When creating a circular patterns in SolidWorks there is a limitation that the resulting pattern of extrusions and filets cannot overlap on to itself.
However there is a trick we can use to get around this. Instead of patterning the feature we can pattern the body.
This will give us a set of individual solid bodies that can overlap. Then the combine command can be used to turn that set into a single solid model.
Jordan Nardick, CSWE
Computer Aided Technology, Inc.