AFX doesn't always Work

Hello everybody,

I am part of a Formula SAE team for my University. our chassis is set up and modeled in creo 3.0 using AFX for all the profiles and is created based on a point cloud. We seem to have problems when adding in more profiles to the chassis when using the profile tool. typically we create a new instance with the profile we require between two of the points however it seems that it often only makes the curve through the points and fails to assemble the remainder of the part.

Any help or insight into this problem would be greatly appreciated.