Check your mesh settings:
http://www.hydraulicdesign.net/meshes.htm
http://wiki.mcneel.com/rhino/meshfaq
Is the object shown above a valid polysurface? The meshing looks as if it is a single surface. If so, try DivideAlongCreases SplitAtKinks=Yes.
–Mitch
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Awesome article. Object checked so I followed the meshfaq and changed render mesh quality to smoother & slower which I believe fixed the problem.
Thanks for the great information.