A tool can look perfectly fine in shaded view and still have awkward elements. Turn on the mesh edges and you may notice very small elements or twisted quadrilaterals that were hidden by the display.
Let us deal with those before building the other tools. Save a copy first. The cleanup dialog has its own undo tools, but the documented cleanup undo is no longer available after closing that dialog.
Run the first checks
Show the tool you want to inspect and open Mesh Check and Cleanup. It checks the mesh currently visible in the 3D view. A hidden tool is not included simply because it belongs to the project.
Start with Edge/Element size and Element warping angle, as described in the workflow. Keep the angle-between-elements check for a separate pass.
Use size criteria appropriate to your model. A value used for a large body panel is not automatically suitable for a small component.
What do you do with the highlighted zones?
Pick one and zoom into it. Nearby defects are grouped, which helps you follow the local problem. Apply the relevant cleanup and read the updated report.
If most of the tool is highlighted, I would go back to the meshing strategy and source geometry first. There is little benefit in repairing the same issue everywhere if it was created by an import choice.
Have a look at the repaired surface
The report compares modified regions with the original surface. Use that comparison and a close-up view. Fewer reported defects are welcome, but not if an important radius has disappeared in the process.
Use local undo while the dialog is open if needed. Then examine angles between elements separately. Some sharp transitions are real tool features; others are mesh problems.
The Mesh Quality contours can help you locate characteristic lengths, aspect ratios and angles. Once the surface is in good shape, we can use it for building offset tools. That is a much better starting point than carrying the same mesh problem into several objects.
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[…] that source mesh has problems, clean it first. Otherwise, the new tools can inherit a poor starting […]
[…] it is an unintended sliver or badly distorted area, investigate why it exists. Mesh checks and local refinement help you trace the setup […]