Hi Jonah, it is kind of a general problem that arbitrary n-gons and subd do not mix well, regardless of a "perfect" vertex alignment.
Part of the sub-d process involves taking a centroid of the polygon, and if your polygon is not a convex shape, it won't have a nice centroid-ization to it.
Here's an example:
From an n-gon structure standpoint, that is pretty much a perfect mesh structure with a minimal amount of vertices. Yet regardless if you try to sub-d it, it will work but the result will be ugly as pieces radiate toward the centroid of the n-gon and kind of fold over the concave areas.
For nice sub-d-ifiying, you don't really want minimal vertex count n-gons at all, but rather a set of convex polygons even if that requires adding a lot more points to the entire mesh.
It's a completely different thing... Just more vertex alignment does not solve the problem.
- Michael
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