What is zero thickness geometry?
Zero thickness geometry is when a feature is created that can not be solved due to the fact that there is precisely zero material at only a point or an edge. An example would be if you created an extruded circle that is tangent to an extruded square. There is a good explanation here: http://help.solidworks.com/2012/English/SolidWorks/sldworks/HIDE_ZeroThickness.htm
I've reposted the general guidelines from that site below as reference.
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Step 1:
Every edge of a solid body must have exactly two adjacent faces.
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Step 2:
Edge where zero thickness geometry is located.
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Step 3:
Vertices where zero thickness is located.
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Step 4:
Tangent line where zero thickness is located.
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Step 5:
Zero thickness occurs when you attempt to extrude a cut tangent to a hole.
This is frequently the cause of failed section views in drawings.
