As a former Tool and Die designer I came to appreciate the power of SolidWorks when designing Embossing Dies. Most of the times, I would use the face of the part sent by my customer for either “Extrude to Surface” or “Cut with Surface” commands as a reference in designing my embossing punches and die sections.
There are situations when this approach does not work. One workaround, involving the “Thicken Cut” command is presented in this video (no audio provided):
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