[axel]

I am using the 'new' GMSH boundary layer command. I meshed a 3D-wing and it looks really nice in GMSH (with all physical surfaces / volumes defined correctly).
I have many boundary layer volumes on the surface of the wing, outside a box filled with tetrahedras and the outer boundary layer surface (which is NOT a physical surface, thus should not be exported - loading .msh file in GMSH shows it correctly).

Conversion with gmsh2ToFoam results in many errors:
meshes/meshShapes/cellModel/cellModel::centre at line 76: zero or negative pyramid volume

and once:
meshes/polyMesh/polyMeshFromShapeMesh::polyMesh at line 577 found 19702 undefined faces in mesh -> adding to default patch

Somehow there are just 1678 faces in defaultFaces (but there should be none in there). These faces are partly randomly, partly symmetrically distributed over the wing. Sometimes connected, sometimes not. They are the outer hull of the boundary layer, but just ~20% of it.

checkMesh failed in 6 mesh checks. I have ~250000 prisms and ~250000 tets, and mysteriously 59 polyhedras.
The thing is that it worked correctly without the boundary layer.

One possible workaround could be to mark the defaultFaces patch as some kind of invisible, but I did not find such option.

If you need more information I'll be glad to post them. I could also post a simple box example that behaves similarly.

Help is greatly appreciated,

Axel