Swept blend - how to create project outside profile.

Try creating a sketch of the silhouette using the project in the sketcher.

Project this new sketch instead of the silhouette.

Setting up the sketch is obviously normal to the projection direction.

Note the obvious limitations this adds to advanced projection techniques.

But normal projection onto flat planes, this will work for you. 

Also note that silhouettes tend to be fleeting (vulnerable to instability) when the model changes.

Is this during sketch creation? If you are trying to skip making a sketch you will not be including the projection direction which is required to understand the direction the silhouette is being evaluated.

See http://support.ptc.com/help/creo/creo_dma/usascii/index.html#page/dma%2Fdirect_modeling%2Fexample_silhouette_edges_of_faces.html%23

(Edited after: Eventually there will be a system to notify that another reply is in progress.)