Hi Andy, it's because the target surface has uneven parameterization, some areas are stretched out and some are compressed in how the surface's UV parameter space relates to 3D space. If you turn on surface control points you can see some neighboring control points are close together and some are far apart from each other.
A couple of solutions are to use the Rebuild command ( https://moi3d.com/4.0/docs/moi_command_reference10.htm#rebuild) on your original curve used to generate the surface and extrude a new one out from that. That will have arc length parameterization and so won't have areas of compression and expansion like your current surface has.
Another solution is to use curve-to-curve flow instead of surface-to-surface flow. Curve-to-curve flow matches based on distance traveled along a curve rather than matching by UV parameter space like surface-to-surface flow.
Also note that your object is kind of mangled as a result of applying a fillet with a radius larger than will fit in available space.
- Michael
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