Hmmm. Yes, meshing techniques for FEA can be more stringent than for CFD. Sounds like the automesher is not robust enough, though. You may want to repost this question in the Structural Engineering/FEA forum; if you do so, post a note here redirecting people to your new thread. Some questions you could answer in that post or here include: What software package(s) are you using (I assume SolidWorks and the Cosmos FEA solver). Does the part have multiple holes, and/or is it an assembly of multiple parts; if an assembly, have you tried exporting the assembly as a part file first? Is the automesher working from a "native" solid part file, or have you tried exporting the solid using STEP or similar, and meshing that?