Hi
my advise (i have posted several comments already, and that applies for 3.5 as for 4) is to cut up your complex models into several domains/geometrical objects. Even if this adds interior boundaries, it helps the mesher, try to avoid parts with long loops (doughnut or torus shapes), cut them in the middle or in 4 to "open" the loop, and not to mesh it in one go. then mesh from inside and out, minimise parts meshed at the end with all surrounded boundaries already meshed
play with the mesh density, add seed mesh along edges, specially in the region of small features, or where you mesher reports difficulties
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Good luck
Ivar
my advise (i have posted several comments already, and that applies for 3.5 as for 4) is to cut up your complex models into several domains/geometrical objects. Even if this adds interior boundaries, it helps the mesher, try to avoid parts with long loops (doughnut or torus shapes), cut them in the middle or in 4 to "open" the loop, and not to mesh it in one go. then mesh from inside and out, minimise parts meshed at the end with all surrounded boundaries already meshed
play with the mesh density, add seed mesh along edges, specially in the region of small features, or where you mesher reports difficulties
--
Good luck
Ivar