This was created as a surface, then thickened. The surface seems quite healthy. The thickness is relatively small compared to the radius of curvature. The window below is from a version that was exported then imported, but this happens on versions that have not been exported also. Any idea what the deal with this is? Maximum gap is about .0012 inches, FWIW.
..so, you ran analysis on the step import (auto) but not manually on the parasolid (or sldprt)?
I would definitely share this with your VAR.
I can't share it with the VAR, it's part of a helicopter.
I mean share the file with your VAR....they should already have an NDA with your company. If you can't share the specific file, then re-create the problem on a dummy part and send it to your VAR (Value Added Reseller, the person you bought Solidworks from, assuming you are on subscription).
They should be able to take the part, diagnose the problem, and either tell you what the issue is, or submit it as a bug to be fixed in a later version.
In the meantime, you may need to use your work around. Not sure why it is happening.
Update: Cycling this as a step file fixes the problem, cycling it as a parasolid does not (no reason it would in hind sight). but I'd like to keep my native files.