I'm running EMPro 2015.01 and I've been running into this same problem on a few different simulations. They're all FEM simulations where I get the following error while:
Mesh boundary is overlapping, the pairs of overlapping triangles can be found in design_mesh_overlaps.sat.
I've tried excluding various models from the mesh until the simulation will run, and then manually re-creating the geometries that are causing the error, but no luck. I've tried looking at the design_mesh_overlaps.sat file, but the information in it is not meaningful to me.
I've attached an image of one of the simulations which is a right-angle SMA connector (waveguide port, 1W modal source) on a PCB (lumped port, 50ohm voltage source).
Any idea what is causing this and how to fix it?