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I've not seen this "open polysurface" problem before

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@saucerdesigner wrote:

Usually the extrusions of the tooth profiles join up without any issues. I don't know what I'm doing differently other than this is a larger diameter gear than I usually work with and it has an almost flat pitch angle. I've looked at Analyze>Edge Tools>Show Edges>Naked Edges but have no clue how to use that to solve the issue.
Any help would be greatly appreciated.

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