Which version of SW did you use to create the model? Because if I copy the sketch to a new model and recreate the sweep, the problem is gone. I suspect the version of SW that you use is the problem. I have used 2017 SP3.
try making it out of two extrusions and a revolve. The beams don't like the higher order geometry of sweeps too much, at least in my experience. No guarantee it will work but worth a shot.
Odd behavior indeed. I could replicate the issue on the original part. I recreated the part exactly in SW 2017 SP 4 and it works fine. Bill McEachern is right, reworking your part with extrudes and a revolve also works. Also, on the original part, simply checking the "merge tangent faces" option on the sweep makes the beam mesh properly too.
Hi all, many thanks for your input, I've tried the merge tangent faces trick, works a treat and is the least hassle solution. We're updating to SP4 next week in the office so will see if that helps too then.