unfortunately, your 1mm model hangs the same way as the previous step file you provided. the model looks fine but it won't mesh. it has an issue with a surface, but i don't know which one. when i get moi i can experiment. your filleting seems better than rhino. perhaps if i did the projections in moi those would be better too. it seems the rhino projections are the base of the problem. the filleting can get messed up by all sorts of things so it's hard to debug. thanks for your insights. last question; do you know if you have to rotate seams out of the way of filleting in moi, like you do in rhino.