Reply To: Extra parts are forming at the contact between two curved bodies when geometry transfers to meshing

[peteroznewman]

It may be because the thin slab was not made using the surfaces of the mould and there is a small mismatch in the two surfaces.
SpaceClaim has a Volume Extract button on the Prepare tab. This creates the solid that fills a mould. You would then use the Share button on the Prepare tab to create Shared Topology.