Hi Gord, the shell command can only really handle thickening an open surface into a solid if it has all smooth pieces. When there are sharp edges like you have here the surface offsets do not touch each other and would need to be extended and intersected with each other and MoI's shell function is not good at doing that.
Additionally if you have any really tight bends or bumps in it that will be difficult for it to generate an offset surface from as well. An offset surface is generated by moving a distance away from the surface along its surface normal. If the surface normal is wiggling around chaotically it will become magnified in the offset and mess it up.
It's this area here that you have some of the most pronounced little bends and wiggles, but there are some wiggles in other areas too:
You'd need it to be a lot simpler, cleaner and less wiggly throughout for it to have any chance of generating good offset surfaces.
There's also a gap between some pieces here which will prevent it from being made into a solid:
For the back you'd want to do something like have a plane cut it off and then fillet that rather than trying to make a 3 sided network that has these little bends and folds in it:
3 sided networks can be problematic because the surface generated from it will have one of its sides collapsed down to a point and it is pretty easy for something with bends in it to then have really small tight bends in the collapsed down spot. Instead of a 3 sided network it is usually better to form areas like that by having a larger extended 4 sided surface that then becomes 3 sided by it being trimmed rather than trying to directly construct a surface to those curves. Then a fillet or blend can connect it to the other part. Something like more like this:
Another thing that's not so good is to have skinny fragments like these:
Those are probably caused by some of your curves that are being networked having sharp corners in them rather than being all smooth. Any segments in curves that are not smooth to their next or previous neighbor segment will divide the end network up at that sharp area.
Do you have the curves used to make this? If you can post those too I can take a look and see if I can call out any problems coming from them to start with.
- Michael
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