Hi Steve,
quote: I made 2 rail sweep, then used planer to create solid. I attempted to add a small rad on that top edge but could only get a rad as small as 0.5(or 0.4). so I separated the surfaces then used the 2 top surfaces to produce the rad. I then tried to used the top of the rad produced to offset.
Right, so that edge with the little gap in it was not produced by sweep, it came from fillet.
It looks like the filleter wasn't able to make a completely great fillet surface there, if you separate it out and untrim it you can see the fillet surface itself actually has that gap in it.
So as far as I can tell there is nothing wrong with the sweep command there, it was a problem with fillet.
I think in v3 I may add some processing to automatically seal up curves for edges that are topologically closed like this.
- Michael
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