Actually I had the customer go back and modify his model so that there is a .001 gap between overlapping faces and coincident edges. But when imported there is a big red explanation mark on the imported solid. When I run the diagnosis it tells me there are 9 faulty faces. I just went back and check for consistent material thickness and proper inner and outer bend radii and all this looks good. I would be willing to save a SolidWorks files of the imported STEP file and email to anyone who would like to take a look. I'm importing with these options set:
Surface/solid entities Try forming solid(s) B-Rep mapping
Perform full entity check and repair errors
Document template specified unit
Sorry I can't send the STEP file because it would be so easy to see who the customer is. If you would like to have a go at it, drop me a line at:
snipped-for-privacy@NnmbyersprecisionNnm.com (remove the (3) "Nnm" occurrences)