> Basically, every time I run Gmsh on the same file I get a different mesh. 
> Sometimes the differernce is very small, but there are times when it quite 
> large. For example, for the same CAD file and meshing parameters, half of the 
> time I am getting a good mesh while half of the time I get one that crashes 
> the solver (because of a few “flat” elements).

Are you optimizing the mesh? This isn't done by default but can be
quite important for subsequent finite element analysis.

 
http://geuz.org/gmsh/doc/texinfo/gmsh.html#index-g_t_002doptimize_005b_005fnetgen_005d-34

> Doing some googleing on the subject I found out that this is the intended 
> behaviour of Gmsh and that this randomness cannot be stopped.  However, it is 
> very inconvenient for us, one reason being that we cannot support other users 
> since we cannot reproduce their exact problems.

Dipl.-Ing. A. P. reported a few weeks ago being able to fix the
randomness by meshing from the command line.  I haven't tried it, but
it seems like an easy fix.

 http://www.geuz.org/pipermail/gmsh/2011/006347.html

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