Ansys Employee

I am sorry the background color threw me off, as we don't have such colors by default. So if I am understanding correctly you are using workbench meshing and from looks of it I think that can be a multizone method, and also from the looks of it the bodies are not sliced, but only faces seem to be split.

And your problem seems with larger mesh size it ignores some face split? is it? if yes, multizone is a patch independent method, so if the larger file size is given, it will ignore your face splits. One thing you can try is give named selection to those edges that split faces so that they are respected by the multizone method.