Step export fails, unhelpful error

Windows 10, latest Nightly 11th Jan 2018
I have a complex board that used to export .stp on another PC, but now fails with a warning to check the board outline and models
Selecting details just displays the command line with no useful information.
Is there any way to get a log?

Could it be a board outline issue? Segments must be mathematically connected.

The 3D viewer works smoothly with no warnings or artifacts.
The VRML export also works

I have pinned this down to the edge.cuts
I have some arcs on the outline that are off by 0.001mm due to the way arcs are defined. STEP export appears to be over fussy

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