrude will result in zero thickness geometry.  Add some space between the points of each diamond.  As they are currently sketched, the points touch.  This is why you can extrude down to .75in but no more: the second intersecting diamond comes into play deeper than .75

    Good luck

Answers

  • craig_18craig_18 Member Posts: 4
    Ref. Sketch 3, Extrude 2.
  • jakeramsleyjakeramsley Member, Moderator, Onshape Employees, Developers Posts: 595
    Accepted Answer
    Because your quadrangles share vertices, when extruded you are going to be creating a non-manifold edge at these points.  This is why you can extrude part of the way, but once a second profile starts intersecting with your cone, you create an infinitely thin edge which is rejected by our solver.  

    If you change your extrude from Remove to New, you'll notice that each profile comes in as a different color indicating a different part.  This is how the solver wants to handle infinitely thin edges, but can't be done when subtracting from the same part.
    Jake Ramsley

    Director of Quality Engineering              onshape.com
  • colemancoleman OS Professional Posts: 242 PRO
    Accepted Answer
    @Craig Wheeler  I figured out the problem.  The sketch you are using to execute the extrude will result in zero thickness geometry.  Add some space between the points of each diamond.  As they are currently sketched, the points touch.  This is why you can extrude down to .75in but no more: the second intersecting diamond comes into play deeper than .75

    Good luck

  • craig_18craig_18 Member Posts: 4
    Many thanks!
  • cyclonewadecyclonewade OS Professional, Mentor, Developers Posts: 53 ✭✭
    edited May 2015
    Coleman said:
    @Craig Wheeler  I figured out the problem.  The sketch you are using to execute the extrude will result in zero thickness geometry.  Add some space between the points of each diamond.  As they are currently sketched, the points touch.  This is why you can extrude down to .75in but no more: the second intersecting diamond comes into play deeper than .75

    Good luck

    @Coleman just outed himself as a SolidWorks user.  :)
    imagine.create.deliver
  • colemancoleman OS Professional Posts: 242 PRO
    edited May 2015
    @cyclonewade - very true  :)

    It does take one to know one.
  • philip_thomasphilip_thomas Member, Moderator, Onshape Employees, Developers Posts: 1,373
    Sometimes these threads just make me smile - 
    We are ALL reformed SolidWorks users :)
    Philip Thomas - Onshape
  • christopher_owenschristopher_owens Member Posts: 235 ✭✭
    The "Zero Thickness" just helped me with a Boolean that wouldn't create a part. I had to do some profile sketch modifications and reelecting entities for my lofts.... but in the end I got a solid part!
  • christopher_owenschristopher_owens Member Posts: 235 ✭✭
    edited July 2015
    And some of us are Pro/E to SolidWorks to Onshape addicts!  >:)
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