Hi,
your part is not fused correctly… (always reload your part after a fusion to check it)
in some cases FC doesn’t make a union of parts because of OCC kernel
as pointed out in the StepUp starter guide here there are some tips to fuse correctly objects in
FreeCAD http://forum.freecadweb.org/viewtopic.php?t=8451#p69489
In this case the problem is in your model which is done as open faces and not as solid…