Thanks guys,

 

I've tried every setting for smoothing angle, from 0 to 90 degs and nothing works. I've tried welding and splitting objects in Vue 5, grouping and ungrouping them in SU5, smoothing inside groups, smoothing outside groups. I'm simply baffled why this used to work effortlessly and now it totally evades me. I guess I'll have to try e-on's support.

 

Thanks again,

Jackson