SOLIDWORKS Hole Wizard Zero Thickness Geometry Rebuild Error

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:

Hole Position

This can also happen in a pattern as shown below:

Hole Pattern

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.

Repositioned hole

Have a look at some more tips related to the SOLIDWORKS Hole Wizard.