Yes that is exactly the problem.
ed version 3.8 and checked the settings.
.. the point distance was 0.25?
After changing to your suggested 0.0001, the gear geometry was correctly rendered.
So, I reverted to the previous version and checked the settings ... the point distance was 0.0001.
ing v 3.8 the point distance remained at 0.0001.
I'm guessing that these settings are saved in some configura
tion file that is untouched between installat
ions, but why would version 3.61 work with a point distance of 0.25 and how did it become initialis
ed to that value ( I don't recall changing any settings except to inch from metric )
edit>> I forgot to say thank you for your rapid reply and fix