Also I tried your suggestion of dividing the faces but still it is not working and getting same problem for each divided segments. By some trial and error I came to know that when the first layer height is large, there is no such problem. But as I start decreasing the first layer height, the distortion starts appearing after some thickness. n Also I am using very high bias factor 15000 in edge sizing instead of inflation layer. Can this be the reason for such problem?.