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I was suffered by the Vertex size mismatch problem as well and I developed a two steps approach to fix it: 1. identify the mismatched surface pair. 2. split the mismatched surface pair to smaller convex surface pairs. you can use projection function cast the slice line to both surfaces. Usually, your mismatched surfaces are non-convex surfaces. when you slice your surfaces, mismatched surfaces will be downsizing to one pair of the sliced surfaces. keep cutting your surfaces until the mismatched "Sub" surfaces become a quadrangle or even triangle. The problem should be solved. This process seems somewhat cumbersome. However, it is effortless when you actually try it.