Fixed in 3.2.

Fixed in 3.2.

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Alright so I solved it for my case. When any of the verts end up clipping into each other and merge due to mirror mod when making the shape keys. The exporter throws that error. I fixed it by hunting down verts that merged during movement of the shape key and it fixed it. So not exactly an issue as it can be easily worked around. Just was confusing at first.

Thanks for reporting this. It is indeed a difficult problem to solve, and perhaps even impossible given the way Blender currently works.

I could add a more descriptive error message when this happens, but I don't see anything that can be done programatically to avoid the problem. It's up to the user to fix their input data.

I can't tell what is happening without the model. But AFAIK a shape's vertices and faces are always 1:1 with the base mesh. It could be that the Blender model is corrupt somehow.

Sounds like a bug. Can you upload your .blend file, please?

https://pasteall.org/blend/

You could also try exporting a DMX file.

I understand exactly what you are trying to do, and I am telling you for the third time that you cannot do it.

Ah, there is actually a specific warning about this:

Bone constraint "foo" found on "object", which already has a bone parent. Ignoring.

It writes out the final bone positions, but the position of your rigid object is affected by multiple bones at the same time. That relationship can't be described in DMX or in SMD.

Bone constraints do not exist in the Source engine. The exporter does its best by making the target object a child of the bone, but only one parent is supported. I expect you are seeing a warning about the object having multiple armatures each time you export?

You must bake this down to a normal skeletal animation if you want it to work in a game engine.

There is no mesh to import. I've seen a few people with similar problems lately, it seems to be a bug with a decompiler.