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I recently had a similar problem using cosmosxpress and was almost to the point of running my PC through the band saw. This can be very frustrating! Are you able to upload your file for others to view? The issue I was having was due to a tiny face within the geometry of the part I was performing a stress test on. I was told that removing some of the features in the model (fillets, etc.) helps out. Post up a copy of the file and let us have a look!
It works now?!?! It must have been a setting I missed or something. Man, I feel noobish. Thanks for the reply.