I have created a part which when halved looks fine: http://i.imgur.com/i26Qb5I.png?1, but when I try to mirror it something really screws up. This is what happens when immediately after mirroring: http://i.imgur.com/Uh4AkYB.png. This is what happens the moment I scroll in or out: http://i.imgur.com/oK2wW3H.png. I understand why the surfaces have mirrored but I don't get why the thickened walls just disappear. Does anyone have any ideas? I've uploaded the file though it's the student version so I think you can only open it if you have the student version also. (Also when I add the part to my assembly it still keeps this screwed up view).
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I just noticed something. The surfaces at the center of the model don't quite make it to the mirror plane.
If you create another datum plane slightly inside the model, cut with it (solidify), and then mirror from that plane, everything is happy.
I can't open your naitive model, but I think you may want to extend your surfaces past the mirror plane, and then either trim them off before thickening, or possibly trim the solid geometry after thickening.
Another view of before it was mirrored to show how it should look from the side: http://i.imgur.com/SyZzWnm.png
I wonder if it's a graphical thing. Try saving a copy as a step file and then bringing it back in just to see what happens. Also, maybe try increase your model accuracy and see if that makes any difference.
I wondered if it could be graphical, I'm not running it on a PC but on a bootcamped iMac (21.5" one of the new thin ones) but I haven't had any problems before, it just seems to be this part. I tried the step file and when taking a cross section something even weirder happens: http://i.imgur.com/HZISIEk.png. It seems that where it should be hollow it has become solid and where it should be solid it is hollow. Increasing the accuracy seems to cause the model to fail.
The original file is in the original comment (though you need the student version of creo I think). Here's the step file:
Increasing the accuracy has the potential to make more errors as the software can now see better. I often find that decreasing the accuracy allows Creo to smooth over errors that would otherwise cause problems. The ideal thing to do would be to model it perfectly but sometimes that isn't possible (part driven by another user's skeleton, import, etc.)