* Sketch001 is attached to a Face : TNP.
* why a Revolution instead of a Pad ?
* why a Hole instead of a Pocket ?

* You should use Sketcher_CreateSlot then suppress '=' radius. This tool will be quicker and righter than line by line.
* To find your error, you should try to fully constrain your sketch.

1st sketch : wire not close (https://wiki.freecad.org/Tree_view#Whit ... background)

Sketcher_ValidateSketch : 1st button :

* why do you not use axis for symetry ?
* keep sketches as simple as possible.
* 1st pad with reversed enables to sketch on XY-plane.
* why do you not use Sketcher_ConstrainTangent for your arcs ?

PartDesign_Fillet :

Fillets cannot completely consume the adjacent faces.

For a 2 mm thickness, you can use a 0.99 radius fillet.

Logie-wan-kenobi wrote: ↑Tue Apr 23, 2024 1:02 am the file is to large to upload

Set number of repetition/pattern to a lower value.

If you don't like TNP, you should use PartDesign_AdditivePipe.

different sketches/features for different functions.

ArduinoLego611 wrote: ↑Tue Apr 23, 2024 2:22 pm what can I do to fix it?

Provide a file.