1. Try a standard mesh (if possible) as it will reduce the computation time, complexity, etc.
2. Your aspect ratio is WAY too high and might present a problem even if most elements are well-formed.
3. Can you use shell elements for your thin parts?
IDK what the contact limit is, did you look it up?
The number 3 item isn't an option for Drop Tests. They only use solid mesh elements.
SW is not able to mesh in Standard because of complex geometries.
That's a good point. I do realize some of the elements are very acute. However, at this point, I am concerned more about just getting something up and running and then go back in to fine tune the results.
As Ryan mentioned, there are no shell elements in drop test. I searched for contact limit, but no success.
From what it sounds like the mesh for this model is being controlled from he global mesh settings. It might be a better approach to set the global mesh settings to be much coarser than they are right now along with applying mesh controls just to the thin portions of the model to bring the mesh element size down just in those areas. That should reduce the number of elements in contact regions and allow your analysis to then solve.
I did try that, I am currently just playing with every combination possible. Since there is no incompatible meshing in drop test, mesh controls have the just the right sized to able to be meshed correctly.