Interesting. I've never observed this, but then I usually uncheck collisions rigorously, and haven't sim'd that much headgear. But I also notice wayward vertices and crumpling and jaggies in many sims and simply smooth them away with either the smoothing morph brush or the tighten fit as a matter of course. If I can prevent some of that by making a tiny alteration before the sim, then it's worth experimenting on. Thanks for the thread.

Frequency -- Yes, it's good to know about this specific bug, because I suppose I may come across it at some point. And, indeed, I've never had an issue with any of your products (except the issue of not owning them all, yet.) :)

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PoserPro 2014, PS CS5.5 Ext, Nikon D300. Win 8, i7-4770 @ 3.4 GHz, AMD Radeon 8570, 12 GB RAM.