Do you know, that… ?

In a sweep, there are some restrictions related to the radius of the path. More precisely, it is about the proportion of the profile with respect to the curvature of the path. If the radius is too small – the extrude will fail or the resulting surface will be deformed.

So how can this be fixed?

The most important thing is to divide this process into stages. In the first step, I pull out the outer one surface along the path (sweep feature), where the profile is half a circle (1). Then I add an operation to close the cylinder (2), it can also be a sweep or a boundary surface. There is symmetry in this example, so I mirror the object and merge the results.

The last most important step is to patch the resulting gap. It can be done border area or by profiles. However, the auxiliary sketch is very important (3), which allows you to shape it properly.

Due to this, I use the surface for this, I can even give up the ray from within. In any case, the freedom of formation is incomparably greater than in the case of solid modeling.