It seems some of the errors are due to the union sequence. I inserted the beam as the first item with its intersected elements and most of the errors are gone. But there are still two errors - INCONS_FACE -- inconsistent face-body relationships and FACE_BOUNDARY -- wire being deleted crosses face boundary. To be more clear, I think it is better to open another topic. The new topic is here Solid union errors - INCONS_FACE -- inconsistent face-body relationships and FACE_BOUNDARY -- wire being deleted crosses face boundary Thanks.