by SmileTime on Fri Nov 22, 2013 9:00 pm
Agree with what Knights said but this is odd, the side face doesn't seem to lineup with the top face so it might be a more serious issue.
Usually it's not that the geometry is bad, but rather that the file format has a limited precision so it's not being saved accurately. Here are a few tricks that often fix the problem by changing the brush slightly without changing your design:
Making the brushes thicker. Your top face remains the same so your geometry isn't changing, but since it's thicker so there more precision.
Make the bottom flat. Have the bottom of the brush parallel to the grid rather than parallel to the top.
Pyramiding. Like triangulating the top face you take it one step further and have each of those triangle be part of a three sided pyramid. So the bottom three vertices collapse into a single vertex.
These might not fix it but often do.