What is zero thickness geometry?

And why does it happen?

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Zero thickness geometry is when a feature is created that can not be solved due to the fact that there is precisely zero material at only a point or an edge. An example would be if you created an extruded circle that is tangent to an extruded square. There is a good explanation here: http://help.solidworks.com/2012/English/SolidWorks/sldworks/HIDE_ZeroThickness.htm
I've reposted the general guidelines from that site below as reference.

Answered with a tutorial: https://grabcad.com/tutorials/what-is-zero-thickness-geometry

 
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