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I forgot to metion that the cut is in a SOLID not a surface... So i am trying to make a pocket in a solid using a thicken-cut.

Sorry about that. I tried it but i get the same error: failed to thicken a surface and cut from workpiece

i checked the minimum radius of curvature for the original faces: 4,99 mm. I want to make a 0.5 mm pocket so this should be no problem. (when i try to make a 0.0001 mm pocket this isn't working as well....) I tried to only thicken the surface (no cut-thicken) this isn't working....

But the zero-offset surface is already a single surface in the right contour? (the contour of the sketch..)

Hi Dan, Yes i am trying to make a pocket in the area of the projected sketch. According to these topics the method i mentioned above should work: http://www.solidsmack.com/solidworks-tips/how-to-recess-surface-solidworks/ https://forum.solidworks.com/thread/25468 Do you know a solution?

Hi,SW.png I'm trying make a cut by using these steps: 1. Project a Split Line of your sketch onto the surface (Insert, Curve, Split Line… Projection) 2. Offset (Copy) the Split Faces a depth of zero (Insert, Surface, Offset…) 3. Cut-Thicken the offset (Insert, Cut, Thicken…)...