Hi Patrick, the thickness of 0.5 giving weird results looks like a bug in the geometry library - something is messed up in the resulting trim curves of the generated object and that makes for strange "leaky" type of shapes. I will try to investigate it, but it's a pretty tricky area to mess around with without a huge amount of time involved.

I do have an updated version of the geometry library that I'm going to be rolling out with the next v3 beta release, hopefully it will fix some various issues.

A distance of 1.0 is probably not going to work because it involves some faces being entirely consumed away to nothing, like this one here is almost consumed at 0.5mm already:




The geometry library that MoI uses is not so good at handling cases where entire faces disappear like that, it's just not a strong area of the library currently. Some other CAD programs like ones based on the ACIS kernel should handle that case better probably.

- Michael