just check if bonded option is used in contact sets.
where as if there is no contact between the surfaces
these error occurs.
My understanding is that you might have edges, corners intesecting the face (which sometimes is a problem for meshing) in your assembly. This might require very small element size. Make face to face contact if possible.
One other things that might cause the mesh to fail is small gaps in your assembly.
try using failure diagnostics tool which might show you why and where your mesh failed.
Your parts are not in perfect contact with each other. SW is very picky about this. If you do interference check and mark the "treat coincidence as interference" box, you still get the "no interference" result.
Easiest thing to do, in my opinion, is to modify the "Cut-Extrude2" feature in part "NSF_ST_03" and use the inner edge from part "NSF_ST_01" as the sketch with the help of convert entities. This will guarantee that the parts are in perfect in touch with each other. If you don't want the relation between the parts, which comes with "convert entities", just replace the added relation with a dimension or fix relation.
I am currently having a similar issue. The parts that is lists as interfering in the error message are about an inch apart. I do an interference check and the only things I get are the mates that are supposed to make faces coincident (with the box checked).
Thanks in advance for any help.
If anyone in the future meets this problem (as I did) and the answer is not written above, try the following:
Right click on the bonded connection (global), then select "edit definiton", and you will find there a pickable option: incompatible mesh.
Leave the connection bonded, just pick "incompatible mesh" instead of "compatible mesh". That should solve the problem.
fixing the interference is the fix in this case