Hi,
I am having similar issues, I create 3D geometries in Inventor uniting together several surfaces so that Inventor itself sees one unique surface; however, whenever I export it as a .sat, .stp or even binary file for Parasolid and then I import it in Comsol I see again all those surfaces that are not supposed to be there.
What type of geometry are you actually building? Volumes? Do you fuse surfaces together to yield a volume?
Regarding the meshing error, I got errors after importing only when I imported threaded holes or similar. I resolved the problem (thanks to support) with the mesher of the 3.5 version.
Cheers
For some parts I am extruding surfaces to solids, and for some parts I am building solids out of intersecting surfaces. All in all, it is a kind of a box structure with a hole on one side. I started importing it to Comsol part by part, and as soon as I have top and bottom plate and two sides, the meshing fails. How did you exactly resolve this meshing problem? I am actually using 4.0a instead of 3.5.
Regarding the small details, I have tried the repair function in Comsol. I will definitely check the spikes, but I have been very careful in building my geometry in Rhino. What I don't get is the reason why the union works in Rhino, but not in Comsol..
Thanks,
Henna