Extra surface BCs showing up in pointwise in PLOT3D file?

Hi,

Not sure if this is really an issue or support request, but I'm hoping that someone has come across this before!

The setup:

• I use pointwise to generate a structured surface mesh, and export PLOT3D
• I use pyhyp to extrude ~80-100 layers
• Import volume mesh back into pointwise to set EXODUSII boundary conditions

I'm getting really nice extrusions on certain surface meshes, but in some specific cases, I see surface domains (that are selectable as BCs in pointwise) showing up at the interface between extrusion volumes (i.e. perpendicular to the wall). Is this expected? It seems to happen most at wing tips where there are wall surfaces that aren't tangent to one another?

Below is an example at a wing tip:

Ideally the only boundaries I would like to select are the initial wall surface mesh and the outer overset boundary. Is there something I'm doing in my surface mesh to cause a disconnect betwwen blocks? Or maybe this this just something that the pointwise import script is interpreting?

Apologies if this isn't really a pyhyp issue....

Start by reproducing the structured surface mesh export from Pointwise, the pyHyp extrusion of roughly 80–100 layers, and the subsequent PLOT3D import into Pointwise. Compare the wing-tip case with a successful mesh to determine whether the extra selectable domains originate in pyHyp or the Pointwise import; done means identifying the source and documenting the expected boundary behavior.