Gary Stofan
Ansys Employee

Hi !

When Workbench updates design points, it normally deletes each individual database, result files etc.  
This is done intentionally to save disk space.
When you enable the "Save Failed Design Point", it should create a new Project for each failed DP.

So, Update all design points.
Look in your Project Folder, and see if there is  {ProjectName_dp{number}, like MyProject_dp2.

We should then be able to open such project, try to update from inside Mechanical, and hopefully see additional errors or clues.