I'm figuring out how to create components without mesh issues. I think my model may be more susceptible to this problem because I have a lot of parts embedded in foam. Modifying parts embedded in foam tends to create some surfaces that are "a molecule thick" which chokes the mesher. It really is a weakness of the code having to do with not handling extrusions to the right number of decimal inches. With extraordinary effort I'm able to make clean parts in multiple steps and in smaller body sizes. There ought to be an option to ignore any bodies less than, say, 0.001" thick. Anyhow, onward.
