First, I need to be able to export SolidWorks drawing files as .AI's and I can. Small assemblies, and assemblies from various projects, "save as" .AI normally, and open in Illustrator with no problems. My drawing artwork saves as vector artwork, part and assembly artwork saves as bitmaps. Fine, that's what it's supposed to do.

Now, I have ONE very large assembly DRAWING that saves as a bitmap - a low resolution one, at that - and I cannot determine as to WHY?? I'm really starting to get annoyed here. I create illustrations for service/maintenance manuals. My writer has asked for various views of this ONE assembly, but I just can't deliver what he needs!!

As work arounds, I've created a SpeedPak of one subassembly in this larger assembly - the most complicated subassembly - so the file opens quickly and can be manipulated easily in SolidWorks. Before this assembly wouldn't even open without crashing SolidWorks. With the SpeedPak, it opens easily.

When I "copy to Adobe Illustrator" the artwork pastes as vector artwork, but the SpeedPak'ed subassembly appears as ONLY THE FACES I'VE SELECTED FOR MATES.

Out of curiousity I've saved the drawing artwork as .DWG and brought it into Illustrator to find that tho it is vector artwork, some parts of the assembly are wire frame, while others are hidden lines removed. Weird.

I'm guessing there's something corrupt in my assembly, most likely in that one subassembly, but I've recreated the subassembly from scratch a few times now to determine what/where the model has gone funny. But, I've found nothing obviously wrong with the file.

I've recently upgraded to SolidWorks 2009 SP2, and would like to note that SolidWorks stability has gone right the Hell out the window, BUT ONLY WHEN DEALING WITH THIS ONE ASSEMBLY.

Please help if you can!!