Dear All,

            I have a problem most frequently combine a parts with variable fillets feature. normally I want use variable fillets in my design, also need to separate body's on  fillets region using cut with surface / subtract/revolve cut ex... to create multi body parts for use to any feature(patterning to isolated body ex..). some time  difficult to separate as a multi body. (operation failed due to geometric condition )  if successfully separate as a multi body, but try to again combine some time to SW pop-up same geometric condition or zero thickness geometry. so how i fix this problem ? any procedure to identified what's wrong? as a example I attached part file herewith.