This can certainly be done. The idea is shown here, but the version of FreeCAD is rather old. It uses Datum planes, but, it can be done with just sketches as well: Screenshot_20240424_130721.png https://youtu.be/LPfH5toLP-Q?si=p189ru7LlVdKJQzK More complex: Screenshot_20240424_130416.png https://you...

Thanks for the idea, I haven't used "Sketch-On-Surface", I have used "Create Projection On Surface". I don't have the Fill faces & thickness parameters in the data tab of my properties view. Screen Shot 2024-04-24 at 17.04.59.png "Create Projection on surface" is a...

Hard to guess, what with no pictures of the tree view, no pictures of the model... and no FreeCAD file attached.

My crystal ball is out for repair.

I think that instead of doing every single pocket you could draw a sketch that includes them all and apply it only once. In my humble opinion, if you choose the face of a geometry as a pocket geometry, you encounter the TNP. Don't choose a face. That's generated geometry and prone to TNP. Create th...

My appologies for a poorly worded question which seemed like another attempt at my previous question. I meant it to get clarification on how robust the thickness operation was (thank you @chrisb) rather than get a solution to the pipe join issue. Unfortunately, the simple answer is, the Thickness t...

When I open your file the report view show a Wire not closed. There is a red exclamation on Sketch and Validate sketch shows 2 troublesome vertexes. With the error in the tree the model won't recompute and what is shown is the last valid recompute. I would ask, why all the Boolean operations? Also, ...

Select in the tree view "Sketch On Surface".

In the Properties view Data tab set:

Fill faces = true
Thickness = <some value>

Method 4??? You have a Std_Part (yellow icon), it is not needed. You have a Part Design Body. But the helix and sketch aren't members of the Body. You could just make the radius of the cylinder the same as the helix. Or, use a Dynamic Data value (or even a spreadsheet cell) and set the radius proper...

I tough, if the sketch is "Fully constrained." and if it the sketch is green then everything should be in perfect condition. But for some reason it is not. So, what did I missing? There is a bit of misconception about the state "fully constrained". It really means all DOF's have...

Thank you again drmacro. After considerable head-scratching and hours of frustration (primarily with my own ignorance) I have succeeded. I think the key was to use the extrusion tool rather than trying to pad the Shapestring. Anyway, I now have what I want (and hopefully can reproduce it when neces...