In attempting to create a solid-body curvature-based mesh, I have encountered an error that I can neither trouble-shoot nor explain.
Attached is a PDF that shows the model and the issue. There are (5) intermediate horizontal members that frame into a vertical member, with sheeting on one side. All bodies are fully combined. When any (4) of the (5) intermediate members are present, the mesh is successful. However, when all (5) are present, the mesh fails at the volume level. Mesh parameters are given in the PDF, and all parameters were kept constant in each mesh. I also do not believe that global size of the mesh is the cause, because I repeated the same procedure using the full model (essentially a mirror of what is seen here) and, again, (4) of (5) meshed correctly for identical element size parameters.
Has anyone seen anything like this? Any additional advice?