SOLIDWORKS Hole Wizard Zero Thickness Geometry Rebuild Error
Article by James Swackhammer updated April 24, 2020
Article
Oh no, a rebuild error has appeared reporting: “Unable to create this feature because it would result in zero-thickness geometry”. Has this ever happened to you when trying to insert a SOLIDWORKS Hole Wizard hole?

Rebuild Error
This most often happens when trying to place a hole in an assembly going through multiple parts but can also happen in part design. The cause of this is typically because the hole is right on an edge:
This can also happen in a pattern as shown below:
The fix is quite simple… and isn’t mind blowing by any means
Ready for this? Just move the hole position slightly past the edge or further inside the part. Although if the hole is too close to the edge you may want to do an engineering design meeting to see if that is approved.
Have a look at some more tips related to the SOLIDWORKS Hole Wizard.
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