Hi Will,

> Okay, but I see that shell doesn't handle sweeps with varying thickness?

It should if the conditions allow it - here's an example:




But if you ask for a shell thickness where there is not room to allow that much thickness without the offset folding over top of itself, then you will run into problems... I think that's what you've got happening there, you probably need to use a smaller thickness to get a clean offset.

Here is an illustration of the problem:



The above was taken from the documetation on Fillet - trying to perform a fillet of too large a radius around a sharp corner is basically the same problem as asking for too large of a shell thickness where the size or curvature of the surface does not allow for that size.

If you want to post your .3dm model file, I can examine it to verify that this is the problem or not.

If you try a smaller thickness you'll probably see it work ok though.

- Michael