given the results of the last test, i went back to your 1mm model. i got it to mesh with netgen this time. not sure what's going on there. it seems to hang on an optimize surface step. last nite i left it there for a few minutes before killing it. today it hung but not for too long and finished meshing. i attached pics. i'll run it through fea just to be sure. but it looks like moi can create a quality step model, even using the messed up rhino projected airfoils.