this error is, sometimes to be avoided by increasing the model scale.
BUT this doesn't mean its the problem. Would work only if the model is 
"perfect".
in Prefab model bounds should be (rule of thumb based on my experience) between 
50k and 80k.
use scenescale option left under on interface for this.

make sure the model is snapped to grid in max, use a coarse size, if two 
vertexes are somehow located 3 units apart, setting snap to 1 doesn't help much 
at all.
Plus this increases performance as less planes are generated.
Use Weld as well, then set model to outline and inspect each vertexes 
connections if problem persists, they should show only one vertex, (3 being at 
same place)
see it as a party balloon. one little hole:bam :)
note that Prefab generates a red region where problem is occuring, due to 
recursion, it might not refflect at all the real bad problem, but in past tests
it was, after i found the error, in 80% of cases holding the bad region in its 
bounds. So when you get that error, do not close generator window directly, 
inspect the scene to
locate visually where things possibly go wrong.

also make sure its continuously modelled, meaning here that once triangulated, 
no triangle side is shared by more than one other triangle side.

Fabrice

On Jun 1, 2010, at 2:56 PM, colouredfunk wrote:

> << BSP build ERROR: Empty faces were created. This could indicate the
> source geometry wasn't aligned properly to a grid.

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