Do you know, that… ?
Sometimes when connecting surfaces are formed slots, which can not be automatically patch. It's about a break in the range of 0.1 mm and larger. With smaller intervals can be dealt with, including during operation Knit surface options Gap control. Of course, a break in the model results in, that they can not form a solid surface (Create block inactive)..
What solution I recommend? By Fill surface LATAM break. Of course Scala results and create a lump, which it is now no longer possible.
The next step is surgery Delete face > Delete and fill. This way you can “get rid of” exposed side, which may interfere with e.g.. inserting a rounding. This step is not necessary, but it allows you to create a perfect surface, after patching where there remains no trace.