Discovery Enclosure – Edge is outside the face tolerance

[kelvin.k.kong]

Hi,

I've been using Discovery and then Fluent to perform half car CFD simulations, following Ansys learning series.
I've done many successful simulations in the past. However, I'm encountering a Check Geometry error in Discovery for the enclosure itself (without physical model, except for the MRFs) for the first time,

"Edge is outside the face tolerance"

No Check Geometry errors for the physical car model present, so I'm confused as to why this is occuring? All the needed geometry repair tools have been successfully used.

 

During Surface Mesh:

I've been trying to get my current discovery model successfully working in fluent for the past day now, to no avail.

The past attempts, each time I have gone and re-did the enclosure again in Discovery as the geometry repair tools are buggy, and most of the time the 1 or 2 geometry errors may pop up again.
During the past Fluent surface mesh attempts, most of the time no warning/error message appeared in the console, and most of them would stall at 75% progress.

I have only managed to to successfully surface meshed once, which afterwards volume mesh failed because too much prism-stair stepping occuring.

Thanks in advance.