I create a cylinder and a single turn helix with a circularprofileusing Swept Boss/Base. Using the Combine feature, I subtractthehelix from the cylinder and get the expected groove: seefilegroove-sample.

I do the same thing with a rectangular profile - but thistimeget a Zero Thickness error message. The file isgroove-sample2.After looking at 'Help' I can't see why. Anythoughts?

SolidworksParts And Features