If you have 2 circles that are tangent to one another. Then you will probably get that error. You can't have 2 cylinders that are tangent and expect them to extrude as one single body. This would cause a Geometric condition failure. However with SW03 & 04 you can use Contours and Multi-bodies to get around this.
What kind of file are you working on? I have seen this often with sweeps and lofts. It would be because the body cannot pass into itself.
Thanks Scott - the surfacing aspect makes sense to me. I'm updating a model that came to me from a consulting firm as a dumb solid. Seems the company modeled in Pro-E (supposedly due to Pro-E's higher surfacing capabilities) then translated into SolidWorks. I'm trying to match surface contours to either remove material or add features. I've come across the geometric condition failure frequently and have usually found a way around it. It's simply becoming a nuisance. Thanks for the response - Dave.
![[borg2]](/data/assets/smilies/borg2.gif "[borg2] [borg2]")
